Complete technical manual with Electrical Wiring Diagrams for John Deere 160LC Excavator, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere 160LC Excavator workshop diagnosis & test technical manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM1661 - John Deere 160LC Excavator Technical Manual (Operation and Tests).pdf

Total Pages: 856 pages
File Format: PDF (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   Technical Information Feedback Form
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels and Lubricants
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory of Operation
      Diagnostic Information
      Adjustments
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Adjustment
      Tests
   Heating and Air Conditioning
      Theory Of Operation
      Diagnostic Information
      Tests

tm1661 - 160LC Excavator Operation and Tests

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Follow Safe Procedures

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Handle Fluids Safely-Avoid Fires

Avoid High-Pressure Fluids

Warn Others of Service Work

Support Machine Properly

Operate Only from Operator's Seat

Park Machine Safely

Stay Clear of Moving Parts

Avoid Power Lines

Use Handholds and Steps

Keep Riders Off Machine

Move and Operate Machine Safely

Wear Protective Clothing

Protect Against Flying Debris

Protect Against Noise

Illuminate Work Area Safely

Service Machines Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Beware of Exhaust Fumes

Use Proper Lifting Equipment

Service Cooling System Safely

Dispose of Waste Properly

Work in a Clean Area

Use Tools Properly

Replace Safety Signs

Live With Safety

Group 02: General Specifications

160LC Excavator Specifications

160LC Excavator Specifications-Continued

160LC Excavator Drain and Refill Capacities

Group 03: Torque Values

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Check Oil Lines And Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations For Flared Connections-Straight or Tapered Threads

Service Recommendations For Inch Series Four Bolt Flange Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Group 04: Fuels and Lubricants

Diesel Fuel

Lubricity of Diesel Fuel

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Fuel Tank

Diesel Engine Oil

Hydraulic Oil

Swing Gearbox and Propel Gearbox Oils

Track Roller, Front Idler, and Carrier Roller Oil

Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease

Oil Filters

Lubricant Storage

Alternative and Synthetic Lubricants

Mixing of Lubricants

Handling and Storing Diesel Fuel

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

PowerTechPowerTech is a trademark of Deere & Company. 4.5 L (4045) John Deere Engine-Use CTM104

Engine-Sectional View

Fan Drive Operation

Engine Speed Control System Operation

Engine RPM Dial Speed Control Circuit Operation

E (Economy) Mode Speed Control Circuit Operation

HP (High Power) Mode Speed Control Circuit Operation

Auto-Idle Mode Speed Control Circuit Operation

Engine Speed Learning Control Circuit Operation

Group 10: System Operational Checks

PowerTechPowerTech is a trademark of Deere & Company. 4.5 L (4045) John Deere Engine-Use CTM104

Engine Operational Checks

Group 15: Diagnostic Information

PowerTechPowerTech is a trademark of Deere & Company. 4.5 L (4045) John Deere Engine-Use CTM104

Diagnose Engine Malfunctions

Group 20: Adjustments

PowerTechPowerTech is a trademark of Deere & Company. 4.5 L (4045) John Deere Engine-Use CTM104

JT05801 Clamp-On Electronic Tachometer Installation

Check and Adjust Fuel Shut-Off Solenoid Linkage

Engine Speed Check

Injection Pump Fast and Slow Idle Stops Adjustment

Engine Control Motor and Sensor Adjustment

Engine Speed Learning Procedure

Cooling System Fill and Deaeration

Group 25: Tests

PowerTechPowerTech is a trademark of Deere & Company. 4.5 L (4045) John Deere Engine-Use CTM104

Fuel Line Leakage Test

Air Filter Restriction Indicator Switch Test

Air Intake System Leakage Test

Radiator Air Flow Test

Engine Power Test Using Turbocharger Boost Pressure

Section 9015: Electrical System

Group 05: System Information

Visually Inspect Electrical System

Circuit Malfunctions

Definition of Circuit Malfunctions

Location of Circuit Malfunctions

Troubleshooting Circuit Malfunctions

Multimeter

Seven Step Electrical Test Procedure

Wiring Diagram, Schematic, And Component Location Information

Reading a System Functional Schematic Diagram

Reading A Wiring Diagram

Reading A Harness Component Location Diagram

Reading Connector End View Diagram

Electrical Schematic Symbols

Group 10: System Diagrams

Fuse Specifications

Fuse (Blade-Type) Color Codes

Component Identification Table

Functional Schematic And Component Location Legend

System Functional Schematic Section Legend

System Functional Schematic (SE1-SE3)

System Functional Schematic (SE4-SE6)

