John Deere 160DLC Excavator Repair Service Manual (TM10091)
Complete repair manual for John Deere 160DLC Excavator (Hitachi ZX160LC-3), with workshop information to maintain, repair, and rebuild like professional mechanics.
John Deere Excavator 160DLC (HITACHI Zaxis160LC-3) 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.
TM10091 - John Deere 160DLC Excavator Technical Manual (Repair).pdf
TM10093 - John Deere 160DLC Excavadora.pdf
TM10092 - John Deere Excavatrice 160DLC.pdf
TM12129 - John Deere Escavadeira 160DLC.pdf
Total Pages: 600 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English Spanish French Portuguese
MAIN SECTIONS
Foreword
Technical Information Feedback Form
General Information
Safety
Torque Values
Tracks
Track System
Axles, Differentials and Suspension Systems
Axle Shaft, Bearings, and Reduction Gears
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary System
Cooling System
Intake System
External Fuel Supply System
Dampener Drive (Flex Coupling)
Elements
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...10
Group 01: Safety...10
Recognize Safety Information...13
Follow Safety Instructions...14
Operate Only If Qualified...15
Wear Protective Equipment...16
Avoid Unauthorized Machine Modifications...17
Add Cab Guarding for Special Uses...18
Inspect Machine...19
Stay Clear of Moving Parts...20
Avoid High-Pressure Fluids...21
Avoid High-Pressure Oils...22
Beware of Exhaust Fumes...23
Prevent Fires...24
Prevent Battery Explosions...25
Handle Chemical Products Safely...26
Dispose of Waste Properly...27
Prepare for Emergencies...28
Use Steps and Handholds Correctly...29
Start Only From Operator's Seat...30
Use and Maintain Seat Belt...31
Prevent Unintended Machine Movement...32
Avoid Work Site Hazards...33
Keep Riders Off Machine...35
Avoid Backover Accidents...36
Avoid Machine Tip Over...37
Use Special Care When Lifting Objects...39
Add and Operate Attachments Safely...40
Park and Prepare for Service Safely...41
Service Cooling System Safely...42
Remove Paint Before Welding or Heating...43
Make Welding Repairs Safely...44
Drive Metal Pins Safely...45
Group 0003: Torque Values...11
Metric Bolt and Cap Screw Torque Values...48
Additional Metric Cap Screw Torque Values...50
Unified Inch Bolt and Cap Screw Torque Values...52
Service Recommendations for 37° Flare and 30° Cone Seat Connectors...54
Service Recommendations for O-Ring Boss Fittings...56
O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators...58
Service Recommendations for Flared Connections—Straight or Tapered Threads...61
Service Recommendations For Flat Face O-Ring Seal Fittings...63
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations...65
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations...67
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations...70
Service Recommendations for Metric Series Four Bolt Flange Fitting...73
Service Recommendations For Inch Series Four Bolt Flange Fittings...75
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations...77
Section 01: Tracks...79
Group 0130: Track System...79
Track Roller Remove and Install...82
Track Roller Disassemble and Assemble...84
Track Roller Pressure Test...86
Track Carrier Roller Remove and Install...88
Metal Face Seals Repair...91
Track Shoe Remove and Install...95
Track Chain Remove and Install...96
Track Chain Disassemble and Assemble...99
Track Chain Repair...101
Sprocket Remove and Install...104
Front Idler Remove and Install...106
Front Idler Disassemble and Assemble...107
Track Adjuster and Recoil Spring Remove and Install...110
Track Adjuster and Recoil Spring Disassemble and Assemble...112
Track Adjuster Cylinder Disassemble and Assemble...118
Section 02: Axles, Differentials and Suspension Systems...120
Group 0250: Axle Shaft, Bearings, and Reduction Gears...120
Travel Gearbox Remove and Install...124
Travel Gearbox Disassemble and Assemble...127
Group 0260: Hydraulic System...120
Travel Motor and Park Brake Remove and Install...142
Travel Motor and Park Brake Disassemble and Assemble...149
Counterbalance Valve Remove and Install...153
Crossover Relief Valve Remove and Install...156
Make-Up Check Valve Remove and Install...159
Travel Speed Change Valve Remove and Install...162
Travel Motor and Park Brake Start-Up Procedure...165
Section 04: Engine...166
Group 0400: Removal and Installation...166
Engine Remove and Install...177
Section 05: Engine Auxiliary System...187
Group 0510: Cooling System...187
Radiator Remove and Install...192
Hydraulic Oil Cooler Remove and Install...196
Intercooler Remove and Install...200
Fuel Cooler Remove and Install...205
Cooling Package Remove and Install...206
Fan, Fan Guard, and Fan Shroud Remove and Install...216
Coolant Surge Tank Remove and Install...222
Group 0520: Intake System...187
Air Cleaner Remove and Install...226
Group 0560: External Fuel Supply System...187
Fuel Tank Remove and Install...232
Primary Fuel Filter (Water Separator) Remove and Install...236
Final Fuel Filter Remove and Install...237
Section 07: Dampener Drive (Flex Coupling)...238
Group 0752: Elements...238
Dampener Drive (Flex Coupling) Remove and Install...242
