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AEM SM1004 SM120 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
07
10/2023
[en-US]
This Operator's Manual includes
the AEM Safety Manual

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Summary of Contents for AEM SM1004 SM120

  • Page 1 Operator’s Manual Utility Track Loader SM100 / SM120 Machine Type This Operator‘s Manual includes the AEM Safety Manual Material Number 5100064108 / 3300031444 Version Date 10/2023 Language [en-US]...
  • Page 2 Imprint Publisher and copyright holder: Original operator’s manual All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable worldwide. This document may be used by the recipient only for the designated purpose. It may in no way be duplicated or translated in any other language, in whole or in part, without prior permission in writing from the manufacturer.

  • 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

    Table of Contents Table of Contents Foreword Information on This Operator’s Manual.................... 9 Machine Reference Information ...................... 9 Machine Documentation ........................ 10 Expectations for Information in This Manual .................. 10 Manufacturer's Approval ........................ 10 Abbreviations ............................ 11 Maintenance Items.......................... 11 Usage Intended Use............................
  • Page 6 Table of Contents Operation Checklists .......................... 46 Adjusting the Operator Platform...................... 47 Machine Controls—Standard .......................  48 Machine Controls—EH Aux .........................  49 Starting and Stopping the Engine ...................... 49 Control Interlock System ........................ 51 6.10 Operating the Machine in Extreme Weather Temperatures .............. 53 6.11 Instrument Display ..........................
  • Page 7 Table of Contents Testing the Control Interlock System .................... 88 8.10 Checking for Leaks .......................... 90 8.11 Checking the Engine Oil ........................ 91 8.12 Checking the Exhaust System ...................... 92 8.13 Checking the Continuous Flow Shutoff System ...................  93 8.14 Draining and Cleaning the Water Separator ..................
  • Page 8 Yanmar Limited Warranty ........................ 131 12.5 Yanmar Power Technology Co., Ltd. Emission Control System Warranty—USA Only .....  133 Compact Tool Carrier AEM Safety Manual Index ................................ 161 Operator’s Manual | 5100064108 / 3300031444 | SM100 / SM120 | 10/2023 | [en-US]...

  • Page 9: Foreword

    Foreword Information on This Operator’s Manual 1.1 Foreword Information on This Operator’s Manual The canister for storing the operator’s manual is located on the underside of the hood. Machine Reference Information The following machines and variants/options are described: Machine Item Number SM100 1000423340 SM120...

  • Page 10: Machine Documentation

    Foreword 1.3 Machine Documentation Write the machine information for your machine on this page. Provide these numbers to your dealer when you need service parts or information about your machine. Machine model Machine item number Machine serial number Engine serial number Wacker Neuson dealer Address Phone number...

  • Page 11: Abbreviations

    Foreword Abbreviations 1.6 • Approved parts or attachments are those either manufactured or pro- vided by the manufacturer. • Approved modifications are those performed by an authorized service center according to written instructions published by the manufacturer. • Unapproved parts, attachments, and modifications are those that do not meet the approved criteria.

  • Page 12: Usage

    Usage 2.1 Intended Use Usage Intended Use In accordance with this designated use, the machine may only be used for moving earth, gravel, coarse gravel or ballast, and rubble. It may also be op- erated with approved attachments for additional applications. No other applications are designated for the use of the machine.

  • Page 13: Residual Risks

    Usage Residual Risks 2.3 Residual Risks WARNING Serious injury or death hazard Improper operation of the machine can result in serious injury or death. Be- fore operating this machine, make sure to: ► Read and understand the operator’s manual. ► Read and understand all labels on the machine. ►...

  • Page 14: Safety

    Safety 3.1 Signal Words Used in This Manual Safety Signal Words Used in This Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of per- sonal injury, damage to the equipment, or improper service. DANGER DANGER indicates a hazardous situation which, if not avoided, will re- sult in death or serious injury.
  • Page 15 Safety Safety Guidelines for Operating the Machine 3.2 When operating this machine: • Do not allow improperly trained people to operate the machine. • Do not operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the alert signals. •...
  • Page 16 Safety 3.2 Safety Guidelines for Operating the Machine – Any necessary barriers separating the jobsite from public roads – Height of the ceiling/clearances – Width of entrances – Maximum load of ceilings and floors – Sufficient room ventilation to reduce the risk of carbon monoxide poi- soning •...
  • Page 17 Safety Safety Guidelines for Operating the Machine 3.2 Demolition or excavation work • When working on roofs or similar structures, check the resistance and the structure itself before starting work. The building can collapse, caus- ing serious injury, death, and damage. •...
  • Page 18 Safety 3.2 Safety Guidelines for Operating the Machine • Do not operate the machine before it has reached its operating tempera- ture. • Do not consume the operating fluids used in this machine. • Do not use the machine as a crane. These loaders are not approved for craning applications.

  • Page 19: Safety Guidelines For Attachments

    Safety Safety Guidelines for Attachments 3.3 Safety Guidelines for Attachments Information regarding attachments • Do not lift, lower, or transport people on the machine or in/on an attach- ment. • Use approved attachments only. See your local Wacker Neuson dealer. •...

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

    Safety 3.5 Safety Guidelines for the Engine Control Unit (ECU) Service training Before servicing or maintaining the machine, see Safety Guidelines for Op- erating the Machine on page Replacing parts and labels • Spare parts must comply with the technical requirements specified by Wacker Neuson.

  • Page 21: Special Hazards

    Safety Special Hazards 3.6 Special Hazards Electrical energy • Use only fuses with the specified current rating. • Stop the machine immediately if an electrical system malfunction occurs. Disconnect the battery and contact a trained technician to perform trou- bleshooting procedures. •...

  • Page 22: Disposal

    Safety 3.8 Disposal Disposal Environment The operating fluids in this machine, including fuel, engine oil, and grease, may be considered hazardous waste in many areas. Responsible disposal prevents toxic chemicals and materials from harming the environment. Fol- low the product-related safety regulations SDS (Safety Data Sheet – MSDS). All fluids, lubricants, materials, etc., used on the machine are subject to spe- cific regulations regarding collection and disposal.

