Page 1 Operator’s Manual Utility Track Loader SM100 This Operator‘s Manual includes the AEM Safety Manual Machine Type 5100064108 / 3300031444 Material Number 5100064108 Version Date 08/2022 Language [en-US]...
Page 2 Imprint Publisher and copyright holder: Wacker Neuson America Corporation N92W15000 Anthony Ave Menomonee Falls, WI 53051, USA www.wackerneuson.us 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 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 .......................... 33 Operation Risk of Injury or Death ......................... 35 Inspecting the Work Area........................ 36 Break-In Period ............................ 36 Operation Checklists .......................... 37 Machine Controls .......................... 38 [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 6 Checking the Exhaust System ...................... 82 7.14 Checking the Continuous Flow Shutoff System ................... 83 7.15 Cleaning the Machine .......................... 84 7.16 Changing the Engine Oil and Filter ...................... 85 Operator’s Manual | 5100064108 | SM100 | 08/2022 | [en-US]...
Page 7 Limited Defect Warranty for Wacker Neuson Emission Control Systems.......... 116 11.4 Yanmar Limited Warranty ........................ 118 11.5 Yanmar Power Technology Co., Ltd. Emission Control System Warranty—USA Only ..... 120 Compact Tool Carrier AEM Safety Manual Index ................................ 148 [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 8: Foreword
The location of the nameplate is shown below. 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 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 9: 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: [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 10 • Permanent damage to the machine which will not be covered under war- ranty Contact your dealer immediately if you have questions about approved or unapproved parts, attachments, or modifications. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 11: Abbreviations
Fuel Water Separator 1000466934 Radiator Cap 1000431928 Hydraulic Oil Filter 1000463685 Fuel Cap 1000340135 Hydraulic Oil 5000164672 Hydraulic Tank Cap 1000340157 Tracks, Wide 1000421187 Hydraulic Tank Screen 1000340159 Grease 1000367563 — — [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 12: Usage
• Using the machine to tow other machines • 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 | 5100064108 | 08/2022 | [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] | 08/2022 | 5100064108 | SM100 | 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 | 5100064108 | 08/2022 | [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] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 16 • Look out for hazards such as high-voltage lines, underground cables, buried utility lines (electrical, gas, water, communication, sewer), etc., during excavation work. Before any digging begins: Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 17 (for example, ropes and chains). This applies, for example, to lifting and lowering pipes, shaft rings or containers. Wear the following PPE while operating this machine: [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 18: Safety Guidelines For Attachments
• Ensure the attachment is securely attached and that it functions cor- rectly. • Connect all hydraulic and electrical devices for the attachment and check their function before operating the machine. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 19: Safety Guidelines For Maintenance
• When replacement parts are required for this machine, use only Wacker Neuson replacement parts or those parts equivalent to the original in all types of specifications, such as physical dimensions, type, strength, and material. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 20: Safety Guidelines For The Engine Control Unit (Ecu)
• Attachments with electrical connections must be compatible with the ma- chine’s voltage specifications (12 volts). • For specific safety precautions when working with batteries, see Main- taining the Battery on page Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 21: Safety Guidelines When Using Internal Combustion Engines
• 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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 22: Vehicle Description
When using these attachments, observe the legal regulations of your country and equip the machine with all the safety equipment re- quired. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 23: Machine Overview
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 [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 24: Labels Overview
Vehicle Description 4.3 Labels Overview Labels Overview Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 25 Vehicle Description Labels Overview 4.3 [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 26: Safety Labels
Avoid abrupt starts and stops. 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. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 27 After jump start, remove negative connection at the engine first. WARNING Hot surface and explosion hazards Dangerous heat and contents under pressure. WARNING Entanglement hazard Avoid all moving parts while the engine is running. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 28 • 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 Cáncer y daño reproductivo www.P65Warnings.ca.gov Cancer and Reproductive Harm AVERTISSEMENT Cancer ou malformations www.P65Warnings.ca.gov congénitales www.P65Warnings.ca.gov 5100045462 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 29: Information Labels
Information Labels Hydraulic oil fill 1000366250 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 [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 30 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 Manual auxiliary control 1000463167 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 31 Vehicle Description Information Labels 4.5 Ignition and rated operating capacity 453kg (1000LB) SM 100 ISO 14397 1000463295 [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 32: 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 | 5100064108 | 08/2022 | [en-US]...
