John Deere 160dlc Repair Manual

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160DLC
Excavator
Repair

TECHNICAL MANUAL
160DLC Excavator Repair
TM10091 11JAN08 (ENGLISH)

For complete service information also see:

160DLC Excavator Operation and Tests . . . TM10088
160DLC Excavator Operator’s Manual . . . . . OMT226911
POWERTECH 4.5L/6.8L POWERTECH E
6.8L Diesel Engines—Base Engine . . . . . . . CTM104
POWERTECH E 6.8L Diesel
Engines—Level 16 Electronic Fuel System
with Denso HPCR . . . . . . . . . . . . . . . . . . . . . CTM502
Alternators and Starter Motors . . . . . . . . . . . CTM77
Undercarriage Appraisal Manual . . . . . . . . . SP326
Super Caddy Oil Cleanup Procedure . . . . . . CTM310

Worldwide Construction
And Forestry Division
LITHO IN U.S.A

This is the cut pages sample. Download all 406 page(s) at: ManualPlace.com
 Introduction
Foreword

This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.

DX,TMIFC –19–29SEP98–1/1

TM10091 (11JAN08) 160DLC Excavator Repair

011108

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 Introduction

Technical Information Feedback Form

We need your help to continually improve our technical

publications. Please copy this page and FAX or mail your
comments, ideas and improvements.

SEND TO: John Deere Dubuque Works

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

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THANK YOU!

TX,TM,FAX –19–03JUL01–1/1

TM10091 (11JAN08) 160DLC Excavator Repair

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 Introduction

TM10091 (11JAN08) 160DLC Excavator Repair

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 Contents
00
SECTION 00—General Information
Group 01—Safety
Group 0003—Torque Values

SECTION 01—Tracks
01
Group 0130—Track System

SECTION 02—Axles, Differentials and Suspension

Systems
Group 0250—Axle Shaft, Bearings, and Reduction
Gears 02
Group 0260—Hydraulic System

SECTION 04—Engine
Group 0400—Removal and Installation
04
SECTION 05—Engine Auxiliary System
Group 0510—Cooling System
Group 0520—Intake System
Group 0560—External Fuel Supply System

SECTION 07—Dampener Drive (Flex Coupling) 05

Group 0752—Elements

SECTION 17—Frame or Supporting Structure

Group 1740—Frame Installation
Group 1749—Chassis Weights
07

SECTION 18—Operator’s Station

Group 1800—Removal and Installation
Group 1810—Operator Enclosure
Group 1821—Seat and Seat Belt
Group 1830—Heating and Air Conditioning 17

SECTION 33—Excavator
Group 3302—Buckets
Group 3340—Frames
Group 3360—Hydraulic System
18

SECTION 43—Swing or Pivoting System

Group 4350—Mechanical Drive Elements
Group 4360—Hydraulic System

SECTION 99—Dealer Fabricated Tools 33

Group 9900—Dealer Fabricated Tools

All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 43

COPYRIGHT  2008
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2007

TM10091 (11JAN08) i 160DLC Excavator Repair

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 Contents

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01

02

04

05

07

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18

33

43

TM10091 (11JAN08) ii 160DLC Excavator Repair

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 Contents

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INDX

TM10091 (11JAN08) iii 160DLC Excavator Repair

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 Contents

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INDX

TM10091 (11JAN08) iv 160DLC Excavator Repair

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 00

Section 00
General Information
Contents

Page

Group 01—Safety . . . . . . . . . . . . . . . . . . . . . .00-01-1

Group 0003—Torque Values

Torque Value
Metric Bolt and Cap Screw . . . . . . . . . . . .00-0003-1
Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Torque Value
Unified Inch Bolt and Cap Screw . . . . . . . .00-0003-4
Service Recommendations for 37° Flare
and 30° Cone Seat Connectors . . . . . . . . .00-0003-5
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6
Service Recommendation
O-Ring Boss Fittings In Aluminum
Housing—Excavators . . . . . . . . . . . . . . .00-0003-8
Service Recommendations For Flared
Connections—Straight or Tapered
Threads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10
Service Recommendations For Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0003-11
Service Recommendation
O-Ring Face Seal Fittings with SAE
Inch Hex Nut and Stud End for High
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-12
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for Standard
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-14
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for High
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-16
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . .00-0003-18
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . .00-0003-19
Service Recommendation
Inch Series Four Bolt Flange For High
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-20

TM10091 (11JAN08) 00-1 160DLC Excavator Repair

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 Contents

00

TM10091 (11JAN08) 00-2 160DLC Excavator Repair

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 Group 01
Safety
00
Recognize Safety Information 01
1

This is the safety alert symbol. When this symbol is

–UN–28AUG00
noticed on the machine or in this manual, be alert for
the potential of personal injury.