  • Page 23: Vehicle Description

    Vehicle Description Machine Description 4.1 Vehicle Description Machine Description The Wacker Neuson Utility Track Loader is a self-propelled work machine. These machines are versatile and powerful helpers for moving earth, gravel, and debris on construction sites and elsewhere. A wide range of attach- ments allow for numerous different applications of the machines in various environments.

  • Page 24: Machine Overview

    Vehicle Description 4.2 Machine Overview Machine Overview Fig. 3: Machine components Ref. Component Ref. Component Handrails Controls 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 Lifting points —...

  • Page 25: Labels Overview-Ansi

    Vehicle Description Labels Overview—ANSI 4.3 Labels Overview—ANSI WARNING ADVERTENCIA DANGER AVERTISSEMENT PELIGRO DANGER 1000461827 1000366250 DANGER PELIGRO DANGER 5" 1000398281 1000461827 1000398268 1000398268 WARNING ADVERTENCIA AVERTISSEMENT 1000398268 1000398268 1000h 500h 500h 250h 250h WARNING 250h 250h 500h 500h 1000h 1000h 1000461833 1000461822 1000397078...
  • Page 26 Vehicle Description 4.3 Labels Overview—ANSI 544kg 453kg (1200LB) (1000LB) SM 120 SM 100 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 Fig. 5: Engine bay and operator console area Operator’s Manual | SM100 / SM120 | 5100064108 / 3300031444 | 10/2023 | [en-US]...

  • Page 27: Labels Overview-Iso

    Vehicle Description Labels Overview—ISO 4.4 Labels Overview—ISO 1000366250 5" 1000398281 1000398268 1000398268 1000398268 1000398268 1000h 500h 500h 250h 250h WARNING 250h 250h 500h 500h 1000h 1000h 1000461833 1000461822 1000397078 Fig. 6: Left, right, back, and front [en-US] | 10/2023 | 5100064108 / 3300031444 | SM100 / SM120 | Operator’s Manual...
  • Page 28 Vehicle Description 4.4 Labels Overview—ISO STOP 544kg 453kg (1200LB) (1000LB) SM 120 SM 100 ISO 14397 ISO 14397 1000474444 1000463295 1000461824 1000516850 1000463167 1000503651 STOP 1000516849 Fig. 7: Engine bay and operator console area Operator’s Manual | SM100 / SM120 | 5100064108 / 3300031444 | 10/2023 | [en-US]...

  • Page 29: Safety Labels

    Vehicle Description Safety Labels 4.5 Safety Labels DANGER Asphyxiation hazard • Engines emit carbon monoxide. • Do not run the machine indoors or in an enclosed area unless adequate ventilation, through such items as exhaust fans or hoses, is provided. •...
  • Page 30 Vehicle Description 4.5 Safety Labels WARNING Do not step off platform with load raised. Keep heavy end uphill. Travel up and down slopes not across them. Never drive over obstructions. STOP 1000516849 Slow down on rough and uneven terrain. Avoid abrupt starts and stops. Operate only from operator’s position.
  • Page 31 Vehicle Description Safety Labels 4.5 WARNING Hot surface hazard to the right WARNING Hot surface hazard Read and understand the operator’s manual. WARNING Hot surface hazard Keep body, loose objects, and clothing away from the surface. WARNING WARNING ADVERTENCIA Injury hazard AVERTISSEMENT Do not stand within 2 m (6.6 ft) of the machine.
  • Page 32 Vehicle Description 4.5 Safety Labels WARNING Keep door closed except for service. Keep engine clean of flammable material. Keep body, loose objects, and clothing away from electrical contacts, mov- ing parts, hot parts, and exhaust. Do not use loader in spaces with explosive dusts or gases or with flammable material near exhaust.
  • Page 33 Vehicle Description Safety Labels 4.5 WARNING Entanglement hazard Avoid all belts while the engine is running. STOP WARNING WARNING ADVERTENCIA Tipping hazard AVERTISSEMENT Carry load low while traveling. WARNING WARNING ADVERTENCIA Injury hazard AVERTISSEMENT • Do not carry passengers anywhere on the machine. •...

  • Page 34: Information Labels

    Vehicle Description 4.6 Information Labels WARNING Crushing hazard • 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. WARNING WARNING Cancer and Reproductive Harm www.P65Warnings.ca.gov California Proposition 65 Warning ADVERTENCIA...
  • Page 35 Vehicle Description Information Labels 4.6 Tie-down point 1000398268 Attachment coupler operation 1000461833 Instructions for using the lift arm support device. For further information, Lift Arm Support Device on page Maintenance schedule 1000h 500h 500h For further information, see Maintenance on page 250h 250h WARNING...
  • Page 36 Vehicle Description 4.6 Information Labels Engine throttle 1000461824 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 / 3300031444 | 10/2023 | [en-US]...
  • Page 37 Vehicle Description Information Labels 4.6 Ignition and rated operating capacity—model SM120 544kg (1200LB) SM 120 ISO 14397 1000474444 Guaranteed sound power level Read and understand the operator’s manual before operating the machine. [en-US] | 10/2023 | 5100064108 / 3300031444 | SM100 / SM120 | Operator’s Manual...

  • Page 38: Transportation

    Transportation 5.1 Preparing the Machine for Transportation Transportation Preparing the Machine for Transportation WARNING Personal injury hazard Improper loading can result in serious injury or death. ► Keep others away from the loading area. ► Drive the machine off the transport vehicle with the help of a guide. Preparing transport vehicles for loading and unloading Ensure the transport vehicle (trailer, truck) is capable of supporting the <...
  • Page 39 Transportation Loading and Unloading the Machine 5.2 NOTICE Machine damage can occur if the machine is not loaded properly. ► Drive the machine onto the trailer with the heaviest end of the machine going up the ramp first. NOTICE Ensure the transport vehicle driver knows the overall height, width, and weight of the transport vehicle (including the machine to be transported) be- fore starting machine travel, and the legal transport regulations of the coun- tries where transport is taking place.