Page 33: Towing The Machine
► Towing the machine can cause excessive, uneven wear. ► The manufacturer’s warranty shall not apply to accidents or damage caused by towing. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 34 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. 5: Towing points Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 35: 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] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 36: Inspecting The Work Area
• Check for adequate traction if working on a slope. 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 | 5100064108 | 08/2022 | [en-US]...
Page 37: Operation Checklists
– An operator standing on the platform – The operator presence pedal engaged • Check the parking brake for proper operation. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 38: Machine Controls
Spaces for optional fea- Instrument display tures Parking brake Key switch Right handrail Workgroup joystick control Auxiliary hydraulic control Continuous flow switch lever Hand throttle Ground drive joystick control Left handrail — — Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 39: Control Interlock System
To disengage the interlock, engage the operator presence pedal before operating the auxiliary control lever (4). For further information on continuous flow operation, see Auxiliary Override on page [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 40: Starting And Stopping The Engine
► Wait 30 seconds before trying to crank the starter again so the battery can recover and the starter does not become overheated. Starting the engine Fig. 8: Positions 0, 1, and 2 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 41 • During the warm-up phase, check for unusual noise, exhaust color, leaks, malfunctions, or damage. • In the case of any malfunctions or damage, do not operate the machine. Contact a Wacker Neuson dealer immediately for assistance. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 42: Operating The Machine In Extreme Weather Temperatures
Cold temperatures affect the engine’s starting capability, and the hydraulic systems will be sluggish until the system temperatures increase to the nor- mal operating range. The following are actions that help minimize cold start effects. Engine/electrical Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 43 – 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] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 44: Instrument Display
6.9 Instrument Display Instrument Display The instrument display informs the operator of the operating states, required maintenance, or possible machine malfunctions. 210° 180° 49.8 140° 12:10 wc_gr013849 Fig. 13: Instrument display Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 45 Instrument display (for further information, see the next section.) — To next menu page/set (instrument display) Green High flow (not used on this model) Hydraulic oil temperature Hydraulic oil pressure Engine stop Yellow Engine warning [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 46: Instrument Display Symbols And Functions
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 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 47 Unable to disengage parking brake—operator not present Unable to disengage parking brake—engine off Unable to disengage parking brake—hydraulic oil temperature too low Operating hours to next maintenance Operator unsafe shutdown warning [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 48: Instrument Display Subpages Menus
0 0 0 0 0 0 0 0 0 0 0 0 ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ Fig. 14: Subpage overview Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 49: Machine Status Screens
Subpages 0.3 through 0.5—Diagnostic trouble codes Engine control unit and display error codes are shown on these screens. For further information, see Diagnostic Trouble Codes on page 103. Fig. 18: Subpage 0.3 [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 50: Machine Options
Fig. 21: Subpage 1.1 6.14 Machine Vitals Page 2.0—Machine Vitals The following machine vitals are accessible through this screen: • Machine sensors • Display data • Machine serial number Fig. 22: Page 2.0 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 51: Instrument Display Settings
Fahrenheit and Celsius, change the language, or increment the machine hours. Fig. 26: Display arrows [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 52: Auxiliary Override
Locate the flange nut (1) around the bumper spring under the operator platform. Loosen the nut (2) against the operator platform weldment. Tighten the flange nut to push the bumper spring against the chassis weldment. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 53: Ground Drive And Loader Controls
Note: Use the handrail when operating the controls. • Move the right joystick back to raise the lift arm. • Move the right joystick forward to lower the lift arm. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 54 Fig. 30: Left 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. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 55 This machine uses a hydrostatic transmission. Track movement is controlled by the movement of the left joystick. The joystick is spring-loaded back to the neutral position. If you remove your hand from the joystick, the machine will stop. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 56: Operating On Slopes
Adjust speed and travel direction as necessary to maintain safe operation. • Machine stability and traction can be severely reduced when operating on uneven or rough terrain, rocky soils, or wet or loosely packed surface materials. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 57: Using The Manual Coupler
