John Deere 160LC Excavator Service Manual (Repair) - TM1662
Complete Repair service manual for John Deere 160LC, with all the workshop information to maintain, repair, and rebuild like professional mechanics.
John Deere 160LC Excavator workshop service repair 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.
* 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.
TM1662 - John Deere 160LC Excavator Technical Manual (Repair).pdf
Total Pages: 756 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
Tracks
Track System
Axles and Suspension Systems
Axle Shaft, Bearings, and Reduction Gears
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary Systems
Cold Weather Starting Aids
Cooling System
Speed Controls
Intake System
External Fuel Supply Systems
Dampener Drive (Flex Coupling)
Elements
Electrical System
Batteries, Support, and Cables
Alternator, Regulator, and Charging System Wiring
Wiring Harness and Switches
System Controls
Instruments and Indicators
Frame or Supporting Structure
Frame Installation
Chassis Weights
Operator’s Station
Removal and Installation
Operator Enclosure
Seat and Seat Belt
Heating and Air Conditioning
Excavator
Buckets
Frames
Hydraulic System
Swing or Pivoting System
Mechanical Drive Elements
Hydraulic System
Dealer Fabricated Tools
Dealer Fabricated Tools
Total Pages: 1,005 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
CONTENTS - Expanded View
00 - General Information
01 - Safety
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Avoid Power Lines
Beware of Exhaust Fumes
Dispose of Waste Properly
Follow Safe Procedures
Handle Chemical Products Safely
Handle Fluids Safely—Avoid Fires
Illuminate Work Area Safely
Keep Riders Off Machine
Live With Safety
Move and Operate Machine Safely
Operate Only from Operator's Seat
Park Machine Safely
Prepare for Emergencies
Prevent Acid Burns
Protect Against Flying Debris
Protect Against Noise
Remove Paint Before Welding or Heating
Replace Safety Signs
Service Cooling System Safely
Service Machines Safely
Stay Clear of Moving Parts
Support Machine Properly
Use Handholds and Steps
Use Proper Lifting Equipment
Use Tools Properly
Warn Others of Service Work
Wear Protective Clothing
Work in a Clean Area
02 - General Specifications
160LC Excavator Drain and Refill Capacities
160LC Excavator Specifications—Continued
160LC Excavator Specifications
03 - Torque Values
Additional Metric Cap Screw Torque Values
Check Oil Lines And Fittings
Metric Bolt and Screw Torque Values
Service Recommendations for 37° Flare and 30° Cone Seat Connectors
Service Recommendations For Flared Connections—Straight or Tapered Threads
Service Recommendations For Flat Face O-Ring Seal Fittings
Service Recommendations For Inch Series Four Bolt Flange Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations for O-Ring Boss Fittings
Unified Inch Bolt and Screw Torque Values
04 - Fuels & Lubricants
Alternative and Synthetic Lubricants
Diesel Engine Oil
Diesel Fuel
Diesel Fuel Storage
Do Not Use Galvanized Containers
Fuel Tank
Handling and Storing Diesel Fuel
Hydraulic Oil
Low Sulfur Diesel Fuel Conditioner
Lubricant Storage
Lubricity of Diesel Fuel
Mixing of Lubricants
Oil Filters
Swing Gearbox and Propel Gearbox Oils
Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease
Track Roller, Front Idler, and Carrier Roller Oil
01 - Wheels or Tracks
Adjust Track Sag
Assemble Front Idler
Assemble Front Idler
Disassemble and Assemble Track Adjuster And Recoil Spring
Disassemble and Assemble Track Adjuster And Recoil Spring
Disassemble and Assemble Track Adjuster Cylinder
Disassemble and Assemble Track Carrier Roller
Disassemble And Assemble Track Chain
Disassemble and Assemble Track Chain to Replace Broken Part
Disassemble and Assemble Track Roller
Disassemble Front Idler
Disassemble Propel Gearbox
Install Track Chain
Measure Front Idler Wear
Measure Track Carrier Roller Wear
Measure Track Chain Bushing Wear
Measure Track Chain Link Wear
Measure Track Chain Link Wear
Measure Track Chain Pitch
Measure Track Roller Wear
Measure Track Shoe Grouser Wear
Remove and Install Front Idler
Remove and Install Front Idler
Remove and Install Propel Gearbox
Remove and Install Sprocket
Remove and Install Track Adjuster Cylinder and Recoil Spring
Remove and Install Track Adjuster Cylinder and Recoil Spring
Remove and Install Track Carrier Roller
Remove and Install Track Roller
Remove and Install Track Shoe
Remove Track Chain