  • Page 40: Towing The Machine

    Transportation 5.3 Towing the Machine Fig. 10: Front and rear tie-down points and angles Attachment Point α ß Maximum Tie-down Force 1 (front) 32° 45° 4,125 (927) N (ft. lbs.) 2 (rear) 58° 51° 4,912 (1,104) N (ft. lbs.) Unloading the machine Ensure the area behind the access ramp is clear and that access to it is not obstructed.

  • Page 41: Lifting The Machine

    Transportation Lifting the Machine 5.4 Do not tow this machine, except out of an immediate risk zone or to load onto a transport vehicle. Do not tow another machine with this machine. 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.
  • Page 42 Transportation 5.4 Lifting the Machine NOTICE Machine damage hazard Lifting the machine unevenly can lead to damage. To avoid damage from additional stress: ► Use spreader bars of appropriate dimension. ► Note that the maximum angle from vertical for lifting chains, straps, or cables is 60 degrees.
  • Page 43 Transportation Lifting the Machine 5.4 Lifting Note: For further information on lifting point locations, see Machine Over- view on page see Labels Overview—ANSI on page 25 see Labels Overview—ISO on page 27, and see Safety Labels on page Move all switches and levers to the neutral or zero positions. Remove the ignition key.

  • Page 44: Operation

    Operation 6.1 Risk of Injury or Death Operation Risk of Injury or Death Before putting the machine into operation, ensure no one is at risk of injury or death. The risk zones are the areas in which persons can be seriously in- jured or killed if struck by, or caught by, the movements of the machine, at- tachment, load, or moving parts of the machine.

  • Page 45: Inspecting The Work Area

    Operation Inspecting the Work Area 6.2 Avoid risk of injury or death Before operating the machine, instruct all personnel in the area to stay away from the machine while it is being operated. While operating the machine, remain aware of people moving in the work area.

  • Page 46: Operation Checklists

    Operation 6.4 Operation Checklists Operating during the break-in period Follow the recommendations below while operating the machine during the break-in period: • During the first hour of operation, vary the engine speed and the load on the engine. Short periods of maximum engine speed and load are desir- able.

  • Page 47: Adjusting The Operator Platform

    Operation Adjusting the Operator Platform 6.5 Operation checklist The following items should be checked after the engine is started: • Check that the indicator lights for engine oil pressure and battery charge functions switch off within a few seconds after the engine is started. •...

  • Page 48: Machine Controls-Standard

    Operation 6.6 Machine Controls—Standard When you have finished the adjustments, tighten the nut against the operator platform weldment to hold the bumper spring in place. Repeat on the other side. Machine Controls—Standard Fig. 14: Operator's console components Ref Description Ref Description 1 Spaces for optional features Instrument display 3 Parking brake...

  • Page 49: Machine Controls-Eh Aux

    Operation Machine Controls—EH Aux 6.7 Machine Controls—EH Aux Fig. 15: Operator's console components Ref Description Ref Description 1 Spaces for optional features Instrument display 3 Parking brake Key switch 5 Left handrail Ground drive joystick control 7 Auxiliary hydraulics switch Workgroup joystick control 9 Right handrail 10 Hand throttle 11 12V adapter...
  • Page 50 Operation 6.8 Starting and Stopping the Engine WARNING Personal injury hazard Personal injury can occur if certain conditions are not met. Before starting the engine, the operator must: ► Remain aware of bystanders. ► Ensure there is sufficient ventilation before operating the machine in en- closed areas.

  • Page 51: Control Interlock System

    Operation Control Interlock System 6.9 Wait until the engine preheat light (1) goes off. Turn and hold the ignition key to position 2 to crank the engine. When the engine starts, release the ignition key. ð The oil pressure and battery charge status lights turn off. The parking brake light continues to stay illuminated until the parking brake switch is pressed to disengage the brake.
  • Page 52 Operation 6.9 Control Interlock System Parking brake switch The parking brake (indicated by an icon on the display and an illumi- nated LED on the parking brake switch (1)) defaults to ON when the engine is not running. When the engine starts, press the parking brake switch to dis- engage the parking brake.

  • Page 53: Operating The Machine In Extreme Weather Temperatures

    Operation Operating the Machine in Extreme Weather Temperatures 6.10 6.10 Operating the Machine in Extreme Weather Temperatures WARNING Accident hazard Cold hydraulic oil can lead to unpredictable machine movement and a possi- ble loss of machine control. ► Do not operate the machine until it has warmed up according to the in- formation below.
  • Page 54 Operation 6.10 Operating the Machine in Extreme Weather Temperatures Hydraulic system • Use proper hydraulic oil. • Prevent damage to the hydraulic system by operating the machine at low loads. Follow the warm-up procedures before using the machine at full load.

  • Page 55: Instrument Display

    Operation Instrument Display 6.11 6.11 Instrument Display The instrument display informs the operator of the operating states, required maintenance, or possible machine malfunctions. Fig. 21: Instrument display [en-US] | 10/2023 | 5100064108 / 3300031444 | SM100 / SM120 | Operator’s Manual...
  • Page 56 Operation 6.11 Instrument Display Instrument display indicator lights Symbol Color Function Yellow Engine preheating Battery charge indicator light Parking brake Engine coolant temperature General malfunction Yellow Low fuel Operator presence Blue Work lights — Down arrow (instrument display) — Instrument display —...

  • Page 57: Instrument Display Symbols And Functions

    Operation Instrument Display Symbols and Functions 6.12 6.12 Instrument Display Symbols and Functions Symbol Function Auto idle Service wrench Cold system restriction warning Hydraulic oil filter clogged Auxiliary continuous flow active Hydraulic oil temperature Engine speed Elapsed operating hours meter Fuel level Unable to disengage parking brake—auxiliary Unable to disengage parking brake—operator not present...

