Wacker Neuson SM100 Operator's Manual
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Wacker Neuson SM100 Operator's Manual

Utility track loader
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SM100 / SM120
Machine Type
Material Number
Version
Date
Language
Operator's Manual
Utility Track Loader
UTL
5100064108 / 3300031444
5100064108
06
03/2023
[en-US]
This Operator's Manual includes
the AEM Safety Manual

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Summary of Contents for Wacker Neuson SM100

  • Page 1 Operator’s Manual Utility Track Loader SM100 / SM120 This Operator‘s Manual includes the AEM Safety Manual Machine Type 5100064108 / 3300031444 Material Number 5100064108 Version 03/2023 Date [en-US] Language...
  • Page 2 Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecu- tion. Wacker Neuson America Corporation reserves the right to change its products and their technical specifications for further technical development at any time without any claim to changes to machines already delivered. The in- formation in the technical documentation supplied with the product applies in each case.

  • Page 3: California Proposition 65 Warning

    California Proposition 65 Warning WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other repro- ductive harm. WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproduc- tive harm.
  • Page 4 This page is intentionally left blank.

  • Page 5: Table Of Contents

    Towing the Machine .......................... 35 Operation Risk of Injury or Death .........................  37 Inspecting the Work Area........................ 38 Break-In Period ............................  38 Operation Checklists .......................... 39 Adjusting the Operator Platform...................... 40 [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 6 Engine Oil Viscosity .......................... 78 Checking and Adding Engine Coolant .................... 79 Checking the Hydraulic Oil Level ...................... 80 Testing the Control Interlock System .................... 81 8.10 Checking for Leaks .......................... 83 Operator’s Manual | 5100064108 | SM100 / SM120 | 03/2023 | [en-US]...
  • Page 7 11.11 Dimensions ............................ 118 Emission Control Systems Information and Warranty—Diesel 12.1 Emission Control System Background Information................ 120 12.2 Limited Defect Warranty for Exhaust Emission Control System ............ 121 [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 8 Yanmar Limited Warranty ........................ 123 12.5 Yanmar Power Technology Co., Ltd. Emission Control System Warranty—USA Only .....  125 Compact Tool Carrier AEM Safety Manual Index ................................ 153 Operator’s Manual | 5100064108 | SM100 / SM120 | 03/2023 | [en-US] viii...

  • Page 9: Foreword

    Fig. 1: Nameplate location Engine nameplate The engine nameplate identifies the model, displacement, and engine num- ber. The location of the engine nameplate is shown below. Fig. 2: Engine nameplate location [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 10: Machine Documentation

    Please contact your dealer if you require more information on the machine or the operator’s manual. Manufacturer's Approval This manual contains references to approved parts, attachments, and modi- fications. The following definitions apply: Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 11: Abbreviations

    Hydraulic oil filter 1000463685 Fuel cap 1000340135 Hydraulic oil 5000164672 Hydraulic tank cap 1000340157 Tracks, wide (SM100) 1000421187 Hydraulic tank screen 1000340159 Tracks, wide (SM120) 1000455009 Grease 1000367563 [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 12: Usage

    • Operating the machine outside of factory specifications • Operating the machine in a manner inconsistent with all warnings found on the machine and in the operator’s manual Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 13: Residual Risks

    • Personal injury from improper lifting techniques • Crushing hazards from improper operation (feet, legs, or arms extending outside of the operator work station) and for other persons in the work zone [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 14: Safety

    • Familiarize yourself with the location and proper use of all controls and safety devices. • Know the rules for the jobsite. • Contact Wacker Neuson for additional training if necessary. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 15 • Familiarize yourself with the jobsite before beginning work, especially when operating in buildings or enclosed areas. Be aware of: – Obstacles in the operating and traveling area [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 16 OSHA or other jobsite rules and regulations. To re- duce the risk of exposure: • Work in a well ventilated area. • Use a dust control system. • Wear an approved dust/particle respirator. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 17 • Do not use a mobile device while operating this machine. • Do not allow anyone underneath a raised load. • Do not leave the machine running unattended. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 18 • Look to the rear before moving the machine in reverse. • In certain situations, use another person to direct movement of the ma- chine on the jobsite safety. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 19: Safety Guidelines For Attachments