Section 17: Frame or Supporting Structure...245
Group 1740: Frame Installation...245
Welding On Machine...248
Welding Repair of Major Structure...250
Group 1749: Chassis Weights...245
Counterweight Remove and Install...254
Section 18: Operator's Station...256
Group 1800: Removal and Installation...256
Cab Remove and Install...263
Group 1810: Operator Enclosure...256
Sliding Windows Remove and Install...271
Windowpanes Remove and Install...273
Windowpanes Dimensions...274
Group 1821: Seat and Seat Belt...256
Seat Remove and Install...280
Seat Belt Remove and Install...282
Mechanical Suspension Seat Disassemble and Assemble...284
Air Suspension Seat Disassemble and Assemble...286
Left and Right Console Covers Remove and Install...288
Group 1830: Heating and Air Conditioning...256
Refrigerant Cautions and Proper Handling...292
Flush and Purge Air Conditioner System...293
R134a Refrigerant Oil Information...297
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure...299
Recover R134a Refrigerant...301
Evacuate R134a System...302
Charge R134a System...304
Compressor Remove and Install...305
Condenser Remove and Install...307
Heater and Air Conditioner Remove and Install...309
Receiver-Dryer Remove and Install...314
Section 33: Excavator...315
Group 3302: Buckets...315
Bucket Remove and Install...319
Bucket Pin-Up Data...321
Group 3340: Frames...315
Bucket Links Remove and Install...325
Arm Remove and Install...327
Boom Remove and Install...332
Inspect Pins, Bushings and Bosses—Front Attachment...339
Bushings and Seal Remove and Install...342
Group 3360: Hydraulic System...315
Apply Vacuum to Hydraulic Oil Tank...346
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy...348
Pump 1 and 2 Remove and Install...350
Pump 1 and 2 Disassemble and Assemble...358
Pump 1 and 2 Inspection...375
Pump 1 and 2 Start-Up Procedure...380
Pump 1 and 2 Regulator Remove and Install...382
Pump 1 and 2 Regulator Disassemble and Assemble...384
Pilot Pump Remove and Install...387
Pilot Pump Disassemble and Assemble...389
Pilot Pump Drive Shaft Remove and Install...392
Pilot Pressure Regulating Valve and Filter Remove and Install...394
Pilot Pressure Regulating Valve and Filter Disassemble and Assemble...396
Pilot Shutoff Solenoid Valve Remove and Install...397
Pilot Shutoff Solenoid Valve Disassemble and Assemble...399
Fan Drive Pump Remove and Install...401
Fan Drive Motor Remove and Install...403
Fan Drive Control Valve Remove and Install...429
Solenoid Valve Manifold Remove and Install...407
Solenoid Valve Remove and Install—Power Dig (SG), Travel Speed (SI), Boom Mode (SC), and Boom Flow Rate (SF)...409
Pilot Valve (Left and Right) Remove and Install...411
Pilot Valve (Left and Right) Disassemble and Assemble...414
Travel Pilot Valve Remove and Install...418
Travel Pilot Valve Disassemble and Assemble...420
Pilot Signal Manifold Remove and Install...424
Pilot Signal Manifold Disassemble and Assemble...426
Control Valve Remove and Install...429
Control Valve Halves Disassemble and Assemble...432
Control Valve (5-Spool) Disassemble and Assemble...434
Control Valve (4-Spool) Disassemble and Assemble...460
Hydraulic Oil Tank Remove and Install...483
Hydraulic Oil Tank Disassemble and Assemble...487
Restriction Valve Remove and Install...490
Hydraulic Oil Cooler Bypass Valve Remove and Install...493
Boom Cylinder Remove and Install...495
Boom Cylinder Disassemble and Assemble...500
Arm Cylinder Remove and Install...504
Arm Cylinder Disassemble and Assemble...509
Bucket Cylinder Remove and Install...515
Bucket Cylinder Disassemble and Assemble...520
Hydraulic Cylinder Bleed Procedure...524
Section 43: Swing or Pivoting System...525
Group 4350: Mechanical Drive Elements...525
Swing Gearbox Remove and Install...528
Swing Gearbox Disassemble and Assemble...530
Swing Gearbox Start-Up Procedure...538
Upperstructure Remove And Install...539
Swing Bearing Remove and Install...543
Swing Bearing Disassemble and Assemble...545
Swing Bearing Upper Seal Install...549
Swing Bearing Lower Seal Install...550
Group 4360: Hydraulic System...525
Center Joint Remove and Install...554
Center Joint Disassemble and Assemble...557
Center Joint Air Test...560
Swing Motor and Park Brake Remove and Install...561
Swing Motor and Park Brake Disassemble...563
Swing Motor and Park Brake Inspection...566
Swing Motor and Park Brake Assemble...570
Swing Motor and Park Brake Start-Up Procedure...574
Crossover Relief Valve and Make-Up Check Valve Remove and Install...575
Make-Up Check Valve Disassemble and Assemble...577
Swing Park Brake Release Valve Remove and Install...579
Section 99: Dealer Fabricated Tools...580
Group 9900: Dealer Fabricated Tools...580
DF1063 Lift Bracket...583
ST4920 Track Recoil Spring Disassembly and Assembly Tool...585
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool...589
DFT1110 Spacer...590
DFT1130 Adapter...591
DFT1036A Travel Gearbox Nut Wrench...592
DF1038 Torque Adapter...593
DFT1109 Holding Bar...594
Center Joint (Rotary Manifold) Lifting Tool...595
DFT1144 Guide Pin...596
DFT1119 Pump Support...597
DFT1220 Swing Gearbox Nut Spanner Wrench...598