  • Page 58: Instrument Display Pages And Subpages

    Operation 6.13 Instrument Display Pages and Subpages 6.13 Instrument Display Pages and Subpages 999 °C 999 °C 999 °C XX XX 2750 RPM 2750 RPM 2750 RPM 999999.9 999999.9 999999.9 999999.9 80 °C 80 °C 80 °C 80 °C AUTO AUTO AUTO AUTO...

  • Page 59: Machine Status

    Operation Machine Status Pages 6.14 6.14 Machine Status Pages Page 0.0—Main display page For descriptions of each of the icons displayed on this page, see Instrument Display Symbols and Functions on page The following machine statuses are accessible through this page: •...

  • Page 60: Machine Options

    Operation 6.15 Machine Options 6.15 Machine Options Page 1.0—Machine options Auto-idle is accessible through the Machine Options page. Fig. 28: Page 1.0 Subpage 1.1—Auto-idle Auto-idle returns the engine RPMs to low idle after a set of criteria have been satisfied. When criteria are no longer met, the engine RPMs return to the throttle commanded value.

  • Page 61: Instrument Display Settings

    Operation Instrument Display Settings 6.17 • View the hydraulic oil temperature, system voltage, and engine coolant temperature • View the software and hardware material number and version • View the OCU software and hardware material number and version (SM120 only) •...

  • Page 62: Ground Drive And Loader Controls

    Operation 6.19 Ground Drive and Loader Controls Stand on the operator platform with the operator presence pedal en- gaged. Set the engine to high idle. For at least 3 seconds, hold the auxiliary hydraulics switch (1) while holding the auxiliary control lever (2) all the way out of NEUTRAL (for- ward or backward).
  • Page 63 Operation Ground Drive and Loader Controls 6.19 Hydraulic pilot ISO controls The ground drive joystick controls all of the ground drive functions (tracks), and the workgroup joystick controls all of the loader functions (lift arm and attachment tilt). Note: Use the handrails when operating the controls. Fig. 40: Moving the right joystick back to raise the lift arm Fig. 41: Moving the right joystick forward to lower the lift arm Fig. 42: Moving the right joystick to the left to roll the attachment inward...
  • Page 64 Operation 6.19 Ground Drive and Loader Controls Fig. 44: Ground drive joystick functions Refer to the illustration for the necessary joystick motions to move the ma- chine as desired. Use the left joystick to move and turn the machine. 1—Forward 5—Forward right turn 2—Reverse 6—Forward left turn 3—Rotate right...

  • Page 65: Cold System Restriction

    Operation Cold System Restriction 6.20 6.19.2 Leveling the Ground Using the Float Function Raise the lift arm. Tilt the bucket to a horizontal position or beyond. Move the lift arm control past the lowering position into the float posi- tion to activate the float function. Adjust the bucket angle.
  • Page 66 Operation 6.21 Operating on Slopes Overview 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 15°. The risk zone on a slope is different from the one on a level surface. Stop machine operation immediately as soon as someone enters the risk zone.

  • Page 67: Machine Tip Over

    Operation Machine Tip Over 6.22 6.22 Machine Tip Over CAUTION Engine damage hazard Engine damage may occur if it is started when there is fluid present in the combustion chamber. ► Do not start the engine if the machine has been tipped over for any length of time.
  • Page 68 Operation 6.23 Using the Manual Coupler Mounting an attachment Set the lock levers (1) to the unlocked (up) position. Note: The attachment should be in a stable position on level ground. Start the engine and disengage the parking brake. Tilt the coupler forward. Ensure the lift arm is completely lowered.
  • Page 69 Operation Using the Manual Coupler 6.23 Testing the attachment system For buckets, lower the lift arm fully and tilt the bucket down until the front of the machine lifts off of the ground. Fig. 53: Testing the attachment With any attachment, ensure the lower coupler pins (5) protrude through the attachment’s lower mounting plate.

  • Page 70: Auxiliary Hydraulic Connections

    Operation 6.24 Auxiliary Hydraulic Connections 6.24 Auxiliary Hydraulic Connections WARNING Severe injury hazard Hydraulic oil, tubes, and hoses are under high pressure and become very hot during operation. ► Relieve the hydraulic system pressure before connecting or disconnect- ing any hydraulic components. ►...

  • Page 71: Manual Auxiliary Controls

    Operation Manual Auxiliary Controls 6.25 Disconnecting hydraulic hoses Lower the lift arm. Stop the engine. Push in the top and bottom couplers or move the auxiliary hydraulic control lever back and forth while holding the parking brake switch to relieve pressure in that auxiliary hydraulic hose circuit. Pull the rings (4) on the couplers to release the hoses from the ma- chine.

  • Page 72: Filling And Dumping The Bucket

    Operation 6.27 Filling and Dumping the Bucket Standard controls Stand on the operator platform with the operator presence pedal en- gaged. Set the engine to high idle. Press the auxiliary hydraulics switch (1). Push the hydraulic control lever (2) fully forward (or backward, depend- ing on the desired flow direction) to its detent position.

  • Page 73: Recommended Fuels-Diesel And Biodiesel

    Operation Recommended Fuels—Diesel and Biodiesel 6.28 While driving the machine slowly forward into the pile, tilt the bucket back and raise the lift arm at the same time to fill the bucket. Reverse away from the pile, turn the machine around on level ground, then travel to the dumping location with the bucket low to the ground.

  • Page 74: Refueling The Machine

    Operation 6.29 Refueling the Machine Fuel requirements • Fuel must meet the ASTM D975, EN590:96, ISO 8217 DMX, BS 2869- A1 or A2, JIS K2204 Grade No. 2, KSM-2610, or GB252 standard. • Biodiesel fuel for blending must meet the EN14214 or ASTM D-6751 and D7467, or JIS K2390 standard.

