John Deere 160DLC Excavator Service Manual (Operation and Tests) - TM10088
Complete service manual with Electrical Wiring Diagrams for John Deere 160DLC Excavator (ZX160LC-3), with all the technical information to maintain, diagnose, and service like professional mechanics.
John Deere Excavator 160DLC (HITACHI Zaxis160LC-3) workshop 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.
Total Pages: 1,086 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English Spanish French Portuguese
TM10088 - John Deere 160DLC Excavator Technical Manual (Operation and Tests).pdf
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MAIN SECTIONS
Foreword
Technical Information Feedback Form
General Information
Safety
Diagnostics
Main Controller (MCF) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
Information Controller (ICF) Diagnostic Trouble Codes
Air Conditioner Controller (ACF) Diagnostic Trouble Codes
Monitor Controller (MON) Diagnostic Trouble Codes
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Diagnostic Information
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
Monitor Operation
References
Power Train
Theory of Operation
Diagnostic Information
Hydraulic System
Theory of Operation
Diagnostic Information
Tests
Heating and Air Conditioning
Theory of Operation
Diagnostic Information
Tests
Reference Material
Terminology Cross Reference Chart
Dealer Fabricated Tools
TABLE OF CONTENTS....1
Section 9000: General Information....16
Group 01: Safety....16
Recognize Safety Information....18
Follow Safety Instructions....19
Operate Only If Qualified....20
Wear Protective Equipment....21
Avoid Unauthorized Machine Modifications....22
Add Cab Guarding for Special Uses....23
Inspect Machine....24
Stay Clear of Moving Parts....25
Avoid High-Pressure Fluids....26
Avoid High-Pressure Oils....27
Beware of Exhaust Fumes....28
Prevent Fires....29
Prevent Battery Explosions....30
Handle Chemical Products Safely....31
Dispose of Waste Properly....32
Prepare for Emergencies....33
Use Steps and Handholds Correctly....34
Start Only From Operator's Seat....35
Use and Maintain Seat Belt....36
Prevent Unintended Machine Movement....37
Avoid Work Site Hazards....38
Keep Riders Off Machine....40
Avoid Backover Accidents....41
Avoid Machine Tip Over....42
Use Special Care When Lifting Objects....44
Add and Operate Attachments Safely....45
Park and Prepare for Service Safely....46
Service Cooling System Safely....47
Remove Paint Before Welding or Heating....48
Make Welding Repairs Safely....49
Drive Metal Pins Safely....50
Section 9001: Diagnostics....51
Group 10: Main Controller (MCF) Diagnostic Trouble Codes....56
Main Controller (MCF) Diagnostic Trouble Codes....56
11000.02 - Abnormal EEPROM....51
11001.02 - Abnormal RAM....51
11002.02 - Abnormal A/D Conversion....51
11003.03 - Abnormal Sensor Voltage....51
11004.02 - Abnormal CAN Communication....51
11100.02 - Abnormal Engine Speed....51
11101.03 - Engine Control Dial Voltage High....51
11101.04 - Engine Control Dial Sensor Voltage Low....51
11200.03 - Pump 1 Delivery Pressure Sensor Voltage High....51
11200.04 - Pump 1 Delivery Pressure Sensor Voltage Low....51
11202.03 - Pump 2 Delivery Pressure Sensor Voltage High....51
11202.04 - Pump 2 Delivery Pressure Sensor Voltage Low....51
11206.03 - Pump 1 Control Pressure Sensor Voltage High....51
11206.04 - Pump 1 Control Pressure Sensor Voltage Low....51
11208.03 - Pump 2 Control Pressure Sensor Voltage High....51
11208.04 - Pump 2 Control Pressure Sensor Voltage Low....51
11301.03 - Swing Pilot Pressure Sensor Voltage High....51
11301.04 - Swing Pilot Pressure Sensor Voltage Low....51
11302.03 - Boom Up Pilot Pressure Sensor Voltage High....51
11302.04 - Boom Up Pilot Pressure Sensor Voltage Low....51
11303.03 - Arm In Pilot Pressure Sensor Voltage High....51
11303.04 - Arm In Pilot Pressure Sensor Voltage Low....51
11304.03 - Travel Pilot Pressure Sensor Voltage High....51
11304.04 - Travel Pilot Pressure Sensor Voltage Low....51
11307.03 - Front Attachment Pilot Pressure Sensor Voltage High....51
11307.04 - Front Attachment Pilot Pressure Sensor Voltage Low....51
11400.02 - Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal....51