    • If any lockout/support devices are removed for setup, maintenance, or repair purposes, they must be refitted and checked immediately upon completion of the maintenance/repair work. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 20: Safety Guidelines For The Engine Control Unit (Ecu)

    ECU will void the engine warranty. • Improper use or misuse of the ECU may result in death or serious injury due to an abrupt and unexpected increase in engine speed. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 21: Special Hazards

    • Do not operate a machine when its fuel cap is loose or missing. • Do not remove the radiator cap when engine is running or hot. The radia- tor fluid is hot and under pressure, and can cause severe burns. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 22: Disposal

    • Follow all applicable safety regulations during machine disposal. • Machine disposal must be performed in accordance with state-of-the-art standards that apply at the time of disposal. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 23: Vehicle Description

    When using these attachments, observe the legal regulations of your country and equip the machine with all the safety equipment re- quired. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 24: Machine Overview

    Display Diesel fuel fill Attachment (options available) Auxiliary hydraulic couplers Tracks Hydraulic oil fill Lift arm Lift arm support device Hood Operator platform Operator presence pedal Tie-down points Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 25: Labels Overview

    1000461827 WARNING ADVERTENCIA AVERTISSEMENT 1000398268 1000398268 1000398268 1000h 500h 500h 250h 250h 1000398268 WARNING 250h 250h 500h 500h 1000h 1000h 1000461833 1000461822 WARNING ADVERTENCIA WARNING AVERTISSEMENT ADVERTENCIA AVERTISSEMENT [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 26 ISO 14397 ISO 14397 1000474444 1000463295 1000461824 1000463167 1000503651 WARNING Cancer and Reproductive Harm www.P65Warnings.ca.gov ADVERTENCIA Cáncer y daño reproductivo www.P65Warnings.ca.gov AVERTISSEMENT Cancer ou malformations congénitales www.P65Warnings.ca.gov 5100045462 Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 27: Safety Labels

    Operate only from operator’s position. Check for utility lines before digging. Keep loads level when raising lift arms. Look behind while backing up. Check risk zone before turning. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 28 For jump start, connect negative cable to loader engine last (never at the battery). After jump start, remove negative connection at the engine first. WARNING Hot surface and explosion hazards Dangerous heat and contents under pressure. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 29 • Do not work under a raised lift arm without securing the lift arm support device. • A disconnected hydraulic line can result in the lift arm dropping. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 30: Information Labels

    Cancer ou malformations www.P65Warnings.ca.gov congénitales www.P65Warnings.ca.gov 5100045462 WARNING Hot surface hazard to the right NOTICE Ultra low sulfur fuel only Information Labels Hydraulic oil fill 1000366250 Tie-down point 1000398268 Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 31 500h 1000h 1000h 1000461822 Push in the auxiliary hydraulic connector for 5 seconds to release the pres- 5" sure in the auxiliary hydraulic circuit. 1000398281 Engine throttle 1000461824 [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 32 4.5 Information Labels Manual auxiliary control 1000463167 Auxiliary hydraulic flow and ride control (optional) 1000503651 Ignition and rated operating capacity—model SM100 453kg (1000LB) SM 100 ISO 14397 1000463295 Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 33 Vehicle Description Information Labels 4.5 Ignition and rated operating capacity—model SM120 544kg (1200LB) SM 120 ISO 14397 1000474444 [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 34: Transportation

    Raise the lift arm so that the attachment (if equipped) does not contact the ramp or the ground. Carefully back the machine onto the middle of the transport vehicle. Lower the lift arm. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 35: Towing The Machine

    ► Towing the machine can cause excessive, uneven track wear. ► The manufacturer’s warranty shall not apply to accidents or damage caused by towing. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 36 Only use the points on the frame (1) designated for towing. If towing a short distance is unavoidable, use a towing chain or cable rated at 1.5 times the weight of the machine. Fig. 6: Towing points Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 37: Operation

    Before starting setup or repair work (for example, installing or removing a hy- draulic attachment), release the pressure in the sections of the system and pressure lines that are to be opened. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 38: Inspecting The Work Area

    Break-In Period New machines require a break-in period to ensure maximum efficiency. Dur- ing the break-in period, the machine’s moving parts stabilize. This machine has a 6-hour break-in period. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 39: Operation Checklists

    – An operator standing on the platform – The operator presence pedal engaged – The parking brake disengaged • Check the parking brake for proper operation. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 40: Adjusting The Operator Platform