  • Page 75: Lift Arm Manual Override

    Operation Lift Arm Manual Override 6.30 CAUTION Fire and health hazard Fuel expands when heated. Expanding fuel in an over-filled tank can lead to spills and leaks. ► Do not fill the fuel tank completely. NOTICE Keep the fuel tank and fuel-handling equipment clean at all times. Be careful not to let any contaminants or even dust from the outside into the filler port when supplying fuel.

  • Page 76: Lift Arm Support Device

    Operation 6.31 Lift Arm Support Device Turn the ignition key to position 1. Press and hold the parking brake switch. Push the workgroup joystick forward to lower the lift arm. 6.31 Lift Arm Support Device WARNING Crushing hazard A disconnected hydraulic line can result in the lift arm dropping, resulting in serious injury or death.

  • Page 77: Parking The Machine

    Operation Parking the Machine 6.32 6.32 Parking the Machine Park the machine on a level surface with the lift arm completely low- ered. Note: If the machine is parked on a slope, position the front of the ma- chine downhill. If possible, tilt the attachment (such as a bucket) down so that it digs into the ground.

  • Page 78: Factory-Installed Options

    Factory-Installed Options 7.1 Ride Control Factory-Installed Options Ride Control Ride control reduces the machine’s pitching motion to provide a smoother ride and to prevent loss of material from the bucket while traveling. Relieving hydraulic pressure in the ride control accumulator To relieve hydraulic pressure: Lower the lift arm to the ground.

  • Page 79: Maintenance

    Maintenance Maintenance Introduction 8.1 Maintenance Maintenance Introduction WARNING Personal injury and machine damage hazard A poorly maintained machine can malfunction, causing injuries or permanent damage to the machine. ► Keep the machine in safe operating condition by performing periodic maintenance and making repairs as needed. ►...

  • Page 80: Maintenance Label

    Maintenance 8.2 Maintenance Label Maintenance Label 1000h 500h 500h 250h 250h WARNING 250h 250h 500h 500h 1000h 1000h 1000461822 Fig. 72: 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.
  • Page 81 Maintenance Maintenance Label 8.2 Symbol Task Reference Every 10 Operating Hours (Daily) Check the fluids and lubricants (engine oil, engine coolant, hydraulic oil). [} 91] [} 86] [} 87] Check the engine air filter condition indicator for leaks and damaged compo- [} 83] nents. Check the water separator.
  • Page 82 Maintenance 8.2 Maintenance Label Symbol Task Reference Check battery for damage and recharge. Check cables, connections, and elec- [} 109] trolyte level. Every 250 Operating Hours Replace engine oil and filter. [} 97] Check lift arm support device for damage. [} 76] Check condition of all drive belts. Adjust or replace as needed. [} 99] Check and clean radiator fins.

  • Page 83: General Daily Checks

    Maintenance General Daily Checks 8.3 General Daily Checks • Perform an overall visual check of the machine: – Clean dirt and debris from the operator platform. – Check for loose and broken parts, instrument operation, and oil leaks. • Visually inspect the engine compartment, including the engine itself. If you find any problems during the visual check, take the necessary cor- rective action before operating the engine.

  • Page 84: Lubrication Plan

    Maintenance 8.5 Lubrication Plan Adjusting the hood There are two adjustment points for the hood—one at the right hood hinge (2), and the other at the front bracket (3). The bolt holes are slotted to provide a minimal amount of adjustment. Adjustments at both points are ob- tained in a similar fashion, as follows: Fig. 74: Hood adjustment points Loosen the carriage bolts that secure the bracket.

  • Page 85: Engine Oil Viscosity

    Maintenance Engine Oil Viscosity 8.6 Position Location Lubrication Point Quantity Lift cylinder (front) Lift cylinder (back) Upper tilt cylinder Lower tilt cylinder Coupler B-pin Attachment coupler pin Brake pin Engine Oil Viscosity WARNING Health hazard Most used liquids from this machine contain small amounts of materials that can cause cancer and other health problems if inhaled, ingested, or left in contact with skin for prolonged periods of time.

  • Page 86: Checking And Adding Engine Coolant

    Maintenance 8.7 Checking and Adding Engine Coolant The viscosity of the engine oil is an important factor when determining the correct engine oil to use in your machine. Use an engine oil of appropriate viscosity based on the expected outside air temperature. See the table be- low.

  • Page 87: Checking The Hydraulic Oil Level

    Maintenance Checking the Hydraulic Oil Level 8.8 WARNING Burn hazard Engine coolant can contain alkali. ► Avoid engine coolant contact with skin and eyes. When Every 10 hours or daily Requirements • Machine parked on a level surface • Machine shut down and cool to the touch •...

  • Page 88: Testing The Control Interlock System

    Maintenance 8.9 Testing the Control Interlock System Requirements • Machine parked on a level surface • Machine shut down • Lift arm down • New hydraulic oil as needed Overview The hydraulic oil filler cap and sight glass are located on the left side of the machine.
  • Page 89 Maintenance Testing the Control Interlock System 8.9 • Disengage the operator presence pedal, wait 5 seconds, and move the ground drive joystick, workgroup joystick, and auxiliary hydraulic con- trols. • With the operator presence pedal engaged, engage the parking brake and move the ground drive joystick only. Note: After all controls are enabled, engaging the parking brake will only en- gage the brake itself and limit the ground drive controls to hold the machine stationary.

  • Page 90: Checking For Leaks

    Maintenance 8.10 Checking for Leaks Shut down the machine. 8.10 Checking for Leaks WARNING Fire hazard Flammable liquids and residue can easily ignite when exposed to flame. ► Never use an open flame to inspect for leaks. When Every 50 hours Requirements •...

  • Page 91: Checking The Engine Oil

    Maintenance Checking the Engine Oil 8.11 8.11 Checking the Engine Oil WARNING Health hazard Most used liquids from this machine contain small amounts of materials that can cause cancer and other health problems if inhaled, ingested, or left in contact with skin for prolonged periods of time. ►...

