A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• CONTENTS
• SAFETY
• GENERAL PRECAUTIONS
• PREPARATIONS FOR WORK
• PRECAUTIONS DURING WORK
• STANDARD TIGHTENING TORQUE
• STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
• TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
• TIGHTENING TORQUE FOR NUTS OF FLARED
• COATING MATERIALS
• ELECTRICAL WIRE CODE
• CLASSIFICATION BY THICKNESS
• CLASSIFICATION BY COLOR AND CODE
• WEIGHT TABLE
• TABLE OF OIL AND COOLANT QUANTITIES
• ENGINE TESTING AND ADJUSTING
• TESTING AND ADJUSTING DATA
• TESTING AND ADJUSTING TOOL LIST
• LUBRICATION SYSTEM
• LUBRICATION SYSTEM CHART
• ADJUSTING VALVE CLEARANCE
• MEASURING COMPRESSION PRESSURE
• ADJUSTING FUEL INJECTION TIMING
• TESTING AND ADJUSTING FAN BELT TENSION
• BLEEDING AIR FROM FUEL LINE
• ENGINE DISASSEMBLY AND ASSEMBLY
• REMOVAL OF STARTING MOTOR ASSEMBLY
• INSTALLATION OF STARTING MOTOR ASSEMBLY
• REMOVAL OF ALTERNATOR ASSEMBLY
• INSTALLATION OF ALTERNATOR ASSEMBLY
• REMOVAL OF FAN PULLEY ASSEMBLY
• INSTALLATION OF FAN PULLEY ASSEMBLY
• REMOVAL OF WATER PUMP ASSEMBLY
• INSTALLATION OF WATER PUMP ASSEMBLY
• REMOVAL OF THERMOSTAT ASSEMBLY
• INSTALLATION OF THERMOSTAT ASSEMBLY
• REMOVAL OF NOZZLE HOLDER ASSEMBLY
• INSTALLATION OF NOZZLE HOLDER ASSEMBLY
• REMOVAL OF FUEL INJECTION PUMP ASSEMBLY
• INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
• REMOVAL OF CYLINDER HEAD ASSEMBLY
• REMOVAL OF RADIATOR ASSEMBLY
• INSTALLATION OF RADIATOR ASSEMBLY
• REMOVAL OF ENGINE ASSEMBLY
• INSTALLATION OF ENGINE ASSEMBLY
• POWER TRAIN STRUCTURE AND FUNCTION
• POWER TRAIN (S/N 11999 & Below)
• POWER TRAIN (S/N 12001 & Above)
• SWING CIRCLE (S/N 11999 & Below)
• SWING CIRCLE (S/N 12001 & Above)
• SWING MACHINERY (S/N 11999 & Below)
• SWING MACHINERY (S/N 12001 & Above)
• SPROCKET (S/N 11999 & Below)
• SPROCKET (S/N 12001 & Below)
• TRACK FRAME AND RECOIL SPRING (S/N 12001 & Above)
• IDLER (S/N 12001 & Above)
• TRACK ROLLER
• TRACK SHOE (S/N 12001 & Above)
• POWER TRAIN DISASSEMBLY AND ASSEMBLY
• REMOVAL OF SWING CIRCLE ASSEMBLY
• INSTALLATION OF SWING CIRCLE ASSEMBLY
• REMOVAL OF SWING MACHINERY ASSEMBLY
• INSTALLATION OF SWING MACHINERY ASSEMBLY
• DISASSEMBLY OF SWING MACHINERY ASSEMBLY
• ASSEMBLY OF SWING MACHINERY ASSEMBLY
• POWER TRAIN MAINTENANCE STANDARD
• SWING CIRCLE (S/N 11999 & Below)
• SWING CIRCLE (S/N 12001 & Above)
• SWING MACHINERY (S/N 11999 & Below)
• SWING MACHINERY (S/N 12001 & Above)
• SPROCKET (S/N 11999 & Below)