Stand on the operator platform and engage the operator presence pedal. Start the engine and disengage the parking brake. Tilt the coupler forward. Ensure the lift arm is completely lowered. Fig. 34: Lock levers [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 58 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. 39: Testing the attachment Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 59 Move the machine in reverse away from the attachment. Fig. 41: Lock levers, guide, and Note: Tilting the attachment back reduces the force to set the lock levers in mount the locked and unlocked positions. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 60: Auxiliary Hydraulic Connections
Fig. 43: Connecting hydraulic hoses Push the female connector attachment to the male auxiliary hydraulic connector (top) (2). Push the case drain connector attachment (if present) onto the case drain line (middle) (3) connector (deluxe only). Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 61: Manual Auxiliary Controls
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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 62: 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 | 5100064108 | 08/2022 | [en-US]...
Page 63: 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] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 64: 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 | 5100064108 | 08/2022 | [en-US]...
Page 65: Lift Arm Support Device
Raise the lift arm support device to its storage position and insert the pin. 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. 50: Install pin [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 66: Parking The Machine
Turn the ignition key to the OFF position to stop the engine. Step off the operator platform. Chock the . Make sure the parking brake pins are engaged (at least one). Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 67: Maintenance 7.1 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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 68: 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. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 69 Check the undercarriage for loose bolts and nuts. [} 89] — Drain the water separator. [} 81] Check battery for damage and recharge. Check cables, connections, and electrolyte [} 98] level. Every 250 Operating Hours [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 70 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. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 71: General Daily Checks
Lower the hood slowly to make sure the lock eye (1) goes through the hole in the hood and the door latches engage properly. Push down firmly to engage the door latches. Install the lock (if applicable). Fig. 53: Hood lock eye [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 72: Lubrication Plan
Repeat the previous steps until the correct adjustment is obtained. Tighten the bolts. For standard torque specifications, see Tightening Torques on page 113. Lubrication Plan Fig. 55: Lubrication points Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 73 Maintenance Items on page 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 [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 74: Engine Oil Viscosity
The engine oil must meet the API CD, CF, CF-4, CI-4, ACEA E-3, E-E, E-5, or JASO DH-1 standard. Fig. 56: Engine oil viscosity In particularly hot environments where ambient temperatures stay near and over 38°C (100°F), use SAE 15W-40 engine oil. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 75: Checking And Adding Engine Coolant
The engine coolant recovery reserve tank is located on the ride side of the engine compartment. Procedure Check that the engine coolant level is between the min and max lines (1). Fig. 57: Coolant bottle and fill cap [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 76: Checking The Hydraulic Oil Level
If the oil level is low, remove the hydraulic fill access plate by removing Fig. 58: Hydraulic oil sight glass and the retaining bolt (2) and loosening the pivot bolt (3). access plate Rotate the access plate out of the way. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 77: Testing The Control Interlock System
Shut down the machine and wait for the engine to stop completely. Make sure the area around the machine is clear. Move the right joystick forward to lower the lift arm. ð The lift arm should not lower. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 78: Checking For Leaks
► Seek medical attention immediately if hydraulic oil penetrates the skin or eyes. When Every 50 hours Requirements • Flashlight or shielded light (never use an open flame) • Protective gloves • A piece of cardboard, wood, or a mirror Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 79: Checking The Engine Oil
Engine damage can occur if the oil level is too high or if the incorrect oil is used. ► Oil must be removed from the engine if the oil level is above the max line. ► Use only the recommended oil. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 80 ð Repeat steps 1, 2, and 3 to check engine oil level. ð Install engine oil cap when engine oil level is sufficient. Fig. 61: Dipstick marks Install the dipstick and close the engine door. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 81: Draining And Cleaning The Water Separator
(battery and hood hidden for clarity) Remove the side panel (2) next to the water separator. Place a container beneath the water separator. Clean the area of the filter cartridge and housing. Fig. 63: Water separator panel [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 82: Checking The Exhaust System
