John Deere 160GLC Excavator Workshop Repair & Service Manual (TM12551) PDF Download - PIN 1FF160GX - TM12551 - John Deere 160GLC Excavator Technical Manual (Repair).pdf
A full workshop and repair guide for the John Deere 160GLC Excavator, containing every piece of shop-level detail needed to service, troubleshoot, and overhaul the machine with the skill of a trained technician.
Inside the John Deere 160GLC Excavator service and repair manual, you'll find:
* 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.
TM12551 - John Deere 160GLC Excavator Technical Manual (Repair).pdf
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Covered models: 160GLC (PIN: 1FF160GX__D055001-)
Total Pages: 745 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English French SpanisPortugueseh
John Deere - Excavator - 1FF160GX__D055001 (T3/S3A)
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 Systems
Intake System
External Fuel Supply Systems
Damper 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
Sheet Metal
Hood and Engine Side Shields
Excavator
Buckets
Frames
Hydraulic System
Swing or Pivoting System
Mechanical Drive Elements
Hydraulic System
Dealer Fabricated Tools
tm12551 - 160GLC Excavator
Table of Contents
Foreword
Technical Information Feedback Form
Section 00: General Information
Group 0001: Safety
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Add Cab Guarding for Special Uses
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Work In Ventilated Area
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Prepare for Emergencies
Clean Debris from Machine
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Inspect and Maintain ROPS
Avoid Machine Tip Over
Use Special Care When Lifting Objects
Add and Operate Attachments Safely
Park and Prepare for Service Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Group 0003: Torque Values
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Service Recommendations for 37° Flare and 30° Cone Seat Connectors
Service Recommendations for O-Ring Boss Fittings
Service Recommendations for Flared Connections—Straight or Tapered Threads
Service Recommendations for Flat Face O-Ring Seal Fittings
O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators
O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations For Inch Series Four Bolt Flange Fittings
Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings
Service Recommendations For O-Ring Boss Fittings With Shoulder
Metric 24° O-Ring Seal DIN 20078 Service Recommendations
Section 01: Tracks
Group 0130: Track System
Track Roller Remove and Install
Track Roller Disassemble and Assemble
Track Roller Pressure Test
Track Carrier Roller Remove and Install
Metal Face Seals Repair
Track Shoe Remove and Install
Track Chain Remove and Install
Track Chain Disassemble and Assemble
Track Chain Repair to Replace Broken Part
Sprocket Remove and Install
Front Idler Remove and Install
Front Idler Disassemble and Assemble
Track Adjuster and Recoil Spring Remove and Install
Track Adjuster and Recoil Spring Disassemble and Assemble
Section 02: Axles, Differentials, and Suspension Systems
Group 0250: Axle Shaft, Bearings, and Reduction Gears
Travel Gear Case Remove and Install
Travel Gear Case Disassemble and Assemble
Group 0260: Hydraulic System
Travel Motor and Park Brake Remove and Install
Travel Motor and Park Brake Disassemble and Assemble
Park Brake Valve Disassemble and Assemble
Travel Motor and Park Brake Start-Up Procedure
Section 04: Engine
Group 0400: Removal and Installation
Engine Remove and Install
Section 05: Engine Auxiliary System
Group 0510: Cooling Systems
Radiator Remove and Install
Hydraulic Oil Cooler Remove and Install
Charge Air Cooler Remove and Install
Fuel Cooler Remove and Install
Cooling Package Remove and Install
Fan, Fan Guard, and Fan Shroud Remove and Install
Serpentine Belt Remove and Install
Coolant Surge Tank Remove and Install
Group 0520: Intake System
Air Cleaner Remove and Install
Group 0560: External Fuel Supply Systems
Fuel Tank Remove and Install
Primary Fuel Filter and Water Separator Remove and Install
Final Fuel Filter Remove and Install
Auxiliary Fuel Filter Remove and Install (If Equipped)
Section 07: Damper Drive (Flex Coupling)
Group 0752: Elements
Damper Drive (Flex Coupling) Remove and Install
Section 17: Frame or Supporting Structure
Group 1740: Frame Installation
Welding on Machine
Group 1749: Chassis Weights
Counterweight Remove and Install
Section 18: Operator's Station
Group 1800: Removal and Installation
Cab Remove and Install
Monitor Remove and Install
Group 1810: Operator Enclosure
Windshield Remove and Install
Windshield Disassemble and Assemble
Sliding Windows Remove and Install
Windowpanes Remove and Install