Follow the precautions and safe operating practices

T133555
highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.

–19–28AUG00
On the machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION

T133588
labels.

TX03679,00016CC –19–03JAN07–1/1

Follow Safety Instructions

Read the safety messages in this manual and on the

–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently.

Be sure all operators of this machine understand every

T133556
safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.

TX03679,00016F9 –19–03JAN07–1/1

Operate Only If Qualified

Do not operate this machine unless the operator’s machine functions with the machine in an open area
manual has been read carefully, and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Operator should be familiar with the job site and every work situation and work site.
surroundings before operating. Try all controls and

TX03679,00016FA –19–08JAN08–1/1

TM10091 (11JAN08) 00-01-1 160DLC Excavator Repair

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 Safety

00
01 Wear Protective Equipment
2

Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.

Wear close fitting clothing and safety equipment

appropriate to the job.

–UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or

TS206
uncomfortable loud noises.

TX03679,00016D0 –19–03JAN07–1/1

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John machine stability or reliability, and may create a hazard
Deere replacement parts to ensure machine for the operator or others near the machine. The
performance. Never substitute genuine John Deere installer of any modification which may affect the
parts with alternate parts not intended for the electronic controls of this machine is responsible for
application as these can create hazardous situations or establishing that the modification does not adversely
hazardous performance. Non-John Deere Parts, or any affect the machine or its performance.
damage or failures resulting from their use are not
covered by any John Deere warranty. Always contact an authorized dealer before making
machine modifications that change the intended use,
Modifications of this machine, or addition of weight or balance of the machine, or that alter
unapproved products or attachments, may affect machine controls, performance or reliability.

AM40430,00000A9 –19–17JUL07–1/1

TM10091 (11JAN08) 00-01-2 160DLC Excavator Repair

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 Safety

00
Add Cab Guarding for Special Uses 01
3

Special work situations or machine attachments may

–UN–15SEP00
create an environment with falling or flying objects.
Working near an overhead bank, doing demolition work,
using a hydraulic hammer, or working in a wooded area,
for example, may require added guarding to protect the

T133733
operator.

FOPS (falling object protective structures) and special

screens or guarding should be installed when falling or
flying objects may enter or damage the machine. Contact
your authorized dealer for information on devices intended
to provide protection in special work situations.

TX03679,00016CE –19–03JAN07–1/1

Inspect Machine

Inspect machine carefully each day by walking around it

before starting.

Keep all guards and shields in good condition and

–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.

T6607AQ
TX03679,0001734 –19–03JAN07–1/1

Stay Clear of Moving Parts

–UN–12SEP01
Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
T133592

Keep guards and shields in place. Replace any guard or

shield that has been removed for access as soon as
service or repair is complete.

TX03679,00016D2 –19–03JAN07–1/1

TM10091 (11JAN08) 00-01-3 160DLC Excavator Repair

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 Safety

00
01 Avoid High-Pressure Fluids
4

Escaping fluid under pressure can penetrate the skin

causing serious injury.

Avoid the hazard by relieving pressure before

–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands

X9811
and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Oils

This machine uses a high-pressure hydraulic system.

Escaping oil under pressure can penetrate the skin
causing serious injury.

–UN–17MAR06
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
T133509

If hydraulic oil penetrates your skin, see a doctor

immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
–UN–20SEP00
T133840

TX03679,00016D3 –19–01OCT07–1/1

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 Safety

00
Beware of Exhaust Fumes 01
5

Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

–UN–24AUG00
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring

T133546
outside air into the area.

TX03679,00016D4 –19–03JAN07–1/1

Prevent Fires

–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.

T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.

–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil

T133553
spills. Examine electrical wiring and connectors frequently
for damage.

Keep A Fire Extinguisher Available: Always keep a

multipurpose fire extinguisher on or near the machine.

–UN–07SEP00
Know how to use extinguisher properly.

T133554

TX03679,00016F5 –19–08MAR07–1/1

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.

Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
–UN–23AUG88

Do not charge a frozen battery; it may explode. Warm

battery to 16°C (60°F).
TS204

TX03679,000174A –19–03JAN07–1/1

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 Safety

00
01 Handle Chemical Products Safely
6

Exposure to hazardous chemicals can cause serious

–UN–25AUG00
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.