11400.03 - Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal....51
11400.04 - Pump 2 Flow Rate Limit Solenoid Feedback Current Low....51
11401.02 - Torque Control Solenoid Feedback Current Abnormal....51
11401.03 - Torque Control Solenoid Feedback Current High....52
11401.04 - Torque Control Solenoid Feedback Current Low....52
11402.02 - Dig Regenerative Solenoid Feedback Current Abnormal....52
11402.03 - Dig Regenerative Solenoid Feedback Current High....52
11402.04 - Dig Regenerative Solenoid Feedback Current Low....52
11403.02 - Arm Regenerative Solenoid Feedback Current Abnormal....52
11403.03 - Arm Regenerative Solenoid Feedback Current High....52
11403.04 - Arm Regenerative Solenoid Feedback Current Low....52
11404.02 - Power Dig Solenoid Feedback Current Abnormal....52
11404.03 - Power Dig Solenoid Feedback Current High....52
11404.04 - Power Dig Solenoid Feedback Current Low....52
11405.02 - Travel Speed Solenoid Feedback Current Abnormal....52
11405.03 - Travel Speed Solenoid Feedback Current High....52
11405.04 - Travel Speed Solenoid Feedback Current Low....52
11410.02 - Pump 1 Flow Rate Limit Solenoid Current Feedback Abnormal....52
11410.03 - Pump 1 Flow Rate Limit Solenoid Feedback Current High....52
11410.04 - Pump 1 Flow Rate Limit Solenoid Feedback Current Low....52
11901.03 - Hydraulic Oil Temperature Sensor Voltage High....52
11901.04 - Hydraulic Oil Temperature Sensor Voltage Low....52
11910.02 - Actual Engine Speed Message Error....52
11911.02 - Security Signal Received from Monitor....52
11914.02 - Radiator Coolant Temperature Message Error....52
11918.02 - Work Mode Received Message Error....52
11920.02 - Fuel Flow Rate Message Error....52
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes....225
Engine Control Unit (ECU) Diagnostic Trouble Codes....225
171.03 - Intake Air Temperature Sensor Out of Range High....52
171.04 - Intake Air Temperature Sensor Out of Range Low....52
647.05 - Proportional Fan Speed Solenoid Driver Open....52
647.31 - Fan Manual Reverse Mode Input Active Too Long....52
898.09 - Engine Speed Request Not Received or Timed Out....52
1638.09 - Hydraulic Oil Temperature Message Not Received or Timed Out....52
Group 30: Information Controller (ICF) Diagnostic Trouble Codes....264
Information Controller (ICF) Diagnostic Trouble Codes....264
14000.02 - Abnormal CAN Communication....53
14001.02 - ICF: Flash Memory: Read/Write Error....53
14002.02 - ICF: External RAM: Read/Write Error....53
14003.02 - ICF: EEPROM: Sum Check Error....53
14006.02 - ICF: Satellite Communication Terminal: Communication Error....53
14008.02 - ICF: Abnormal Internal RAM....53
14100.02 - Satellite Communication Terminal: Abnormal EEPROM....53
14101.02 - Satellite Communication Terminal: Abnormal IB/OB Queue....53
14102.02 - Satellite Communication Terminal: Abnormal Local Loop Back....53
14103.02 - Satellite Communication Terminal: The Satellite is not found....53
14104.02 - Satellite Communication Terminal: Fail 1 of Remote Loop Back....53
14105.02 - Satellite Communication Terminal: Tail 2 of Remote Loop Back....53
14106.02 - Satellite Communication Terminal: Sending and Receiving Data are Mismatched....53
Group 40: Air Conditioner Controller (ACF) Diagnostic Trouble Codes....297
Air Conditioner Controller (ACF) Diagnostic Trouble Codes....297
21 - Mix Door Open Circuit....53
Section 9005: Operational Checkout Procedure....331
Group 10: Operational Checkout Procedure....331
Operational Checkout....378
Section 9010: Engine....424
Group 05: Theory of Operation....424
Engine Fuel System Component Location....427
Engine Cooling System Component Location....429
Cold Weather Starting Aid....431
Engine Speed Control System Operation....432
Group 15: Diagnostic Information....424
PowerTech Plus™ 4.5 L and 6.8 L (4045 and 6068) John Deere Engines....437
Group 25: Tests....424
Radiator Temperature Differential Check....441
Engine Power Test Using Turbocharger Boost Pressure....444
Section 9015: Electrical System....447
Group 05: System Information....447
Electrical Diagram Information....459
Group 10: System Diagrams....447
Explanation of Wire Markings....468
