John Deere 160DLC Excavator Repair Technical Manual (TM10091)

John Deere 160DLC Excavator Repair Technical Manual (TM10091 11JAN08)

This official repair manual provides in-depth service, troubleshooting, and maintenance procedures for the John Deere 160DLC Excavator. It includes hydraulic system repairs, engine overhauls, undercarriage servicing, electrical diagnostics, and structural component inspections to ensure peak machine performance.

File Format: PDF

Size: 10.12 MB

No. of pages: 406

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Table of Contents Overview:

General Information & Safety

• Recognizing safety information
• Operator qualification and protective equipment
• Preventing unintended machine movement
• Handling high-pressure fluids and oils
• Fire prevention and battery explosion hazards
• Proper welding and structural repair procedures

Tracks & Undercarriage

• Track roller removal, installation, and pressure testing
• Track carrier roller and sprocket servicing
• Track adjuster and recoil spring maintenance
• Front idler and track shoe replacement

Axles & Suspension Systems

• Travel gearbox servicing and diagnostics
• Travel motor and park brake troubleshooting
• Rotary manifold disassembly and reinstallation

Engine & Cooling System

• Engine removal, installation, and servicing
• Radiator, oil cooler, and intercooler maintenance
• Fuel tank, filter, and water separator servicing

Frame & Structural Components

• Welding repairs and counterweight installation

Operator’s Station

• Cab removal, installation, and window servicing
• Seat and seat belt maintenance
• Heating and air conditioning troubleshooting
• Refrigerant recovery and system recharging

Excavator Boom, Arm & Attachments

• Bucket, boom, and arm inspections
• Boom, arm, and bucket cylinder servicing
• Pin and bushing removal and replacement

Hydraulic System

• Hydraulic pump removal, testing, and calibration
• Control valve and pilot system maintenance
• Hydraulic oil filtering and contamination cleanup

Swing & Rotation System

• Swing gearbox maintenance and repairs
• Swing motor and park brake troubleshooting
• Swing bearing removal, servicing, and reinstallation

Dealer Fabricated Tools

• Track recoil spring assembly tool
• Rotary manifold lifting tool
• Swing gearbox spanner wrench

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

This John Deere 160DLC Excavator Repair Technical Manual is an essential resource for technicians, mechanics, and excavator owners, providing detailed repair instructions, diagnostics, and maintenance procedures to keep your machine operating efficiently.