System Functional Schematic (SE7-SE9)

System Functional Schematic (SE10-SE12)

System Functional Schematic (SE13-SE15)

System Functional Schematic (SE16-SE17)

Engine and Frame Harness (W1) Component Location

Engine and Frame Harness (W1) Connectors, Wire and Pin Location

Cab Harness (W2) Component Location

Cab Harness (W2) Component Location-Detail A (Harness Mating Connectors)

Cab Harness (W2) Component Location-Detail B (Fuse Block)

Cab Harness (W2) Connectors, Wire and Pin Location

Monitor and Relay Harness (W3) Component Location

Monitor and Relay Harness (W3) Component Location-Detail A (Monitor Controller Connectors)

Monitor and Relay Harness (W3) Component Location-Detail B (Monitor Controller Indicators)

Monitor and Relay Harness (W3) Connectors, Wire and Pin Location

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory of Operation

Power Circuit Schematic

Charging Circuit Operational Information

Charging Circuit Theory Of Operation

Charging Circuit Schematic

Alternator Theory of Operation

Starting and Fuel Shutoff Circuit Operational Information

Starting and Fuel Shutoff Circuit Theory of Operation

Starting and Fuel Shutoff Circuit Schematic

Windshield Wiper and Washer Circuit Operational Information

Windshield Wiper And Washer Circuit Theory of Operation

Windshield Wiper And Washer Circuit Schematic

Work and Drive Light Circuit Operational Information

Work and Drive Light Circuit Theory of Operation

Work and Drive Light Circuit Schematic

Accessory Circuits Operational Information

Accessory Circuits Theory of Operation

Accessory Circuits Schematic

Monitor Controller and Display Circuit Specifications

Monitor Controller and Display Circuit Operational Information

Monitor Controller and Display Circuit Theory of Operation

Monitor Controller and Display Circuit Schematic

Engine and Pump Controller Circuit Operational Information

Engine and Pump Controller Circuit Theory of Operation

Engine and Pump Controller Circuit Schematic

Travel Alarm Circuit Operational Information

Travel Alarm Circuit Theory of Operation

Travel Alarm Circuit Schematic

Group 20: References

Fuse Test

Battery Operation

Battery Specifications

Diagnose Battery Malfunctions

Check Battery Electrolyte Level and Terminals

Procedure for Testing Batteries

Using Booster Batteries-24 Volt System

Replacing Batteries

Adding 12 or 24 Volt Accessories

Changing Travel Alarm Volume

Proportional Solenoid Test Harness

Pump Control Test Harness

Pump Pressure Sensor Test Harness

Windshield Wiper Circuit Test Harness

Section 9020: Power Train

Group 05: Theory of Operation

Track Adjuster and Recoil Spring Operation

Propel Gearbox Operation

Group 15: Diagnostic Information

Diagnose Undercarriage Components Malfunctions

Measure Track Chain Bushing Wear

Measure Track Chain Link Wear

Measure Track Chain Pitch

Measure Track Shoe Grouser Wear

Measure Track Roller Wear

Measure Track Carrier Roller Wear

Measure Front Idler Wear

Measure Swing Bearing Wear

Group 20: Adjustments

Adjust Track Sag

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Diagram

Pilot Pump Operation

Pilot Pressure Regulating Valve and Filter Operation

Pilot Shut-Off Valve Operation

Pilot Controller Operation-Neutral

Pilot Controller Operation-Metering and Full Stroke

Propel Pilot Controller Operation

Pilot Controller Operation of Control Valve

Flow Regulator Valve Operation

Hydraulic Pump Operation

Hydraulic Pump Regulator Component Operation

Hydraulic Pump Regulator-Pump Control Valve Operation

Hydraulic Pump Regulator-Delivery Pressure and Summation Operation

Hydraulic Pump Regulator-Speed Sensing Operation

Solenoid Valve Manifold Operation

Proportional Solenoid Valve Operation

Engine Speed Sensing Control Circuit Operation

Control Valve Operation

Control Valve Circuit Schematic

Control Valve Pilot Pressure Signal Passage Operation

Control Valve Neutral and Power Passages Operation

System Relief Valve Operation

Circuit Relief and Anti-Cavitation Valve Operation

Pump Control Valve Operation

Flow Combiner Valve Operation

Arm Regenerative Valve Operation

Boom and Arm Reduced Leakage Valves Operation

Bucket Flow Control Valve Operation

Propel Flow Control Valve Operation

Propel-Boom Down Selector Valve Operation

Boom Regenerative Valve Operation

Propel and Arm In Combined Operation