    Loosening the operator platform Loosen the nut (2) against the operator platform weldment. Loosen the flange nut (1) to pull the bumper spring away from the chassis weldment. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 41: Machine Controls-Standard

    5 Left handrail Ground drive joystick control 7 Auxiliary hydraulics switch Auxiliary hydraulic control lever 9 Workgroup joystick control 10 Right handrail 11 Hand throttle 12 12V adapter [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 42: Machine Controls-Eh Aux

    ► Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 43 Wacker Neuson dealer or service center for assis- 100046182 4 tance before operating the engine. Fig. 11: Throttle [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 44: Control Interlock System

    If any of these interlocks do not function properly, contact your Wacker Neu- son dealer for service. Do not modify the system. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 45 To disengage the interlock, engage the operator presence pedal before op- erating the auxiliary. For further information on continuous flow operation, see Auxiliary Override on page [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 46: Operating The Machine In Extreme Weather Temperatures

    • Check the engine coolant mixture for proper antifreeze mix. • Make sure the battery is fully charged. • Check to see if the battery connections and the connections to the starter and engine block are clean. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 47 – Holding the right hand lever or joystick in place when the attachment has been fully extended or retracted – Holding the auxiliary lever in place when an attachment stops mov- • Avoid driving for excessive amounts of time. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 48: Instrument Display

    Operation 6.11 Instrument Display 6.11 Instrument Display The instrument display informs the operator of the operating states, required maintenance, or possible machine malfunctions. Fig. 15: Instrument display Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 49 — Instrument display — To next menu page/set button (instrument display) Hydraulic oil temperature Hydraulic oil pressure Engine stop Yellow Engine warning Air filter restriction Engine oil pressure [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 50: Instrument Display Symbols And Functions

    Fuel level Unable to disengage parking brake—auxiliary Unable to disengage parking brake—operator not present Unable to disengage parking brake—engine off Operating hours to next maintenance Operator unsafe shutdown warning Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 51: Instrument Display Pages And Subpages

    Use the selector button and to next menu page/set button to navigate the display’s pages and subpages. For further information, see Instrument Dis- play on page Note: Subpage 2.3 is available on the SM120 only. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 52: Machine Status

    Subpages 0.3 through 0.5—Diagnostic trouble codes Engine control unit and display error codes are shown on these subpages. For further information, see Diagnostic Trouble Codes on page 109. Fig. 21: Subpage 0.3 Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 53: Machine Options

    Use the next menu button (1) and the selector button (2) at the bottom of the instrument display to scroll through the subpages. These subpages allow the user to: Fig. 26: Display arrows [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 54: Instrument Display Settings

    While in auxiliary override mode, the parking brake is engaged, and the hy- draulic oil flow for an attachment is continuous. Fig. 30: Page 4.0 Standard controls To engage auxiliary override mode, perform the following: Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 55: Ground Drive And Loader Controls

    Fig. 33: Handrails All ground drive and loader controls are spring centered to neutral. This means when you let go of the controls, they will return to neutral. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 56 Fig. 37: Moving the right joystick to the right to roll the attachment outward Ground drive control joystick functions The ground drive joystick controls all of the ground drive functions. Note: Use the handrails when operating the controls. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 57 (beyond the maximum lift arm down position) The tilt func- tion can be used while the float function is active. To disengage float, move the workgroup joystick to raise the lift arm. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 58: Cold System Restriction

    When operating on slopes or hills, special care must be taken to reduce the risk of personal injury or damage to the machine. The maximum operating angle rating is 17.5°. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 59 • Do not drive the machine in reverse over a curb with no load or the lift arm raised. • If repeatedly driving over a curb is necessary, build a dirt ramp to make the ascent more gradual. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 60: Machine Tip Over

    • Read and understand the instructions for use and operation of any at- tachment used on this machine. • Ensure the mounting pad on the attachment is clear of any debris to al- low to proper mounting of the attachment. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 61 Fig. 44: Tilting the coupler back 10. Set the lock levers (4) down to the locked position. 11. Check the coupler to ensure the attachment is secure. Fig. 45: Lock levers down [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 62 Move the machine in reverse away from the attachment. Note: Tilting the attachment back reduces the force to set the lock levers in the locked and unlocked positions. Fig. 48: Lock levers, guide, and mount Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 63: Auxiliary Hydraulic Connections

