John Deere 160CLC Excavator Technical Manual (Repair) - TM1933
Complete service manual for John Deere 160CLC Excavator (Hitachi ZX160LC), with all the workshop information to maintain, repair and rebuild like professional mechanics.
John Deere Excavator 160CLC (Hitachi Zaxis160 LC) 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.
* 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.
TM1933 - John Deere 160CLC Excavator Technical Manual (Repair).pdf
TM2991 - John Deere Excavatrice160CLC Remise en état.pdf
Total Pages: 536 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English French
MAIN SECTIONS
Foreword
Technical Information Feedback Form
General Information
Safety
Torque Values
Tracks
Track System
Axles and Suspension Systems
Axle Shaft, Bearings, and Reduction Gears
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary Systems
Cooling System
External Fuel Supply Systems
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
TABLE OF CONTENTS...1
Section 00: General Information...9
Group 0001: Safety...9
Recognize Safety Information...12
Follow Safety Instructions...13
Operate Only If Qualified...14
Wear Protective Equipment...15
Avoid Unauthorized Machine Modifications...16
Add Cab Guarding for Special Uses...17
Inspect Machine...18
Stay Clear of Moving Parts...19
Avoid High-Pressure Oils...20
Beware of Exhaust Fumes...21
Prevent Fires...22
Prevent Battery Explosions...23
Handle Chemical Products Safely...24
Dispose of Waste Properly...25
Prepare for Emergencies...26
Use Steps and Handholds Correctly...27
Start Only From Operator's Seat...28
Use and Maintain Seat Belt...29
Prevent Unintended Machine Movement...30
Avoid Work Site Hazards...31
Keep Riders Off Machine...33
Avoid Backover Accidents...34
Avoid Machine Tip Over...35
Use Special Care When Lifting Objects...37
Add and Operate Attachments Safely...38
Park and Prepare for Service Safely...39
Service Cooling System Safely...40
Remove Paint Before Welding or Heating...41
Make Welding Repairs Safely...42
Drive Metal Pins Safely...43
Group 0003: Torque Values...9
Unified Inch Bolt and Screw Torque Values...46
Metric Bolt and Screw Torque Values...48
Additional Metric Cap Screw Torque Values...50
Check Oil Lines And Fittings...52
Service Recommendations for O-Ring Boss Fittings...53
Service Recommendations For Flat Face O-Ring Seal Fittings...55
Service Recommendations for 37° Flare and 30° Cone Seat Connectors...57
Service Recommendations For Flared Connections—Straight or Tapered Threads...59
Service Recommendations For Inch Series Four Bolt Flange Fittings...61
Service Recommendations for Metric Series Four Bolt Flange Fitting...63
Section 01: Tracks...65
Group 0130: Track System...65
Track Roller Repair...71
Track Carrier Roller Repair...76
Metal Face Seal Inspect...80
Track Shoe Remove and Install...82
Track Chain Repair...83
Broken Track Chain Repair...87
Sprocket Remove and Install...90
Front Idler Repair...92
Track Adjuster and Recoil Spring Repair...97
Track Adjuster Cylinder Disassemble and Assemble...104
Section 02: Axles and Suspension Systems...107
Group 0250: Axle Shaft, Bearings, and Reduction Gears...107
Propel Gearbox Repair...129
Group 0260: Hydraulic System...107
Propel Motor Repair...176
Propel Motor Start-Up Procedure...202
Rotary Manifold Repair...203
Section 04: Engine...207
Group 0400: Removal and Installation...207
Remove Engine...212
Install Engine...216
Engine Repair...219
Section 05: Engine Auxiliary Systems...220
Group 0510: Cooling System...220
Cooling Package Remove and Install...224
Fan, Fan Guard, and Fan Shroud Remove and Install...227
Fan Belt Remove and Install...229
Group 0560: External Fuel Supply Systems...220
Fuel Tank Remove and Install...232