  • Page 92: Checking The Exhaust System

    Maintenance 8.12 Checking the Exhaust System Procedure Open the hood. Carefully remove the dipstick (1) and wipe it clean. Fully insert the dipstick into the dipstick tube (2) and remove it again to check the engine oil level. Fig. 80: Dipstick, dipstick tube, and oil cap If the engine oil level is between the min (3) and max (4) marks, the level is acceptable.

  • Page 93: Checking The Continuous Flow Shutoff System

    Maintenance Checking the Continuous Flow Shutoff System 8.13 Start the engine. Listen carefully for: ð Excessive noise. Some noise is normal when the engine starts or shuts down as the engine mount contacts with stop blocks. ð Rumbling ð High-pitched whine ð...

  • Page 94: Draining And Cleaning The Water Separator

    Maintenance 8.14 Draining and Cleaning the Water Separator 8.14 Draining and Cleaning the Water Separator 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—check •...

  • Page 95: Cleaning The Machine

    Maintenance Cleaning the Machine 8.15 Interrupt the fuel supply by turning the fuel valve (3) 180° to the CLOSED (up) position. Unscrew the threaded fitting (4) using an appropriate filter wrench, if necessary. Carefully remove the cartridge. Clean up any spills immediately. Draining the water separator Pour the fuel and water mixture into an approved container and dis- pose of waste properly.
  • Page 96 Maintenance 8.15 Cleaning the Machine NOTICE A pressure washer can damage the electrical system, damage seals, and disable the controls. ► Do not clean the inside of the machine using a pressure washer. NOTICE Direct, high water pressure at close range will damage certain components on the machine.

  • Page 97: Changing The Engine Oil And Filter

    Maintenance Changing the Engine Oil and Filter 8.16 Clean interior and electronic machine components using a damp, clean cloth. 8.16 Changing the Engine Oil and Filter WARNING Health hazard Most used liquids from this machine contain small amounts of materials that can cause cancer and other health problems if inhaled, ingested, or left in contact with skin for prolonged periods of time.
  • Page 98 Maintenance 8.16 Changing the Engine Oil and Filter • Recommended oil (for oil specifications, see Engine Oil Viscosity on page 85 see Fluids on page 121) • Filter wrench Procedure Loosen the two bolts (1) securing the access cover (2) on the right side of the machine.

  • Page 99: Checking And Adjusting The Drive Belts

    Maintenance Checking and Adjusting the Drive Belts 8.17 11. Remove the oil fill cap (7) from the engine. 12. Fill the engine with the required amount of oil. 13. Install the oil fill cap. 14. Start the engine and check for leaks. 15.
  • Page 100 Maintenance 8.17 Checking and Adjusting the Drive Belts Check the tension values in the applicable table below. Note: A “used” V-belt is a belt that has been used on a running engine for five minutes or more. Check the belt condition. Adjust the tension or replace the belt as needed.

  • Page 101: Checking The Undercarriage

    Maintenance Checking the Undercarriage 8.18 Loosen but do not remove the two screws (8) securing the tensioner. Using a standard 3/8 in. socket driver, rotate the adjustable tensioner spacer (9) counterclockwise until the end of travel is reached. While holding the tensioner spacer in place, retighten the screws. Fig. 99: Hydrostatic belt adjustment 8.18 Checking the Undercarriage...

  • Page 102: Servicing The Air Cleaner

    Maintenance 8.20 Servicing the Air Cleaner 8.20 Servicing the Air Cleaner WARNING Fire hazard Flammable liquids pose a fire hazard when cleaning. ► Do not use gasoline or other types of low flash point solvents to clean the air cleaner. NOTICE Foreign material entering the engine may damage it.

  • Page 103: Checking And Adjusting Track Tension

    Maintenance Checking and Adjusting Track Tension 8.21 Install the cover and fasten the latch. 8.21 Checking and Adjusting Track Tension Note: Follow the below procedures for increasing and reducing track tension when they are referred to in these instructions. WARNING Personal injury hazard Grease escaping under pressure can penetrate the skin and cause serious injury or death.
  • Page 104 Maintenance 8.21 Checking and Adjusting Track Tension Increasing track tension On the side of the machine that needs its track adjusted, loosen the screws (1) securing the grease valve cover and swing the cover (2) down. Fig. 102: Screws and cover Apply grease into the valve (3) with a grease gun.

  • Page 105: Checking And Cleaning The Radiator Fins

    Maintenance Checking and Cleaning the Radiator Fins 8.22 8.22 Checking and Cleaning the Radiator Fins CAUTION Personal injury hazard Using compressed air or high-pressure water may cause eye injuries due to flying debris, dust, and steam. ► Wear eye protection when using compressed air or high-pressure water. NOTICE Cleaning the radiator improperly will damage the radiator fins.
  • Page 106 Maintenance 8.23 Replacing the Fuel Filter Procedure Raise the lift arm and install the lift arm support device. For more infor- mation, see Lift Arm Support Device on page Shut down the machine. Allow the machine to cool for at least 5 minutes. Lift the hood.

  • Page 107: Replacing The Hydraulic Tank Filler Cap

    Maintenance Replacing the Hydraulic Tank Filler Cap 8.24 15. Open the fuel supply fuel by turning the fuel valve to the OPEN (down) position on the water separator. 16. Prime the fuel system by turning the key switch to the ON position (po- sition 1) for 10 to 15 seconds.
  • Page 108 Maintenance 8.25 Replacing the Hydraulic Fluid and Filter • Replacement fluid • Replacement filter Replacing the hydraulic oil 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. 108: Hydraulic fill access plate Remove the hydraulic tank filler cap (4).

  • Page 109: Maintaining The Battery

    Maintenance Maintaining the Battery 8.26 10. Observe the hydraulic oil level through the sight glass and add fluid as necessary. 11. Install the rear access panel. 8.26 Maintaining the Battery DANGER Explosion hazard Batteries can emit explosive hydrogen gas. ► Keep all sparks, flames, and other ignition sources away from the bat- tery.