Fuse and Relay Specifications....469
System Functional Schematic, Component Location, and Wiring Diagram Master Legend....473
System Functional Schematic....480
Cab Harness (W1) Component Location....490
Cab Harness (W1) Wiring Diagram....492
Machine Harness (W2) Component Location....497
Machine Harness (W2) Wiring Diagram....502
Monitor Harness (W3) Component Location....508
Monitor Harness (W3) Wiring Diagram....509
Engine Harness (W4) Component Location....511
Engine Harness (W4) Wiring Diagram....518
Engine Interface Harness (W5) Component Location....521
Engine Interface Harness (W5) Wiring Diagram....523
Right Console Harness (W7) Component Location....526
Right Console Harness (W7) Wiring Diagram....529
Pump Harness (W8) Component Location....531
Pump Harness (W8) Wiring Diagram....533
Auxiliary Fuse Box Harness (W9) Component Location....534
Auxiliary Fuse Box Harness (W9) Wiring Diagram....536
Pilot Shutoff Switch Harness (W11) Component Location....538
Pilot Shutoff Switch Harness (W11) Wiring Diagram....539
Air Suspension Seat Harness (W12) Component Location....540
Air Suspension Seat Harness (W12) Wiring Diagram....542
Seat Heater Switch Harness (W13) Component Location....543
Seat Heater Switch Harness (W13) Wiring Diagram....544
Multi-Function Pilot Control Lever Harness (W14) Component Location....545
Multi-Function Pilot Control Lever Harness (W14) Wiring Diagram....547
Travel Alarm Cancel Switch Harness (W15) Component Location....548
Travel Alarm Cancel Switch Harness (W15) Wiring Diagram....549
Fan Reversing Switch Harness (W16) Component Location....550
Fan Reversing Switch Harness (W16) Wiring Diagram....551
Pilot Shutoff Valve Harness (W17) Component Location....552
Pilot Shutoff Valve Harness (W17) Wiring Diagram....553
Attachment Harness (W20) Component Location....554
Attachment Harness (W20) Wiring Diagram....555
2-Speed Harness (W21) Component Location....448
2-Speed Harness (W21) Wiring Diagram....448
Alternator Harness (W22) Component Location....558
Alternator Harness (W22) Wiring Diagram....559
Start Aid Switch Harness (W23) Component Location....560
Start Aid Switch Harness (W23) Wiring Diagram....561
Starter Harness (W27) Component Location....562
Starter Harness (W27) Wiring Diagram....564
JDLink™ System Harnesses (W50, W51, W52, W53, and W54) Component Location—If Equipped....566
Machine Information Gateway (MIG) Harness (W50) Wiring Diagram—If Equipped....568
GlobalTRACS® Terminal (GTT) Harness (W51) Wiring Diagram—If Equipped....569
JDLink™ CAN Harness (W52) Wiring Diagram—If Equipped....570
JDLink™ Power Harness (W53) Wiring Diagram—If Equipped....572
JDLink™ Jumper Harness (W54) Wiring Diagram—If Equipped....573
Auxiliary Solenoid Harness (W61) Component Location....574
Auxiliary Solenoid Harness (W61) Wiring Diagram....576
JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Component Location—If Equipped....578
JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram—If Equipped....580
Group 15: Sub-System Diagnostics....448
Controller Area Network (CAN) Theory of Operation....584
Starting and Charging Circuit Theory of Operation....587
Monitor Controller Circuit Theory of Operation....592
Engine Control Unit (ECU) Circuit Theory of Operation....596
Main Controller (MCF) Circuit Theory of Operation....600
Information Controller (ICF) Circuit Theory of Operation....606
Travel Alarm Circuit Theory of Operation....608
Windshield Wiper and Washer Circuit Theory of Operation....610
Pilot Shutoff Circuit Theory of Operation....612
Attachment Control Circuit Theory of Operation....614
JDLink™ Circuit Theory of Operation—If Equipped....621
Group 16: Monitor Operation....449
Monitor Menu Operation....625
Monitor Service Menu Operation....626
Group 20: References....449
Monitor Data Items....634
Reading Diagnostic Trouble Codes With Monitor Display....636
Service ADVISOR™ Diagnostic Application....640
Service ADVISOR™ Connection Procedure....641
Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application....642
JDLink™ Connection Procedure—If Equipped....645
Information Controller (ICF) Recorded Data....646
Fuse Test....649
Relay Test....654