    Push the female connector attachment onto the male auxiliary hy- draulic connector (top) (2). Push the case drain connector attachment (if present) onto the case drain line (middle) (3) connector. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 64: Manual Auxiliary Controls

    6.26 Using Continuous Flow Hydraulics This feature allows the operator to turn on full hydraulic flow in either direc- tion while requiring no additional input from the operator. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 65: Filling And Dumping The Bucket

    ► Dump the load with the machine on a level surface. Filling the bucket Lower the lift arm. Tilt the bucket so it is flat on the ground. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 66: Recommended Fuels-Diesel And Biodiesel

    The rec- ommended fuel complies with the U.S. EPA and ARB protection guidelines. Use the same diesel fuel that is used in cars. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 67: Refueling The Machine

    ► To prevent static electricity buildup when transferring the fuel from the pump to the container, place the fuel container on the ground. Hold the hose nozzle firmly against the side of the container while filling it. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 68: Lift Arm Manual Override

    The lift arm manual override can be used if the machine loses engine power with the lift arm in the raised position. Procedure Stand on the operator platform and engage the operator presence pedal. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 69: Lift Arm Support Device

    Step onto the platform and start the engine. Slowly lower the lift arm to the ground. Stop the engine and step off the platform. Fig. 60: Install pin [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 70: Parking The Machine

    Turn the ignition key to the OFF position to stop the engine. Step off the operator platform. Chock the tracks. Make sure the parking brake pins are engaged (at least one). Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 71: Factory-Installed Options

    Stop the engine and turn the key to position 1. 453kg (1000LB) Press the ride control button. Turn the key to position 0. SM 100 ISO 14397 100046329 5 Fig. 64: Ignition key position 0 [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 72: Maintenance

    • After cleaning, examine all fuel, lubricant and hydraulic oil lines for leaks, chafe marks, and damage. • Do not use the attachment or work equipment as lifting platforms for per- sons. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 73: Maintenance Label

    I Check the functions and fluid levels, filling up and draining. II Check parts for wear, seals, hoses, and threaded fittings. III Check for damage, corrosion, or dirt. Replace if necessary. IV Lubricate daily after operation. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 74 Check the hydraulic fluid, hoses, and tubelines for damage and leaks. Repair or [} 95] replace as needed. Check the tracks (damage, tension, profile). [} 96] Check the undercarriage for loose bolts and nuts. [} 94] — Drain the water separator. [} 87] Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 75 1) This maintenance task should be performed by a qualified technician. Contact an authorized YANMAR industrial engine dealer or distributor for assistance. 2) This maintenance task should be performed by a qualified technician. Contact an authorized Wacker Neuson dealer or service center for as- sistance.

  • Page 76: General Daily Checks

    Lower the hood slowly to make sure the lock eye (1) goes through the hole in the hood and the rubber latches engage properly. Push down firmly to engage the rubber latches. Install the lock (if applicable). Fig. 66: Hood lock eye Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 77: Lubrication Plan

    Torques on page 117. Lubrication Plan Fig. 68: Lubrication points Lubricate the specified lubrication points once a day. For the recommended grease to order, see Maintenance Items on page [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 78: Engine Oil Viscosity

    ► Take steps to avoid inhaling or ingesting used liquids. ► Wash skin thoroughly after exposure to used liquids. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 79: Checking And Adding Engine Coolant

    ► Wear eye protection when handling the engine coolant. ► Tighten the radiator cap securely after checking the radiator. Steam can escape during engine operation if the cap is loose. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 80: Checking The Hydraulic Oil Level

    Environment Use a suitable container to collect, store, and dispose of drained fluids and lubricants in accordance with current environmental protection regulations. When Every 10 hours or daily Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 81: Testing The Control Interlock System

    To test the control interlock system, perform the following functions individu- ally with the engine running and the controls enabled. A successful test means that the machine will not move after each of the following tests are performed: [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 82 Stand on the operator platform with the operator presence pedal en- gaged and start the engine. Carefully try to raise the lift arm. ð The lift arm should not move with the hood raised. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 83: Checking For Leaks

    Procedure When checking for leaks, use a flashlight or other shielded light. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 84: Checking The Engine Oil