  • Page 110: Engine-Jump-Starting

    Maintenance 8.27 Engine—Jump-starting When • Every 50 hours—check the battery for damage; check cables and con- nections, and recharge Maintaining • Keep battery terminals clean and connections tight. • When necessary, tighten the cables and grease the cable clamps with battery terminal grease or petroleum jelly.
  • Page 111 Maintenance Engine—Jump-starting 8.27 CAUTION Personal injury hazard Electrical arcing can cause severe personal injury. ► Do not allow positive and negative cable ends to touch. NOTICE Observe the following precautions to prevent serious damage to the electri- cal system. ► Jump-starting a shorted or defective battery will cause the voltage regu- lator to supply higher than normal voltage.
  • Page 112 Maintenance 8.27 Engine—Jump-starting Procedure There are two procedures listed below. The first is for jump-starting a ma- chine using another machine. The second is for jump-starting a machine with a jump pack. Jump-starting the battery with another machine In very cold weather, check the condition of the electrolytes. If it seems slushy or frozen, do not try jump-starting until it thaws.
  • Page 113 Maintenance Engine—Jump-starting 8.27 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. [en-US] | 10/2023 | 5100064108 / 3300031444 | SM100 / SM120 | Operator’s Manual...

  • Page 114: Fuse And Relay Box Layout

    Maintenance 8.28 Fuse and Relay Box Layout 8.28 Fuse and Relay Box Layout Location The fuse and relay box (1) is located under the hood on the right side of the machine near the battery. Fig. 114: Fuse and relay box Fig. 115: SM100 (left) and SM120 (right) fuse and relay box layouts Description Rating (A)
  • Page 115 Maintenance Fuse and Relay Box Layout 8.28 Description Rating (A) F016 Aux. electric key switch F017 Aux. electric “A” F018 Aux. electric “B” F020 ECU and fuel rack actuator F024 Option controller B+ supply (SM120 only) F031 Key switch / operator presence / telematics / diagnos- tics / ECU F032 Display / telematics / diagnostics F033 12V outlet / work lights...

  • Page 116: Troubleshooting

    Troubleshooting 9.1 Engine and Engine Oil Warning Lights Troubleshooting Engine and Engine Oil Warning Lights Engine Warning Engine Stop Oil Pressure Description Yellow — All warning and indicator lights illuminate for a few seconds if the key is turned to position 1. If the engine stop or oil pressure light illuminates during operation, stop machine operation imme- diately and contact a Wacker Neuson service center.
  • Page 117 Troubleshooting Diagnostic Trouble Codes 9.2 DTC (J1939 Format) Description J1939 Lamp Status (Hex) (DEC) FMI 4 Accelerator Pedal Position Sensor "B" : Shorted to low source 3 Accelerator Pedal Position Sensor "B" : Shorted to high source 2 Accelerator Pedal Position Sensor "B" : Intermittent fault 1 Accelerator Pedal Position Sensor "B"...
  • Page 118 Troubleshooting 9.2 Diagnostic Trouble Codes DTC (J1939 Format) Description J1939 Lamp Status (Hex) (DEC) FMI 2 Cold Start Device : Intermittent fault 4 Oil Pressure Switch : Shorted to low source 1 Oil Pressure : Too Low 4 Battery Charge Switch : Shorted to low source 1 Charge warning 7F84A 522314 0 Engine Coolant Temperature : Abnormal temperature...

  • Page 119: Shutdown

    Shutdown Long-Term Storage 10.1 Shutdown 10.1 Long-Term Storage NOTICE Allowing the battery to freeze or completely discharge is likely to cause per- manent damage. ► Periodically charge the battery while the machine is not in use. ► In cold climates, store and charge the battery indoors or in a warm loca- tion.

  • Page 120: Machine Disposal And Decommissioning

    Shutdown 10.2 Machine Disposal and Decommissioning Storing the machine • Wash the machine and allow it to dry. • Move the machine to a clean, dry, secure storage location. Block or chock the tracks to prevent machine movement. • Use touch-up paint as needed to protect exposed metal against rust. •...

  • Page 121: Technical Data

    Technical Data Engine 11.1 Technical Data 11.1 Engine Item Units SM100 / SM120 Engine make — Yanmar Engine model — 3TNV80FT Emissions — Tier IV final Number of cylinders — Displacement 1.266 Nominal bore and stroke mm (in.) Bore—80 (3.1); stroke—84 (3.3) Output kW (hp) 18.4 (24.7)

  • Page 122: Electrical System

    Technical Data 11.4 Electrical System 11.4 Electrical System Item Units SM100 / SM120 Alternator 12V, 55A Starter 12V, 1.1 kW Battery 12V, 650 CCA 12V adapter 11.5 Hydraulic System Item Units SM100 / SM120 Hydraulic oil type — 10W-30 Hydraulic oil capacity (system) L (qt) 13.2 (14) Hydraulic oil capacity (reservoir)

  • Page 123: Forces

    Technical Data Forces 11.8 Item SM100 / SM120 Parking brake Spring applied pressure release (SAPR) Parking brake control Automatic/switchable 11.8 Forces Item Units SM100 SM120 Rated operating capacity (ROC) at 50% of tip load kg (lb) 647 (1,428) 795 (1,753) Rated operating capacity (ROC) at 35% of tip load kg (lb) 453 (1,000)

  • Page 124: Noise Values

    Technical Data 11.11 Noise Values 11.11 Noise Values Overview of Noise Parameters dB(A) Vehicle with engine 3TNV80FT Average sound power level LwA 100.8 Guaranteed sound power level LwA Specified sound pressure level LpA 87.9 11.12 Tightening Torques Property Class 10.9 12.9 10.9 Screws According to DIN 912, DIN 933, etc.
  • Page 125 Technical Data Tightening Torques 11.12 YANMAR engine standard torque chart The tightening torque in the following table should be applied only to bolts with a "7" head (JIS strength classification: 7T). Torque values shown are for clean, non-lubricated fasteners unless otherwise specified. •...