Test Front Idler for Oil Leakage
Test Front Idler for Oil Leakage
Test Track Roller for Oil Leakage
Towing Machine
02 - Axles and Suspension Systems
50 - Axle Shaft, Bearings, and Reduction Gears
Assemble Propel Gearbox
Disassemble and Assemble First Planet Carrier
Disassemble Propel Gearbox
Inspect Metal Face Seals
Other Material
Remove and Install Propel Gearbox
Service Equipment and Tools
Specifications
Towing Machine
60 - Hydraulic System
Assemble Propel Motor and Brake
Disassemble and Assemble Propel Motor Brake Valve Housing
Disassemble and Assemble Rotary Manifold
Disassemble Propel Motor and Brake
Essential Tools
Propel Motor Start-Up Procedure
Remove and Install Propel Motor and Brake
Remove and Install Rotary Manifold
Rotary Manifold Air Test
Service Equipment and Tools
Specifications
04 - Engine
Bleed Fuel System
Check and Adjust Engine Valve Lash (Clearance)
Clean the Engine Crankcase Ventilation Tube
Firing Order 4-Cylinder Engine
Install Engine
Install In-Line Fuel Injection Pump
Install Oil Pan
PowerTech ® 4.5 L (4045) John Deere Engine—Use CTM104
Remove and Install Starter
Remove Engine
Remove In-Line Fuel Injection Pump
Remove Oil Pan
Repair In-Line Fuel Injection Pump
05 - Engine Auxiliary Systems
05 - Cold Weather Starting Aids
Other Material
Remove and Install Engine Coolant Heater
Remove and Install Starting Aid Solenoid and Nozzle
Specifications
10 - Cooling System
Cooling System Fill and Deaeration
Remove and Install Dual Thermostats (Serial No. —XXXXXX)
Remove and Install Fan Belt
Remove and Install Fan, Shroud and Guard
Remove and Install Radiator
Remove and Install Single High Flow Thermostat (Serial No. XXXXXX— )
Specifications
15 - Speed Controls
Check and Adjust Fuel Shut-Off Solenoid Linkage
Engine Control Motor and Sensor Adjustment
Injection Pump Fast and Slow Idle Stops Adjustment
Remove and Install Engine Control Motor and Sensor
Remove and Install Engine Speed Control Cable
Remove and Install Fuel Shut-Off Solenoid Linkage
Service Equipment and Tools
Specifications
20 - Intake System
Air Intake System Leakage Test
Other Material
Remove and Install Air Cleaner
Specifications
60 - External Fuel Supply Systems
Bleeding the Fuel System
Disassemble and Assemble Primary Fuel Filter (Water Separator)
Other Material
Remove and Install Final Fuel Filter Element
Remove and Install Final Fuel Filter
Remove and Install Fuel Tank
Remove and Install Primary Fuel Filter (Water Separator)
Specifications
07 - Dampener Drive (Flex Coupling)
Other Material
Remove and Install Dampener Drive (Flex Coupling)
Specifications
16 - Electrical System
71 - Batteries, Support, and Cables
Adding 12 or 24 Volt Accessories
Charge Battery
Check Battery Electrolyte Level and Terminals
Checking Electrolyte Specific Gravity
Handle Batteries Safely
Procedure for Testing Batteries
Remove and Install Batteries
Service Equipment and Tools
Specifications
Using Booster Batteries—24 Volt System
72 - Alternator, Regulator, and Charging System Wiring
Alternators and Starting Motors—Use CTM77
Remove and Install Alternator
Specifications
74 - Wiring Harness and Switches
Cab Electrical Component Identification
Disconnecting Spring Wire Clip Connectors
Disconnecting Tab Retainer Connectors
Essential Tools
Front Chassis Electrical Component Identification
Fuse (Blade-Type) Color Codes
Hydraulic and Engine Electrical Component Identification
Install DEUTSCH ™ Contact
Install WEATHER PACK ™ Contact
Remove and Install Cab Ground Straps
Remove and Install Dome Light Switch
Remove and Install Key Switch
Remove and Install Propel Alarm Cancel Switch and Start Aid Switch
Remove Connector Body from Blade Terminals
Replace DEUTSCH ™ Connectors
Replace WEATHER PACK ™ Connector
Replacing Fuses
Specifications
75 - System Controls
Connecting Engine and Pump Controller (EPC) Harness Connector
Engine Speed Learning Procedure
Remove and Install Engine and Pump Controller (EPC)
Remove and Install Monitor Controller
Specifications
Welding On Machine
76 - Instruments and Indicators
Changing Travel Alarm Volume
Remove and Install Hour Meter
Remove and Install Monitor Panel
Replace Monitor Panel Bulbs
17 - Frames, Chassis, or Supporting Structure
40 - Frame Installation
Specifications
Welding On Machine
Welding Repair of Major Structure
49 - Chassis Weight
Remove and Install Counterweight
Service Equipment and Tools
Specifications
18 - Operator's Station
00 - Removal & Installation