    Do not mix different types of engine oil. This can adversely affect the lubri- cating properties of the engine oil. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 85: Checking The Exhaust System

    Install the dipstick and close the hood. 8.12 Checking the Exhaust System When Every 10 hours or daily Requirements • Machine shut down • Exhaust pipes and muffler cool to the touch [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 86: Checking The Continuous Flow Shutoff System

    Repeat steps 3 and 4 with the auxiliary hydraulic control lever pulled fully backward. If the continuous flow system does not function properly, contact an autho- rized Wacker Neuson dealer or service center for assistance. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 87: Draining And Cleaning The Water Separator

    Raise the lift arm and secure the lift arm support device. For further in- formation, see Lift Arm Support Device on page Fig. 78: Water separator location (battery and hood hidden for clarity) [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 88 Prime the fuel system by turning the key switch to the ON position (po- sition 1) for 10 to 15 seconds. 10. Check for any fuel leaks. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 89: Cleaning The Machine

    Regular cleaning is essential for keeping the machine in serviceable condi- tion. It is important to remove dust and dirt from the machine as soon as possible after work has been completed. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 90: Changing The Engine Oil And Filter

    Environment Use a suitable container to collect, store, and dispose of drained fluids and lubricants in accordance with current environmental protection regulations. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 91 Pull the oil drain hose (3) out from the access hole. Drain the oil into a suitable container by removing the cap from the oil drain hose. Fig. 84: Oil drain hose [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 92: Checking And Adjusting The Drive Belts

    Checking the belt tension while the engine is running may cause personal in- jury. ► Shut off the engine before carrying out work in the engine compartment. ► Shut off the power supply. ► Let the engine cool down. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 93 Adjust the belt tension by pivoting the alternator (3) in or out using a pry bar (4). Tighten the alternator adjusting bolt and related fasteners and check the belt tension. Fig. 90: Cooling fan V-belt adjust- ment [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 94: Checking The Undercarriage

    • Check for loose bolts and nuts as shown. For standard torque specifica- tions, see Tightening Torques on page 117. Fig. 94: Undercarriage bolts • Check the condition of the cotter pin on the sprocket castle nut. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 95: Inspecting Hoses And Hard Lines

    Replace the air filter when the indicator is illuminated. Requirements • Machine parked on a level surface • Machine shut down and cool to the touch • Damp cloth [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 96: Checking And Adjusting Track Tension

    ► Open the lubricating valve very carefully. ► Wear protective gloves and safety glasses. ► Release grease only as described below. ► Contact a Wacker Neuson service center if this does not reduce track tension. Environment Use a suitable container to collect, store, and dispose of drained fluids and lubricants in accordance with current environmental protection regulations.
  • Page 97 Slowly turn the valve counterclockwise to release the grease into a suitable container. ð The grease flows out of the groove of the valve. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 98: Checking And Cleaning The Radiator Fins

    For more information, see Lift Arm Support Device on page Use a low pressure water stream to clean dirt from the surface of the Fig. 97: Radiator and front panel radiator. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 99: Replacing The Fuel Filter

    Lift the hood. Interrupt the fuel supply by turning the fuel valve (1) 180° to the CLOSED (up) position on the water separator (2). Fig. 98: Water separator location [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 100: Replacing The Hydraulic Tank Filler Cap

    17. Check for any fuel leaks. 8.24 Replacing the Hydraulic Tank Filler Cap When Every 1000 hours Requirements • Machine parked on a flat, level surface • Machine shut down Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 101: Replacing The Hydraulic Fluid And Filter

    Remove the hydraulic fill access plate (1) by removing the retaining bolt (2) and loosening the pivot bolt (3). Rotate the access plate out of the way. Fig. 102: Hydraulic fill access plate [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 102 Stop the engine and check for leaks. 10. Observe the hydraulic oil level through the sight glass and add fluid as Fig. 105: Hydraulic tank filter necessary. 11. Install the rear access panel. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 103: Maintaining The Battery

    YANMAR before using the equipment in such an environment or the warranty is voided. When • Every 50 hours—check the battery for damage; check cables and con- nections, and recharge [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 104: Engine-Jump-Starting