10. Check for any fuel leaks. 7.13 Checking the Exhaust System When Every 10 hours or daily Requirements • Machine shut down • Exhaust pipes and muffler cool to the touch Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 83: Checking The Continuous Flow Shutoff System
Repeat steps 3–5 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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 84: 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. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 85: Changing The Engine Oil And Filter
Do not mix different types of engine oil. This can adversely affect the lubri- cating properties of the engine oil. Environment Use a suitable container to collect, store, and dispose of drained fluids and lubricants in accordance with current environmental protection regulations. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 86 Fig. 69: Oil drain hose Remove the three bolts (4) securing the cover plate (5). Place a suitable container under the oil filter to catch used oil. Fig. 70: Bolts and cover plate Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 87: Checking And Adjusting The Drive Belts
► Shut off the engine before carrying out work in the engine compartment. ► Shut off the power supply. ► Let the engine cool down. When • After the first 50 hours • Every 250 hours [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 88 After adjusting the tension, run the engine for at least 5 minutes. Check the tension again using the specifications for a used V-belt. Fig. 76: Clearance between V-belt and pulley groove Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 89: Checking The Undercarriage
Tightening Torques on page 113. • Check the condition of the cotter pin on the sprocket castle nut. Fig. 79: Undercarriage bolts 7.19 Inspecting Hoses and Hard Lines When Every 50 hours [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 90: Servicing The Air Cleaner
Requirements • Machine parked on a level surface • Machine shut down and cool to the touch • Damp cloth Overview The air cleaner is located in the engine compartment. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 91: Checking And Cleaning The Radiator Fins
Cleaning the radiator improperly will damage the radiator fins. ► Do not use high-pressure water or compressed air at a pressure greater than 28 psi (193 kPa). ► Do not use a wire brush. When Every 250 hours [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 92: Checking And Adjusting Track Tension
• Plastic sheet to protect work surface • Floor jack and jack stands • Wrench • Grease gun Overview Track wear can vary depending on the type of work and ground conditions. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 93 15 and 18 mm (0.56 and 0.71 in.). If the track tension is still out of specifica- tion, repeat the procedure for increasing or reducing track tension as needed. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 94: Replacing The Fuel Filter
Allow the machine to cool for at least 5 minutes. Lift the hood. Interrupt the fuel supply by turning the fuel valve (1) 180° to the CLOSED (up) position on the water separator (2). Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 95 16. Prime the fuel system by turning the key switch to the ON position (Po- sition 1) for 10 to 15 seconds. 17. Check for any fuel leaks. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 96: Replacing The Hydraulic Tank Filler Cap
Replacing the Hydraulic Fluid and Filter When Every 1000 hours, or as indicated by the display Requirements • Machine parked on a flat, level surface • Machine shut down • Replacement fluid • Replacement filter Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 97 Stop the engine and check for leaks. Observe the hydraulic oil level through the sight glass and add fluid as necessary. Fig. 90: Hydraulic tank filter 10. Install the rear access panel. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 98: 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 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 99: Engine-Jump-Starting
► In the event of ingestion or contact with skin or eyes, wash skin or eyes with water and seek medical attention immediately. CAUTION Personal injury hazard Electrical arcing can cause severe personal injury. ► Do not allow positive and negative cable ends to touch. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 100 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. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 101 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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 102 Maintenance 7.27 Engine—Jump-starting Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 103: Troubleshooting
Accelerator Pedal Position Sensor "A" : Be- low normal operational range (SAE J1843) Accelerator Pedal Position Sensor "A" : Above normal operational range (SAE J1843) 15 Accelerator Pedal Position Sensor "A" : Not available (SAE J1843) [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 104 Sensor 5V : Shorted to high source Sensor 5V : Intermittent fault System Voltage : Too Low System Voltage : Too High 1078 Engine Fuel Injection Pump Speed Sensor : Shorted to low source (Both) (Either) Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 105 12 E-ECU internal fault : FlashROM Check Sum Error (Main Software) E-ECU internal fault : FlashROM Check Sum Error (Data Set 1) E-ECU internal fault : FlashROM Check Sum Error (Data Set 2) [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 106 12 E-ECU internal fault : Engine Map Data Ver- sion Error 7F9EA 522730 12 Immobilizer : CAN Communication fault Immobilizer : Pulse Communication fault 1202 Immobilizer: System fault 1) Yanmar original DTC Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 107: 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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 108: 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. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 109: Technical Data