Pressure Sensor Test....655
Solenoid Test....657
Proportional Solenoid Test....658
Temperature Sensor Test....659
Alternator Test....660
Electrical Component Checks....662
Battery Remove and Install....668
Rear Cover Remove and Install....671
Main Controller (MCF) Remove and Install....672
Engine Control Unit (ECU) Remove and Install....673
Information Controller (ICF) Remove and Install....675
Monitor Controller Remove and Install....676
Key Switch Remove and Install....679
Switch Panel Remove and Install....681
Travel Alarm Remove and Install....683
Left Console Switch Remove and Install....684
Disconnect Tab Retainer Connectors....685
Disconnecting Spring Wire Clip Connectors....686
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors....450
Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors....450
Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact....450
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector....450
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact....450
Replace (Pull Type) Metri-Pack™ Connectors....697
Replace (Push Type) Metri-Pack™ Connectors....699
Replace CINCH CINCH is a trademark of the Cinch Co. Connectors....450
Install CINCH CINCH is a trademark of the Cinch Co. Contact....450
Repair 32 and 48 Way CINCH CINCH is a trademark of the Cinch Co. Connectors....450
Remove Connector Body from Blade Terminals....708
Section 9020: Power Train....709
Group 05: Theory of Operation....709
Track Adjuster and Recoil Spring Operation....712
Travel Gearbox Operation....714
Group 15: Diagnostic Information....709
Diagnose Undercarriage Components Malfunctions....709
Measure Swing Bearing Wear....730
Section 9025: Hydraulic System....734
Group 05: Theory of Operation....734
Hydraulic System Diagram and Operation....740
Fan Drive System Operation....742
Pilot System Diagram and Operation....746
Pilot Pump, Pressure Regulating Valve and Filter Operation....749
Pilot Shutoff Solenoid Valve Operation....751
Pilot Control Valve Operation....785
Travel Pilot Control Valve Operation....785
Pilot Operation of Control Valve Operation....785
Pilot Signal Manifold Operation....762
Pump 1, Pump 2 and Drive Gearbox Operation....772
Pump 1 and Pump 2 Regulator Operation....775
Engine Speed Sensing Control Circuit Operation....783
Control Valve Operation....785
Control Valve Check Valves Identification and Operation....797
Main Relief and Power Digging Valve Circuit Operation....801
Circuit Relief and Anticavitation Valve Operation....806
Travel Flow Combiner Valve Operation....808
Boom Lower Meter-In Cut Valve Operation....811
Boom Regenerative Valve Circuit Operation....814
Dig Regenerative Valve Circuit Operation....817
Arm Regenerative Valve Circuit Operation....821
Bucket Regenerative Valve Circuit Operation....826
Boom and Arm Reduced Leakage Valves Operation....829
Arm 1 Flow Rate Control Valve Circuit Operation....831
Arm 2 Flow Rate Control Valve Circuit Operation....835
Bucket Flow Rate Control Valve Circuit Operation....839
Boom Flow Rate Control Valve Circuit Operation....843
Auxiliary Flow Rate Control Valve Circuit Operation....847
Swing Reduction Gearbox Operation....852
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation....853
Swing Motor Dampener Valve Operation....857
Swing Motor Park Brake Release Circuit Operation....869
Center Joint Operation....870
Travel Motor and Park Brake Valve Operation....871
Travel Motor Speed Circuit Operation....878
Cylinder Operation....881
Return Filter Operation....883
Auxiliary System Operation....884
Auxiliary Pilot Control Valve Operation....885
Flow Rate Select Solenoid Valve Operation....892
Flow Rate Pressure Reducing Valve Operation....894
Secondary Auxiliary Relief Valve Solenoid Valve Operation....896
Secondary Auxiliary Relief Control Valve Operation....897
Secondary Auxiliary Relief Valve Operation....898
Selector Valve Solenoid Valve Operation....899
Selector Valve Operation....900
Auxiliary Flow Combiner Valve Operation....902
Auxiliary Shuttle Valve Operation....905
Auxiliary High Flow Line Kit Operation....907
Two Way Solenoid Kit Operation....911
Two Pump Combined Flow Kit Operation....915