    CAUTION Personal injury hazard Electrical arcing can cause severe personal injury. ► Do not allow positive and negative cable ends to touch. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 105 In very cold weather, check the condition of the electrolytes. If it seems slushy or frozen, do not try jump-starting until it thaws. Ensure all controls are in neutral and that the key switch is off. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 106 10. Disconnect the positive cable clamp. 11. When using light or high amperage draw accessories, idle the engine for a period of 20 minutes to bring the battery to charge state. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 107: Fuse And Relay Box Layout

    K104 Operator presence K151 Aux. letdown K157 ECU main K169 Starter safety interlock K186 Aux. electric “K” K902 Main ignition Fuses F002 Starter solenoid F003 Glow plugs F004 Main ignition [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 108 F032 Display / telematics / diagnostics F033 12V outlet / worklights F034 Parking brake / workgroup / fuel pump / miscella- neous Diode V001 Parking brake-workgroup ISO V003 ECU supply ISO Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 109: Troubleshooting

    (SAE J1843) 0 Accelerator Pedal Position Sensor "A" : Above normal opera- tional range (SAE J1843) 15 Accelerator Pedal Position Sensor "A" : Not available (SAE J1843) [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 110 3 Air Heater Relay : Circuit fault B 2 Air Heater Relay : Intermittent fault 7F802 522242 4 Cold Start Device : Circuit fault A 3 Cold Start Device : Circuit fault B Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 111 7F9E8 522728 12 E-ECU internal fault : Engine Map Data Version Error 7F9EA 522730 12 Immobilizer : CAN Communication fault 8 Immobilizer : Pulse Communication fault 1202 2 Immobilizer: System fault 1) Yanmar original diagnostic trouble code [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 112: Shutdown

    • Use a stabilizer with a biocide to restrict or prevent bacteria and fungus growth. • Add the correct amount of stabilizer per the manufacturer’s recommen- dations. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 113: Machine Disposal And Decommissioning

    • Dispose of recyclable parts as specified by local regulations. • Dispose of all non-hazardous components that cannot be recycled. • Dispose of waste fuel, oil, and grease in accordance with local environ- mental protection regulations. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 114: Technical Data

    L (qt) 3.22 (3.41) Coolant type — 50/50 ethylene glycol / water (ATSM D6210, D4985) Coolant capacity L (qt) 6.88 (7.25) Fuel Tank capacity L (gal) 64.0 (14.1) Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 115: Electrical System

    Relief pressure bar (psi) 300 (4,351) 11.7 Controls Item SM100 / SM120 Type Hydraulic pilot Pattern Workgroup type ISO manual lever Engine speed Electronic dial Service brake Hydrostatic trans [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 116: Forces

    28.8 (4.1) 26.9 (3.9) Note: Add the weight of all subsequently installed equipment to the machine weight, which must be read off the label. Weight can vary by +/- 2%. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 117: Tightening Torques

    900 (664) M27 x 2.0 1,100 (811) 1,550 (1,143) 1,800 (1,328) 920 (679) 1,300 (959) M30 x 2.0 1,500 (1,106) 2,150 (1,586) 2,500 (1,844) 1,300 (959) 1,850 (1,364) [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 118: Dimensions

    226.0 ± 9.8 kgf m 1 .1 ± 0.1 2.6 ± 0.3 5.0 ± 0.5 9.0 ± 1.0 14.0 ± 1.5 23.0 ± 2.0 11.11 Dimensions Fig. 110: Machine dimensions Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 119 896.4 (35.3) Bucket width mm (in.) 914.4 (36) 1,070 (42) Overall height mm (in.) 1,478 (58.2) Track width mm (in.) 230 (9.1) 280 (11) Maximum rollback at ground degrees [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...

  • Page 120: Emission Control Systems Information And Warranty-Diesel

    • Removing or altering of any part of the air intake, fuel, or exhaust sys- tems. • Altering or defeating the speed-adjusting mechanism causing the engine to operate outside its design parameters. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 121: Limited Defect Warranty For Exhaust Emission Control System

    EPA regulations. All defective parts replaced under this warranty become property of Wacker Neuson. System Covered Components Exhaust system Flex section of the exhaust pipe Tail pipe [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 122 You must take your Wacker Neuson engine/equipment along with proof of original purchase date, at your expense, to the authorized Wacker Neuson dealer/service center during their normal business hours. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 123 [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 124 YANMAR Operation Manual, unauthorized alterations or modifications, ordinary wear and tear, and rust or Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...