Idling speed 1,200 Fuel injection system — Mechanical indirect injection 10.2 Machine Speeds Item Units SM100 Forward travel speed km/h (mph) 8.4 (5.2) Reverse travel speed km/h (mph) 8.4 (5.2) [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 110: Fluids
Hydraulic oil capacity L (qt) 13.2 (14qt) Aux hydraulic flow - standard L/min (gal/min) 49.3 (13.0) Aux hydraulic relief pressure bar (psi) 210 (3,045psi) Fuel Tank capacity L (gal) 64.0 (14.1) Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 111: Electrical System
Item SM100 Type Hydraulic pilot Pattern Workgroup type ISO manual lever Engine speed Electronic dial Service brake Hydrostatic trans Parking brake Spring applied pressure release (SAPR) Parking brake control Automatic/switchable [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 112: Forces
Ground pressure kPA (psi) 28.8 (4.1) 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 | 5100064108 | 08/2022 | [en-US]...
Page 113: Tightening Torques
• For 4T bolts and locknuts, apply 60% of the torque listed in the table. • If aluminum alloy is contained in the parts to be tightened, apply 80 % of the torque listed in the table. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 114: Dimensions
137.0 ± 9.8 226.0 ± 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 10.11 Dimensions Fig. 93: SM100 dimensions Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 115: 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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 116: 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 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 117 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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 118: Yanmar Limited Warranty
Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 119 YANMAR Operation Manual, unauthorized alterations or modifications, ordinary wear and tear, and rust or [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 120: Yanmar Power Technology Co., Ltd. Emission Control System Warranty-Usa Only
2020, 2021, or 2022 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 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 121 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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 122 • 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. Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 123 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. [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 124 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 125: 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 126: 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 127: 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 128 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 129 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 130: 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 131 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 132 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 133: 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 134: 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 135 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 136 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 137 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 138 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 139: 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 140: 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 141 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 142 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 143 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 144 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 145 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 146 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 147: 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 148 77 Instrument display indicator lights (Tier IV)........ 45 symbols and functions ........ 47 Demolition ............ 16, 35 Dust precaution ............ 16 Jobsite .............. 15 Jump-starting............ 100 Electrical safety ............ 20 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 149 .......... 18 training.............. 14 Overhead electric lines .......... 16 Testing attachment system .......... 59 control interlock system ........ 39 Instrument display ........... 44 Parts Tightening torques.......... 113 replacing............. 19 [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 150 ...... 92 Transportation ............ 32 Traveling surface conditions .......... 56 with a load ............ 56 without a load ............. 56 Usage intended use............ 12 unintended use........... 12 Warm-up phase ............ 41 Operator’s Manual | SM100 | 5100064108 | 08/2022 | [en-US]...
Page 151 Index [en-US] | 08/2022 | 5100064108 | SM100 | Operator’s Manual...
Page 154 Wacker Neuson America Corporation N92W15000 Anthony Ave USA-53051 Menomonee Falls, WI Tel.: +01 262 255-0500 EMail: info@wackerneuson.com www.wackerneuson.us Material Number: 5100064108 Language: [en-US]...

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