Secondary Auxiliary Relief Kit Operation....921
Low Flow Kit Operation....925
Group 15: Diagnostic Information....735
All Hydraulic Functions Slow....735
Hydraulic Oil Overheats....735
No Hydraulic Functions....735
No Hydraulic Functions—Electrical Checks....735
Function Does Not Stop When Control Lever Released....735
Load Drifts Down When Control Lever is in Neutral Position....735
Load Falls When Control Valve is Actuated To Raise Load....735
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal....735
Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal....735
Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal....735
Swing Speed Slow During Arm In Function....736
Boom Cannot Raise Track Off Ground....736
Swing Function Does Not Operate in Both Directions....736
Swing Speed Slow in Both Directions....736
Swing Speed Slow or Does Not Operate in One Direction....736
Upperstructure Drift With Swing Valve in Neutral....736
Machine Freewheels Down an Incline....736
Track Will Not Move in Either Direction....736
Machine Mistracks....736
Machine Mistracks Left During Combined Travel and Dig Functions....736
Machine Will Not Shift Into Fast (Rabbit) Speed....736
Pump 1, Pump 2, and Pilot Pump Line Identification....990
Control Valve Line Identification....992
Swing Motor Line Identification....996
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern....997
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern....999
Pilot Signal Manifold-to-Control Valve Line Connection....1001
Travel System Component Location....1003
Travel Hydraulic System Line Connection....1005
Auxiliary Attachment Schematic....1007
Auxiliary System Line Connections....1016
Hydraulic System Schematic....1018
Hydraulic System Component Location....1027
Hydraulic System Line Connections....1029
Fan Drive Hydraulic System Schematic....1030
Fan Drive System Component Location....1033
Group 25: Tests....736
JT05800 Digital Thermometer Installation....1035
JT02156A Digital Pressure/Temperature Analyzer Installation....1036
Hydraulic Oil Cleanup Procedure With Portable Filter Caddy....1037
Hydraulic Oil Warm-Up Procedure....1038
Pilot Pressure Regulating Valve Test and Adjustment....1041
Control Valve Spool Actuating Pilot Pressure Test....1045
Dig Regenerative Solenoid Valve Test and Adjustment....1048
Arm Regenerative Solenoid Valve Test and Adjustment....1052
Power Digging Solenoid Valve Test and Adjustment....1056
Travel Speed Solenoid Valve Test and Adjustment....1060
Torque Control Solenoid Valve Test and Adjustment....1065
Pump Control Pilot Pressure Signal Test....1069
Main Relief and Power Digging Valve Test and Adjustment....1072
Circuit Relief Valve Test and Adjustment....1078
Swing Motor Crossover Relief Valve Test and Adjustment....1084
Travel Motor Crossover Relief Valve Test and Adjustment....1089
Pump Regulator Test and Adjustment—Minimum Flow....1094
Pump Regulator Test and Adjustment—Maximum Flow....1098
Pump Flow Test....1101
Swing Motor Leakage Test....1110
Travel Motor Leakage Test....1113
Cylinder Drift Test—Boom, Arm, and Bucket....1117
Fan Drive Pump Flow Test....1119
Fan Speed Test....1123
Section 9031: Heating and Air Conditioning....1127
Group 05: Theory of Operation....1127
Air Conditioning System Cycle of Operation....1130
Group 15: Diagnostic Information....1127
Diagnose Air Conditioning System Malfunctions....1135
Diagnose Heating System Malfunctions....1138
Heater and Air Conditioner Diagnostic Trouble Code Check....1140
Heater and Air Conditioner Component Location....1147
Group 25: Tests....1127
Refrigerant Cautions and Proper Handling....1149
Heater and Air Conditioner Operational Checks....1150
Air Conditioner Compressor Clutch Test....1154
Refrigerant Leak Test....1155
Refrigerant Hoses and Tubing Inspection....1156
Air Conditioner Compressor Belt Check and Adjustment....1157
Operating Pressure Diagnostic Chart....1158
Section 9050: Reference Material....1160
Group 05: Terminology Cross Reference Chart....1163
Terminology Cross Reference Chart....1163
Section 9900: Dealer Fabricated Tools....1165
Group 99: Dealer Fabricated Tools....1165
DFT1218 Split Flange Hose Cap....1167