  • Page 125: Warranty-Usa Only

    2023, 2024, or 2025 model year industrial compression-ignition engine. California-certified, new off-road compression- ignition engines must be designed, built and equipped to meet the State's [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 126 This warranty is transferable to each subsequent purchaser for the duration of the warranty period. YANMAR recommends that repair or replacement of any warranted part will be performed at an authorized YANMAR dealer. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 127 • Emission Control Information Labels Since emissions related parts may vary slightly between models, certain models may not contain all of these parts and other models may contain the functional equivalents. [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 128 Keep a log of the number of hours the en- gine is operated for both emergency use and non-emergency use. Also, note the reason for the operation. Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 129 COMPACT TOOL CARRIER Contents Acknowledgment ....... . 2 Foreword ........3 Safety Alerts .

  • Page 130: Foreword

    Foreword This safety manual is intended to point out some of the basic safety situations that may be encountered Read and during the normal operation and maintenance of your Understand machine and to suggest possible ways of dealing with Manuals Before Operating these conditions.

  • Page 131: A Word To The User/Operator

    A Word to the User/Operator It is YOUR responsibility to read and understand the Remember that YOU are the key to safety. Good safety manual and the manufacturer’s manuals before safety practices not only protect you but also protect operating this machine. This safety manual takes you the people around you.

  • Page 132: One-Call First

    One-Call First service. Always inspect the jobsite for evidence of unmarked utilities and contact others if necessary. Plan Your Work Call Before You Dig Be aware of the lead time for marking in your area. This Dial 811 (USA only) time may vary from state to state and county to county.
  • Page 133 Follow a Safety Program Be Alert! For Safe Operation Know where to get assistance. Know how to use a first You must be a qualified and authorized operator for safe aid kit and fire extinguisher/fire suppression system. operation of your machine. You must clearly understand the written instructions supplied by the manufacturer, Be Aware! be trained—including actual operation of the compact...
  • Page 134 Follow a Safety Program Some Rules You Must Work By Know — Know the capacity and operating characteristics of Weight of your compact tool carrier. Do not overload it. Load — Never modify or remove any part of the equipment (except for service—then make sure it is replaced).

  • Page 135: Prepare For Safe Operation

    Prepare for Safe Operation Check the Machine Before you begin your workday inspect your compact Maintain tool carrier and have all systems in good operational Machine condition. Do not operate the machine until all problems are corrected. — Perform daily and periodic service procedures as instructed by the equipment manufacturer.
  • Page 136 Prepare for Safe Operation Know the Work Area Before you operate the compact tool carrier, learn as Walk much as possible about the work area. Walk around Around the the worksite and inspect the surfaces you will travel on Worksite when using the compact tool carrier.
  • Page 137 Prepare for Safe Operation Plan Your Work Before you operate, plan how and where you will travel, Avoid Ruts turn and pick up, lift and place loads. and Ditches Choose a smooth level route to prevent possible tipover or loss of load. If possible, avoid crossing: —...

  • Page 138: Start Safely

    Start Safely Start the Machine Before starting the compact tool carrier and operating Keep the machine, walk completely around the compact tool Bystanders carrier and check that it is clear of personnel. Away — Clean your footwear and wipe your hands before using the compact tool carrier.

  • Page 139: Operate Safely

    Start Safely Check Attachment and Coupler Installation When changing buckets or installing attachments follow Read and the manufacturer’s instructions for proper maintenance Understand and coupling. Make sure all connectors are securely Manuals fastened. Tighten all bolts, nuts and screws to torques recommended.
  • Page 140 Operate Safely Remember These Rules: (continued) — Never leave the compact tool carrier unattended with- out lowering the lift arms, placing the attachment flat — Always make sure the work area is clear of other on the ground and safely shutting down the machine machines and personnel.
  • Page 141 Operate Safely Transporting Loads After engaging the load, tilt the load back to position it Carry Load for travel. Keep the load level when lifting. Lift the load only high enough to clear obstacles that may be in the path of the compact tool carrier. Carry the load as close to the machine as possible to: —...
  • Page 142 Operate Safely Traveling on Slopes and Inclines You must exercise additional care if operating on slopes Do Not Travel or inclines. Driving on slopes and inclines can be with Lift Arms dangerous and result in a tipover or loss of load. Raised WARNING! Do not travel on slopes or inclines with lift arms elevated.
  • Page 143 Operate Safely Follow these important practices when lifting loads: — The load must be centered when lifting. The likelihood for the compact tool carrier to tip is greatly Operate Controls increased if the load is not centered before lifting. Smoothly —...