Remove and Install Cab
Specifications
10 - Operator Enclosure
Other Material
Remove and Install Bonded Windowpane
Remove and Install Sliding Windows
Remove and Install Windowpane and One Piece Molding
Remove and Install Windowpane and Two Piece Molding
Windowpane Dimensions
21 - Seat & Seat Belt
Check Seat Adjustments
Inspect Seat Belt
Remove and Install Seat Belt
Remove and Install Seat
Specifications
30 - Heating & Air Conditioning System
Charge R134a System
Evacuate R134a System
Flush and Purge Air Conditioner System
R134a Refrigerant Oil Information
R134a Refrigerant Recovery _ Recycling and Charging Station Installation Procedure
Recover R134a Refrigerant
Refrigerant Cautions and Proper Handling
Remove and Install Air Conditioner
Remove and Install Compressor
Remove and Install Condenser
Remove and Install Heater Core and Blower Motor
Remove and Install Heater Hoses
Remove and Install Receiver-Dryer
33 - Excavator
02 - Buckets
Adjust Bucket Pivot End Play
Bucket Pin-Up Data
Disassemble And Assemble Bucket
Remove and Install Bucket
Remove and Install Tooth Shank
Repair Cracked Cutting Edge
Replace Bucket Tooth
Replace Bucket Tooth Tip—Heavy-Duty Bucket
Replace Welded Cutting Edge
Specifications
Welding On Machine
40 - Frames
Inspect Arm and Boom Pins and Bushings
Other Material
Remove and Install Arm
Remove and Install Boom
Remove and Install Bucket Links
Remove and Install Bushings and Seals
Service Equipment and Tools
Specifications
60 - Hydraulic System
Assemble Boom, Arm or Bucket Cylinder
Assemble Hydraulic Pump
Assemble Hydraulic Pump Regulator
Control Lever Pattern Conversion
Disassemble and Assemble Control Valve
Disassemble And Assemble Dig Function Pilot Controller
Disassemble and Assemble Flow Regulator Valve
Disassemble and Assemble Hydraulic Oil Tank
Disassemble and Assemble Hydraulic Oil Tank Relief Valve and Breather Filter Cap
Disassemble and Assemble Oil Cooler
Disassemble and Assemble Pilot Pressure Regulating Valve and Filter
Disassemble and Assemble Pilot Pump
Disassemble and Assemble Pilot Shut-Off Valve
Disassemble and Assemble Propel Pilot Controller
Disassemble and Assemble Proportional Solenoid Valve
Disassemble Boom, Arm or Bucket Cylinder
Disassemble Hydraulic Pump
Disassemble Hydraulic Pump Regulator
Hydraulic Cylinder Bleed Procedure
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Hydraulic Pump Start-Up Procedure
Lower Boom with Engine Stopped
Other Material
Pilot Shut-Off Valve Linkage Adjustment
Remove and Install Arm Cylinder
Remove and Install Boom Cylinder
Remove and Install Bucket Cylinder
Remove and Install Control Valve
Remove and Install Dig Function Pilot Controller
Remove and Install Flow Regulator Valve
Remove and Install Hydraulic Oil Tank
Remove and Install Hydraulic Pump
Remove and Install Oil Cooler Bypass Valve
Remove and Install Oil Cooler
Remove and Install Pilot Pressure Regulating Valve and Filter
Remove and Install Pilot Pump
Remove and Install Pilot Shut-Off Valve
Remove and Install Propel Pilot Controller
Remove and Install Proportional Solenoid Valve
Remove and Install Restriction Valve
Remove and Install Return Filter And Bypass Valve
Remove and Install Suction Filter (Screen)
Service Equipment and Tools
Specifications
43 - Swing or Pivoting System
50 - Mechanical Drive Elements
Disassemble and Assemble Swing Bearing
Disassemble and Assemble Swing Gearbox
Install Swing Bearing Lower Seal
Install Swing Bearing Upper Seal
Install Upperstructure
Other Material
Remove and Install Swing Bearing
Remove and Install Swing Gearbox
Remove Upperstructure
Service Equipment and Tools
Specifications
Swing Gearbox Start-Up Procedure
60 - Hydraulic System
Assemble Swing Motor and Park Brake
Disassemble and Assemble Swing Motor Make-Up and Crossover Relief Valves
Disassemble Swing Motor and Park Brake
Remove and Install Swing Motor and Park Brake
Remove and Install Swing Park Brake Orifice and Check Valve
Remove and Install Swing Park Brake Release Valve
Specifications
Swing Motor and Park Brake Start-Up Procedure
99 - Dealer Fabricated Tools
DFT1087 Track Recoil Spring Disassembly And Assembly Guard Tool
DFT1089 Barrel Support
DFT1112 Spacer
DFT1113 Guide Pin
DFT1119 Pump Support
DFT1119 Pump Support
DFT1155 Propel Gearbox Bearing Nut Wrench
Rotary Manifold Lifting Tool
ST4920 Track Recoil Spring Disassembly And Assembly Tool
John Deere 160LC Excavator Service Manual (Repair) - TM1662