T133580
If uncertain about safe handling or use of these chemical
products, contact your authorized John Deere dealer for a
Material Safety Data Sheet (MSDS) or go to internet
website http://www.jdmsds.com. The MSDS describes
physical and health hazards, safe use procedures, and
emergency response techniques for chemical substances.
Follow MSDS recommendations to handle chemical
products safely.

TX03679,00016D7 –19–08JAN08–1/1

Dispose of Waste Properly

Improper disposal of waste can threaten the environment.

–UN–25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or into

T133567
any water source.

Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified
service center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact your

local environmental or recycling center or your authorized
dealer for more information.

TX03679,0001733 –19–03JAN07–1/1

Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88

hospital, and fire department near your telephone.

TS291

TX03679,000174B –19–03JAN07–1/1

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 Safety

00
Use Steps and Handholds Correctly 01
7

Prevent falls by facing the machine when you get on and

–UN–30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.

Use extra care when mud, snow, or moisture present

T133468
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.

TX03679,00016F2 –19–25JAN07–1/1

Start Only From Operator’s Seat

–UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.

T133715
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.

TX03679,0001799 –19–03JAN07–1/1

Use and Maintain Seat Belt

Use seat belt when operating machine. Remember to

–19–14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.

T133716
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.

The complete seat belt assembly should be replaced

every three years, regardless of appearance.

TX03679,00016DD –19–10JAN07–1/1

TM10091 (11JAN08) 00-01-7 160DLC Excavator Repair

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 Safety

00
01 Prevent Unintended Machine Movement
8

Be careful not to accidentally actuate control levers when

co-workers are present. Pull pilot control shutoff lever to
locked position during work interruptions. Pull pilot control
shutoff lever to locked position and stop engine before

–UN–22NOV05
allowing anyone to approach machine.

Always lower work equipment to the ground and pull pilot

control shutoff lever to locked position before standing up

T216779
or leaving the operator’s seat. Stop engine before exiting.

DW90712,00002BF –19–26OCT06–1/1

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 Safety

00
Avoid Work Site Hazards 01
9

Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all

–UN–31OCT00
underground utilities before you dig.

Prepare work site properly. Avoid operating near

structures or objects that could fall onto the machine.

T134986
Clear away debris that could move unexpectedly if run
over.

Avoid boom or arm contact with overhead obstacles

or overhead electrical lines. Never move any part of
machine or load closer than 3 m (10 ft) plus twice the line

–UN–27SEP00
insulator length to overhead wires.

Keep bystanders clear at all times. Use barricades or a

signal person to keep vehicles and pedestrians away. Use

T133650
a signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient to

support machine. When working close to an excavation,
position travel motors away from the hole.

–UN–24AUG00
Reduce machine speed when operating with tool on or
near ground when obstacles may be hidden (e.g., during
snow removal or clearing mud, dirt, etc). At high speeds,

T133549
hitting obstacles (rocks, uneven concrete or manholes)
can cause a sudden stop. Always wear your seat belt.

TX03679,0001748 –19–13DEC07–1/1

Keep Riders Off Machine

Only allow operator on machine.

Riders are subject to injury. They may fall from machine,

be caught between machine parts, or be struck by foreign
–UN–08JUN90

objects.

Riders may obstruct operator’s view or impair his ability to

operate machine safely.
T7273AH

TX03679,0001726 –19–03JAN07–1/1

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John Deere 160dlc Repair Manual
Full download: http://manualplace.com/download/john-deere-160dlc-repair-manual/

Safety

00
01 Avoid Backover Accidents
10

Before moving machine, be sure all persons are clear

of both travel and swing paths. Turn around and look

–UN–24AUG00
directly for best visibility. Use mirrors to assist in checking
all around machine. Keep windows and mirrors clean,
adjusted, and in good repair.

T133548
Be certain travel alarm is working properly.

Use a signal person when backing if view is

obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.

TX03679,00016F3 –19–03JAN07–1/1

Avoid Machine Tip Over

Use seat belt at all times.

–19–14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.

T133716
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
Avoid trucks with steel beds because tracks slip more
easily on steel.

–UN–15SEP00
Be careful on slopes. Use extra care on soft, rocky or
frozen ground. Machine may slip sideways in these
conditions. When traveling up or down slopes, keep the T133545
bucket on uphill side and just above ground level.

Be careful with heavy loads. Using oversize buckets or

lifting heavy objects reduces machine stability. Extending
a heavy load or swinging it over side of undercarriage
may cause machine to tip.
–UN–27SEP00

Ensure solid footing. Use extra care when operating

near banks or excavations that may cave-in and cause
machine to tip or fall.
T133803

TX03679,00016DF –19–03JAN07–1/1

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