  • Page 144: Shut Down Safely

    Operate Safely Watch Out For Hazardous Working Conditions If necessary when working under hazardous conditions, use a second person to warn of dangers. Make certain Be alert for hazards. Know where you are at all times. they do not get too close to the loader. Watch for branches, cables and doorways.

  • Page 145: Load And Unload Your Machine

    Load and Unload Your Machine Loading and Unloading the Compact Tool Carrier When transporting the compact tool carrier, follow the manufacturer’s recommendations for loading and unloading. Precautions — Keep bystanders out of the loading and unloading area. Load and — Load and unload on a level surface. Unload Safely —...
  • Page 146 Perform Maintenance Safely WARNING! Prevent death or serious injury from manufacturer’s manuals or consult your equipment entanglement. Do not wear loose clothing dealer for proper procedures. or accessories. Stay away from all rotating Keep pockets free of all objects that could fall out—and components when the engine is running.
  • Page 147 Perform Maintenance Safely Use Proper Ventilation Make sure the hoists or jacks you use are in good repair. Never use jacks with cracked, bent, or twisted parts. If it is necessary to run an engine in an enclosed area, Never use frayed, twisted or pinched cables. Never use remove the exhaust fumes from the area with an bent or distorted hooks.
  • Page 148 Perform Maintenance Safely Hydraulic System Hazards When venting or filling the hydraulic system, loosen the filler cap slowly and remove it gradually. The hydraulic system is under pressure whenever the Never reset any relief valve in the hydraulic system to a engine is running and may hold pressure even after the pressure higher than recommended by the manufacturer.
  • Page 149 Perform Maintenance Safely Avoid Explosion — Observe the polarity of the batteries and connections. — Make the final cable connection to the engine or the WARNING! Avoid possible serious injury from furthest ground point away from the battery. Never explosion. Lead-acid batteries produce extremely make the final connection at the starter or dead explosive gases especially when being charged.
  • Page 150 Perform Maintenance Safely WARNING! Explosive separation of a tire and/or rim WARNING! Explosive separation of a tire and/or rim parts can cause serious injury or death. Always follow parts can cause serious injury or death. Always use the manufacturer’s recommendations or see your a safety cage or cable restraints when inflating a tire supplier.
  • Page 151 Perform Maintenance Safely Check tracks, rollers and idlers for: — Damaged or worn tracks. — Correct tension according to manufacturer’s Check for instructions. Track Damage — Proper lubrication – track rollers and idlers. Refer to the manufacturer’s manuals. Track Adjustment Follow Track tension is important for good performance, Maintenance...

  • Page 152: Final Word To The User

    Final Word to the User You have just finished reading the AEM Compact Tool of safety will help to build good judgment in all Carrier Safety Manual. It is impossible for this manual situations. Our objective is to help you develop, to cover every safety situation that you may encounter establish and maintain good safety habits to make on a daily basis.
  • Page 153  58 Connecting hydraulic hoses ........ 63 Continuous flow ............ 64 auxiliary override .......... 54 checking the shutoff system .......  86 Control interlock system testing.............. 81 [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 154 Overhead electric lines .......... 16 Parking brake ............  41, 42 Parts replacing .............  20 Performing maintenance and repairs ......  72 PPE .................  18 Preparing for maintenance work...... 72 Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 155 Starting and stopping .......... 38 Storage .............. 38 Testing attachment system .......... 62 control interlock system........ 44 Tightening torques.......... 117 Tipping the machine over ........ 60 Towing the machine .......... 36 [en-US] | 03/2023 | 5100064108 | SM100 / SM120 | Operator’s Manual...
  • Page 156 Index Operator’s Manual | SM100 / SM120 | 5100064108 | 03/2023 | [en-US]...
  • Page 158 Wacker Neuson America Corporation N92W15000 Anthony Ave Menomonee Falls, WI USA-53051 Tel.: +01 262 255-0500 EMail: info@wackerneuson.com www.wackerneuson.us Material Number: 5100064108 Language: [en-US]...

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