• SPROCKET (S/N 12001 & Above)
• UNDERCARRIAGE STRUCTURE AND FUNCTION
• TRACK FRAME AND RECOIL SPRING
• IDLER
• TRACK ROLLER
• TRACK SHOE
• UNDERCARRIAGE DISASSEMBLY AND ASSEMBLY
• REMOVAL OF RECOIL SPRING ASSEMBLY
• INSTALLATION OF RECOIL SPRING ASSEMBLY
• DISASSEMBLY OF RECOIL SPRING ASSEMBLY
• ASSEMBLY OF RECOIL SPRING ASSEMBLY
• REMOVAL OF TRACK SHOE ASSEMBLY
• INSTALLATION OF TRACK SHOE ASSEMBLY
• UNDERCARRIAGE MAINTENANCE STANDARD
• TRACK FRAME AND RECOIL SPRING (S/N 11999 & Below)
• TRACK FRAME AND RECOIL SPRING (S/N 12001 & Above)
• TRACK ROLLER (S/N 11999 & Below)
• TRACK ROLLER (S/N 12001 & Above)
• TRACK SHOE (S/N 11999 & Below)
• TRACK SHOE (S/N 12001 & Above)
• IDLER (S/N 11999 & Below)
• IDLER (S/N 12001 & Above)
• HYDRAULIC CONTROL STRUCTURE AND FUNCTION
• HYDRAULIC PIPING
• HYDRAULIC CIRCUIT SCHEMATICS
• HYDRAULIC CIRCUIT DIAGRAM
• HYDRAULIC CIRCUIT SCHEMATICS (S/N 12001 & Above)
• HYDRAULIC CIRCUIT DIAGRAM (S/N 11999 & Below)
• HYDRAULIC CIRCUIT DIAGRAM (S/N 12001 & Above)
• HYDRAULIC TANK (S/N 11999 & Below)
• HYDRAULIC TANK (S/N 12001 & Above)
• 6-SPOOL CONTROL VALVE (S/N 11999 & Below)
• 6-SPOOL CONTROL VALVE (S/N 12001 & Above)
• 4-SPOOL CONTROL VALVE (S/N 12001 & Above)
• 3-SPOOL CONTROL VALVE (S/N 11999 & Below)
• HYDRAULIC TRIPLE GEAR PUMP (S/N 11999 & Below)
• CENTER SWIVEL JOINT (S/N 11999 & Above)
• CENTER SWIVEL JOINT (S/N 12001 & Above)
• SWING MOTOR (S/N 11999 & Below)
• SWING MOTOR (S/N 12001 & Above)
• TRAVEL MOTOR (with reduction gear) (S/N 11999 & Below)
• BRAKE VALVE
• VALVE CONTROL (S/N 11999 & Below)
• VALVE CONTROL (S/N 12001 & Above)
• HYDRAULIC SYSTEM TESTING AND ADJUSTING
• TABLE OF JUDGEMENT STANDARD VALUE
• TESTING AND ADJUSTING TOOL
• TESTING OPERATING FORCE OF CONTROL LEVER
• TESTING TRAVEL OF CONTROL LEVER
• TESTING TRAVEL OF CONTROL VALVE SPOOL
• TESTING AND ADJUSTING HYDRAULIC PRESSURE
• MEASURING DELIVERY OF PUMP
• 116 HYDRAULIC PUMP CHECK
• Checking the Output of the Hydraulic Pump at the Boom Cylinder
• Adjusting the Main Relief Valve
• Checking the Output of the Hydraulic Pump at the Arm Cylinder
• Adjusting the Main Relief Valve
• Checking the Output of the Hydraulic Pump at the Blade Cylinder
• Adjusting the Main Relief Valve
• 116 PORT RELIEF VALVE CHECK
• MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR
• MEASURING OIL LEAKAGE FROM CYLINDER
• HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY
• REMOVAL OF HYDRAULIC PUMP ASSEMBLY
• INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