Swing and Boom Up Combined Operation

Swing Gearbox Operation

Swing Motor Operation

Swing Motor Crossover Relief Valve Operation

Swing Motor Make-Up Valve Operation

Swing Motor Park Brake Release Valve Operation

Rotary Manifold Operation

Propel Motor Operation

Propel Motor Speed Change Valve Operation

Propel Motor Speed Change Circuit Operation

Propel Motor Brake Valve Operation

Hydraulic Cylinder Operation

Return Filter Operation

Hydraulic System Circuit Symbols

Pilot Circuit for Controllers Schematic

Hydraulic Pump and Control Valve Schematic

Front And Rear Pump Regulators Schematic

Swing and Propel Motor Schematic

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Electronic and Control Valve Component Malfunctions

Diagnose Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Diagnose Propel System Malfunctions

Control Lever Pattern Conversion

Control Valve Line Identification-Left Front

Control Valve Line Identification-Right Rear

Control Valve Line Identification-Bottom

Control Valve Component Identification-Left Front

Control Valve Component Identification-Right Rear

Control Valve Component Identification-Bottom

Main Hydraulic System Component Location

Pilot Controllers-To-Flow Regulator Component Location-SAE Pattern

Pilot Controllers-To-Flow Regulator Component Location-John Deere Pattern

Pilot Flow Regulator-To-Control Valve Component Location

Propel System Component Location

Pressure And Return System Component Location

Group 20: Adjustment

Pilot Shut-Off Valve Linkage Adjustment

Group 25: Tests

Laptop Computer General Description

Excavator Diagnostics Program-Overview

Excavator Diagnostics Program-Install

Excavator Diagnostics Program-Uninstall

Excavator Diagnostics Program-Starting

Excavator Diagnostics Program Feature-Service Codes

Excavator Diagnostics Program Feature-Monitor Data

Excavator Diagnostics Program Feature-Saving Monitor Data

Excavator Diagnostics Program Special Function-Engine Speed Adjustment

Excavator Diagnostics Program-Service Codes List

Excavator Diagnostics Program-Monitor Data Items

Excavator Diagnostics Program Special Function-Engine Speed Factory Settings Parameters

Engine Speed to Pump Flow Rate Chart

Excavator Diagnostic Program Troubleshooting

Reading Service Codes Without Excavator Diagnostics Program

Engine And Pump Controller Functions

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

Hydraulic Pump Start-Up Procedure

Swing Motor Start-Up Procedure

Swing Gearbox Start-Up Procedure

Propel Motor Start-Up Procedure

Hydraulic Oil Filter Inspection Procedure

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic System Warm-Up Procedure

Lower Boom with Engine Stopped

Arm Regenerative Solenoid Valve (SC) Harness Test

Speed Sensing Solenoid Valve (SE) Harness Test

Propel Speed Change Solenoid Valve (SI) Harness Test

Engine Control Sensor (EC Sensor) Harness Test

Engine Control Motor (EC Motor) Harness Tests

Miscellaneous Component Harness Test

Cycle Time Test

Swing Dynamic Braking (Drift) Test

Pilot Pressure Regulating Valve Test and Adjustment

Valve Spool Actuating Pilot Pressure Test

System Relief Valve Test and Adjustment

Circuit Relief Valve Test and Adjustment

Swing Motor Crossover Relief Valve Test and Adjustment

Propel Motor Crossover Relief Valve Test and Adjustment

Proportional Solenoid Valve Test and Adjustment

Pump Control Valve Test

Hydraulic Pump Regulator Adjustments

Hydraulic Pump Regulator Adjustment-Flow Adjusting Screw

Hydraulic Pump Regulator Test and Adjustment-Engine Pulldown

Hydraulic Pump Flow Test

Pilot Pump Flow Test

Propel System Tracking Test

Cylinder Drift Test-Boom, Arm, and Bucket

Swing Motor Leakage Test

Propel Motor Leakage Test

Section 9031: Heating and Air Conditioning

Group 05: Theory Of Operation

Air Conditioning System Cycle Of Operation

Heating and Air Conditioning Circuit Schematic

Group 15: Diagnostic Information

Diagnose Air Conditioning System Malfunctions

Diagnose Heater System Malfunctions

Diagnose Air Conditioning Service Codes

Heating and Air Conditioning Component Location

Group 25: Tests

Heating and Air Conditioning System Checks

R134a Air Conditioning System Test

Air Conditioning Compressor Clutch Test

Refrigerant Leak Test

Refrigerant Hoses and Tubing Inspection

John Deere 160LC Excavator Technical Manual (Operation and Tests) - TM1661