Windowpanes Dimensions
Group 1821: Seat and Seat Belt
Seat Remove and Install
Seat Belt Remove and Install
Mechanical Suspension Seat Disassemble and Assemble
Air Suspension Seat Disassemble and Assemble
Left and Right Console Covers Remove and Install
Group 1830: Heating and Air Conditioning
Refrigerant Cautions and Proper Handling
Flush and Purge Air Conditioning System
R134a Refrigerant Oil Information
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure
R134a Compressor Oil Charge Check
R134a Compressor Oil Removal
Recover R134a Refrigerant
Evacuate R134a System
Charge R134a System
Air Conditioner Compressor Remove and Install
Condenser Remove and Install
Heater and Air Conditioner Remove and Install
Heater and Air Conditioner Blower Motor Remove and Install
Receiver-Dryer Remove and Install
Section 19: Sheet Metal
Group 1910: Hood and Engine Side Shields
Hood Remove and Install
Engine Side Shield Remove and Install
Section 33: Excavator
Group 3302: Buckets
Bucket Remove and Install
Adjust Bucket Pivot End Play
Bucket Pin-Up Data
Group 3340: Frames
Bucket Links Remove and Install
Arm Remove and Install
Boom Remove and Install
Inspect Pins, Bushings, and Bosses—Front Attachment
Cylinder Specifications
Bushings and Seal Remove and Install
Group 3360: Hydraulic System
Apply Vacuum to Hydraulic Oil Tank
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Pump 1 and 2 Remove and Install
Pump 1 and 2 Disassemble and Assemble
Pump 1 and 2 Inspection
Pump 1 and 2 Start-Up Procedure
Pump 1 and 2 Regulator Remove and Install
Pump 1 and 2 Regulator Disassemble and Assemble
Pilot Pump Remove and Install
Pilot Pump Disassemble and Assemble
Pilot Pressure Regulating Valve and Filter Remove and Install
Pilot Pressure Regulating Valve and Filter Disassemble and Assemble
Pilot Shutoff Solenoid Valve Remove and Install
Pilot Shutoff Solenoid Valve Disassemble and Assemble
Fan Drive Pump Remove and Install
Fan Drive Motor Remove and Install
Fan Drive Motor Disassemble and Assemble
Fan Drive Motor Solenoid Valves Remove and Install
Solenoid Valve Manifold Remove and Install
Solenoid Valve Remove and Install—Power Dig (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves
Solenoid Valve Disassemble and Assemble—Power Dig (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves
Pilot Valve (Left and Right) Remove and Install
Pilot Valve (Left and Right) Disassemble and Assemble
Travel Pilot Valve Remove and Install
Travel Pilot Valve Disassemble and Assemble
Pilot Signal Manifold Remove and Install
Pilot Signal Manifold Disassemble and Assemble
Control Valve Remove and Install
Control Valve Halves Disassemble and Assemble
Control Valve (5-Spool) Disassemble and Assemble
Control Valve (4-Spool) Disassemble and Assemble
Hydraulic Oil Tank Remove and Install
Hydraulic Oil Tank Disassemble and Assemble
Restriction Valve Remove and Install
Hydraulic Oil Cooler Bypass Valve Remove and Install
Boom Cylinder Remove and Install (S.N. —055027)
Boom Cylinder Disassemble and Assemble (S.N. —055195)
Boom Cylinder Disassemble and Assemble (S.N. 055196— )
Arm Cylinder Remove and Install (S.N. —055027)
Arm Cylinder Disassemble and Assemble (S.N. —055196)
Arm Cylinder Disassemble and Assemble (S.N. 055197— )
Bucket Cylinder Remove and Install (S.N. —055027)
Bucket Cylinder Disassemble and Assemble (S.N. —055224)
Bucket Cylinder Disassemble and Assemble (S.N. 055225— )
Hydraulic Cylinder Bleed Procedure
Section 43: Swing or Pivoting System
Group 4350: Mechanical Drive Elements
Swing Gear Case Remove and Install
Swing Gear Case Disassemble and Assemble
Swing Gear Case Start-Up Procedure
Upperstructure Remove and Install
Swing Bearing Remove and Install
Swing Bearing Disassemble and Assemble
Swing Bearing Upper Seal Install
Swing Bearing Lower Seal Install
Group 4360: Hydraulic System
Center Joint Remove and Install
Center Joint Disassemble and Assemble
Center Joint Air Test
Swing Motor and Park Brake Remove and Install
Swing Motor and Park Brake Disassemble
Swing Motor and Park Brake Inspection
Swing Motor and Park Brake Assemble
Swing Motor and Park Brake Start-Up Procedure
Crossover Relief Valve and Make-Up Check Valve Remove and Install
Make-Up Check Valve Disassemble and Assemble
Swing Park Brake Check Valve and Orifice Remove and Install
Section 99: Dealer Fabricated Tools
Group 9900: Dealer Fabricated Tools
DF1063 Lift Bracket
ST4920 Track Recoil Spring Disassembly and Assembly Tool
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
DFT1110 Spacer
DFT1130 Adapter
DFT1036A Travel Gear Case Nut Wrench
DFT1109 Holding Bar
Center Joint (Rotary Manifold) Lifting Tool
DFT1119 Pump Support
DFT1220 Swing Gear Case Nut Spanner Wrench
John Deere 160GLC Excavator Repair Service Manual - TM12551