• REMOVAL OF 6-SPOOL CONTROL VALVE ASSEMBLY
• INSTALLATION OF 6-SPOOL CONTROL VALVE ASSEMBLY
• REMOVAL OF 3-SPOOL CONTROL VALVE ASSEMBLY
• INSTALLATION OF 3-SPOOL CONTROL VALVE ASSEMBLY
• DISASSEMBLY OF CONTROL VALVE ASSEMBLY
• ASSEMBLY OF CONTROL VALVE ASSEMBLY
• REMOVAL OF MAIN RELIEF VALVE ASSEMBLY
• INSTALLATION OF MAIN RELIEF VALVE ASSEMBLY
• REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY
• INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY
• DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
• ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
• REMOVAL OF SWING MOTOR ASSEMBLY
• INSTALLATION OF SWING MOTOR ASSEMBLY
• REMOVAL OF TRAVEL MOTOR ASSEMBLY
• INSTALLATION OF TRAVEL MOTOR ASSEMBLY
• REMOVAL OF BOOM CYLINDER ASSEMBLY
• INSTALLATION OF BOOM CYLINDER ASSEMBLY
• REMOVAL OF ARM CYLINDER ASSEMBLY
• INSTALLATION OF ARM CYLINDER ASSEMBLY
• REMOVAL OF BUCKET CYLINDER ASSEMBLY
• INSTALLATION OF BUCKET CYLINDER ASSEMBLY
• REMOVAL OF BLADE CYLINDER ASSEMBLY
• INSTALLATION OF BLADE CYLINDER ASSEMBLY
• REMOVAL OF BOOM SWING CYLINDER ASSEMBLY
• INSTALLATION OF BOOM SWING CYLINDER ASSEMBLY
• DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
• ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
• HYDRAULIC SYSTEM MAINTENANCE STANDARD
• SWING MOTOR (S/N 12001 & Above)
• 6-SPOOL CONTROL VALVE (S/N 11999 & Below)
• 6-SPOOL CONTROL VALVE (S/N 12001 & Above)
• 4-SPOOL CONTROL VALVE (S/N 12001 & Above)
• 3-SPOOL CONTROL VALVE (S/N 11999 & Below)
• HYDRAULIC CYLINDER (S/N 11999 & Below)
• HYDRAULIC CYLINDER (S/N 12001 & Above)
• TRIPLE GEAR PUMP (S/N 11999 & Below)
• TRIPLE GEAR PUMP (S/N 12001 & Above)
• WORK EQUIPMENT STRUCTURE AND FUNCTION
• WORK EQUIPMENT
• WORK EQUIPMENT (S/N 12001 & Above)
• WORK EQUPMENT DISASSEMBLY AND ASSEMBLY
• REMOVAL OF WORK EQUIPMENT ASSEMBLY
• INSTALLATION OF WORK EQUIPMENT ASSEMBLY
• REMOVAL OF BLADE ASSEMBLY
• INSTALLATION OF BLADE ASSEMBLY
• REMOVAL OF ARM AND BUCKET ASSEMBLY
• INSTALLATION OF ARM AND BUCKET ASSEMBLY
• REMOVAL OF BUCKET ASSEMBLY
• INSTALLATION OF BUCKET ASSEMBLY
• REMOVAL OF ARM ASSEMBLY
• INSTALLATION OF ARM ASSEMBLY
• REMOVAL OF BOOM ASSEMBLY
• INSTALLATION OF BOOM ASSEMBLY
• REMOVAL OF FLOOR FRAME ASSEMBLY
• INSTALLATION OF FLOOR FRAME ASSEMBLY
• WORK EQUIPMENT MAINTENANCE STANDARD
• WORK EQUIPMENT
• ELECTRICAL SYSTEM STRUCTURE AND FUNCTION
• ELECTRICAL CIRCUIT DIAGRAM
• ELECTRICAL CIRCUIT DIAGRAM (S/N 12001 & Above)
• SERVICE MANUAL REVISION
• 116-1
• 116-2