  • Page 126: Dimensions

    Technical Data 11.13 Dimensions 11.13 Dimensions Fig. 116: Machine dimensions Operator’s Manual | SM100 / SM120 | 5100064108 / 3300031444 | 10/2023 | [en-US]...
  • Page 127 Technical Data Dimensions 11.13 Description Units Specification SM100 SM120 Overall operating height, fully raised, with bucket mm (in.) 2,892.2 (113.9) 2,889 (113.7) Angle of departure degrees 25.6 Ground clearance, bottom of belly pan mm (in.) 196.9 (7.8) Maximum rollback, fully raised degrees Dump angle at maximum height degrees...

  • Page 128: Emission Control Systems Information And Warranty-Diesel

    Emission Control Systems Information and Warranty—Diesel 12.1 Emission Control System Background Information Emission Control Systems Information and Warranty— Diesel The Emission Control Warranty and associated information is valid only for the U.S.A., its territories, and Canada. 12.1 Emission Control System Background Information Introduction Wacker Neuson engines/equipment must conform with applicable Environ- mental Protection Agency (EPA) and California Air Resource Board (CARB)

  • Page 129: Limited Defect Warranty For Exhaust Emission Control System

    Emission Control Systems Information and Warranty—Diesel Limited Defect Warranty for Exhaust Emission Control System 12.2 12.2 Limited Defect Warranty for Exhaust Emission Control System See the supplied engine owner’s manual for the applicable emission war- ranty statement. 12.3 Limited Defect Warranty for Wacker Neuson Emission Control Systems The Emission Control Warranty is valid only for the U.S.A., its territories, and Canada.
  • Page 130 Emission Control Systems Information and Warranty—Diesel 12.3 Limited Defect Warranty for Wacker Neuson Emission Control Systems What is not covered • Failures other than those resulting from defects in material or workman- ship. • Any systems or parts which are affected or damaged by owner abuse, tampering, neglect, improper maintenance, misuse, improper fueling, im- proper storage, accident and/or collision;...

  • Page 131: Yanmar Limited Warranty

    Emission Control Systems Information and Warranty—Diesel Yanmar Limited Warranty 12.4 For owners located more than 100 miles from an authorized dealer/service center (excluding the states with high-altitude areas as identified in 40 CFR Part 1068, Appendix III), Wacker Neuson will pay for preapproved shipping costs to and from an authorized Wacker Neuson dealer/service center.
  • Page 132 Emission Control Systems Information and Warranty—Diesel 12.4 Yanmar Limited Warranty What the engine owner must do If you believe your YANMAR engine has experienced a failure due to a de- fect in material and/or workmanship, you must contact an authorized YAN- MAR industrial engine dealer or distributor within thirty (30) days of discover- ing the failure.

  • Page 133: Yanmar Power Technology Co., Ltd. Emission Control System Warranty-Usa Only

    Emission Control Systems Information and Warranty—Diesel Yanmar Power Technology Co., Ltd. Emission Control System Warranty—USA Only 12.5 corrosion. This warranty does not cover the cost of parts and/or labor re- quired to perform normal/scheduled maintenance on your YANMAR engine. This warranty does not cover consumable parts such as, but not limited to, filters, belts, hoses, fuel injector nozzles, lubricants and cleaning fluids.
  • Page 134 Emission Control Systems Information and Warranty—Diesel 12.5 Yanmar Power Technology Co., Ltd. Emission Control System Warranty—USA Only stringent anti-smog standards. In the remaining forty nine (49) states, new non-road compression-ignition engines must be designed, built and equipped to meet the United States EPA emissions standards. YANMAR must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.
  • Page 135 Emission Control Systems Information and Warranty—Diesel Yanmar Power Technology Co., Ltd. Emission Control System Warranty—USA Only 12.5 Warranted parts not scheduled for replacement as required maintenance in the owner's manual shall be warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in the owner's manual are warranted for the period of time prior to the first scheduled re- placement.
  • Page 136 Emission Control Systems Information and Warranty—Diesel 12.5 Yanmar Power Technology Co., Ltd. Emission Control System Warranty—USA Only Exclusions Failures other than those arising from defects in material or workmanship are not covered by this warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, or use of non-recommended fuels and lubricating oils;...
  • Page 137 Final Word to the User ......47 Acknowledgment We wish to acknowledge the contributions of the members of AEM’s Compact Loader/Compact Excavator Council to the preparation of this Safety Manual.

  • Page 138: 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 139: 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 140: 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 141 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 142 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 143: 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 144 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 145 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 146: 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 147: 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 148 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 149 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 150 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 151 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 152: 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 153: 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 154 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 155 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 156 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 157 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 158 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 159 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 160: Final Word To The User

    Your knowledge of these safety operating a Compact Tool Carrier easier and safer precautions and your application to the basic rules for you. This manual is one in a series on the safe operation of machinery, published by AEM. FORM CTC–0803...
  • Page 161 Index Index Abbreviations............ 11 Demolition............ 17, 44 Air cleaner Dust precaution ............ 16 servicing ............ 102 Attachments information............ 19 Electrical safety ............ 21 installation ............  19, 68 Emission control system removal............ 19, 69 background information ........ 128 safety guidelines.......... 19 information and warranty—diesel .....
  • Page 162 Index Hydraulics auxiliary connections ..........  70 Machine checking the oil level ..........  87 before operation .......... 17 connecting hoses .......... 70 break-in...............  45 disconnecting hoses...........  71 cleaning ............ 20, 96 operation in cold temperatures...... 54 description ............ 23 operation in hot temperatures ...... 54 disposal and decommissioning......
  • Page 163 Index Preparing transport vehicles........ 38 Tracks checking and adjusting tension ...... 103 Transportation ............ 38 Traveling Ride control .............  78 surface conditions.......... 66 Risk zone............ 17, 44 with a load ............ 66 Running the engine .......... 21 without a load .............  66 Safety Usage after use .............
  • Page 164 Index Operator’s Manual | SM100 / SM120 | 5100064108 / 3300031444 | 10/2023 | [en-US]...
  • Page 166 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 / 3300031444 Language: [en-US]...

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