Primary Fuel Filter (Water Separator) Repair...234
Final Fuel Filter Repair...235
Section 17: Frame or Supporting Structure...236
Group 1740: Frame Installation...236
Welding On Machine...238
Welding Repair of Major Structure...239
Group 1749: Chassis Weights...236
Counterweight Remove and Install...243
Section 18: Operator’s Station...245
Group 1800: Removal and Installation...245
Cab Remove and Install...250
Group 1810: Operator Enclosure...245
Windowpane and Molding Remove and Install...257
Bonded Windowpane Remove and Install...260
Sliding Window Remove and Install...261
Group 1821: Seat and Seat Belt...245
Seat Repair...269
Seat Belt Remove and Install...275
Group 1830: Heating and Air Conditioning...245
Refrigerant Cautions and Proper Handling...278
Flush and Purge Air Conditioner System...279
R134a Refrigerant Oil Information...283
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure...285
Recover R134a Refrigerant...287
Evacuate R134a System...288
Charge R134a System...290
Compressor Remove and Install...291
Receiver-Dryer Remove and Install...292
Air Conditioner and Heater Remove and Install...294
Condenser Remove and Install...296
Section 33: Excavator...298
Group 3302: Buckets...298
Bucket Repair...303
Bucket Pin-Up Data...306
Group 3340: Frames...298
Bucket Link Remove and Install...309
Arm Remove and Install...311
Boom Remove and Install...316
Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses...319
Bushing and Seal Remove and Install...321
Group 3360: Hydraulic System...298
Hydraulic Oil Tank Pressure Release Procedure...324
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy...325
Hydraulic Pump Remove and Install...327
Hydraulic Pump Disassemble...330
Hydraulic Pump Assemble...333
Pilot Pump Disassemble and Assemble...337
Hydraulic Pump Regulator Repair...339
Hydraulic Pump Start-Up Procedure...347
Dampener Drive (Flex Coupling) Remove and Install (S.N. —044369 and S.N. 044416—044439)...348
Dampener Drive (Flex Coupling) Remove and Install (S.N. 044370—044415 and S.N. 044440— )...350
Pilot Filter Remove and Install...353
Attachment Flow Rate and Speed Sense Solenoid Repair...354
Pilot Pressure Regulating Valve Disassemble and Assemble...357
Pilot Shut-Off Valve Repair...359
Propel Speed and Arm Regenerative Solenoid Valve Repair...362
Pilot Controller Repair...365
Propel Pilot Controller Repair...370
Pilot Signal Manifold Repair...374
Control Valve Repair...378
Hydraulic Oil Tank Repair...401
Restriction Valve Remove and Install...408
Oil Cooler Bypass Valve Remove and Install...410
Oil Cooler Remove and Install...412
Boom Cylinder Remove and Install...413
Arm Cylinder Remove and Install...418
Bucket Cylinder Remove and Install...423
Boom, Arm, or Bucket Cylinder Disassemble and Assemble...428
Hydraulic Cylinder Bleed Procedure...446
Section 43: Swing or Pivoting System...447
Group 4350: Mechanical Drive Elements...447
Swing Gearbox Remove and Install...451
Swing Gearbox Disassemble and Assemble...454
Swing Gearbox Start-Up Procedure...461
Upperstructure Remove And Install...462
Swing Bearing Repair...472
Group 4360: Hydraulic System...447
Swing Motor and Park Brake Repair...488
Swing Motor Crossover Relief Valve and Make-Up Valve Repair...496
Swing Motor and Park Brake Start-Up Procedure...499
Section 99: Dealer Fabricated Tools...500
Group 9900: Dealer Fabricated Tools...500
ST4920 Track Recoil Spring Disassembly and Assembly Tool...505
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool...509
DFT1112 Spacer...510
DFT1155 Propel Gearbox Bearing Nut Wrench...511
DFT1109 Holding Bar...512
Rotary Manifold Lifting Tool...513
DFT1089 Barrel Support...514
DFT1113 Guide Pin...515
DFT1119 Pump Support...516
DFT1220 Swing Gearbox Nut Spanner Wrench...517
