John Deere 160DLC Excavator Operator’s Manual – PDF DOWNLOAD

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John Deere 160DLC Excavator Engines 4045HT056 & 4045HT065 Operator’s Manual – PDF DOWNLOAD

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John Deere 160DLC Excavator Engines 4045HT056 & 4045HT065 Operator’s Manual – PDF DOWNLOAD

P/N: OMT226911_RZ
Language: English
Division: Construction
Product Lines: Excavators
Publication Type: Operator’s Manuals
Associated Models: 160DLC
Series: D SERIES
Serial: ENGINES 4045HT056, 4045HT065
For complete service information also see: PC10014, T228735

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 160DLC Excavator Engines 4045HT056 & 4045HT065 Operator’s Manual – PDF DOWNLOAD

Contents 15
Safety—Safety and Operator Conveniences 19
Safety and Operator Convenience Features 19
Safety—General Precautions 20
Recognize Safety Information 20
Follow Safety Instructions 20
Operate Only If Qualified 20
Wear Protective Equipment 20
Avoid Unauthorized Machine Modifications 21
Inspect Machine 21
Stay Clear of Moving Parts 21
Avoid High-Pressure Fluids 21
Avoid High-Pressure Oils 22
Work In Ventilated Area 22
Prevent Fires 23
Prevent Battery Explosions 23
Handle Chemical Products Safely 24
Decommissioning — Proper Recycling and Disposal of Fluids and Components 24
Prepare for Emergencies 25
Clean Debris from Machine 25
Add Cab Guarding for Special Uses 26
Safety—Operating Precautions 27
Use Steps and Handholds Correctly 27
Start Only From Operator’s Seat 27
Use and Maintain Seat Belt 27
Avoid Work Site Hazards 27
Keep Riders Off Machine 28
Avoid Backover Accidents 28
Avoid Machine Tip Over 29
Operating or Traveling On Public Roads 29
Inspect and Maintain ROPS 30
Add and Operate Attachments Safely 30
Use Special Care When Lifting Objects 30
Prevent Unintended Detonation of Explosive Devices 30
Safety—Maintenance Precautions 32
Park and Prepare for Service Safely 32
Service Cooling System Safely 32
Remove Paint Before Welding or Heating 32
Make Welding Repairs Safely 33
Drive Metal Pins Safely 33
Service Tires Safely 33
Safety—Safety Signs 35
Safety Signs 35
Safety Signs Installed in Cab—Hydraulic Coupler—If Equipped 35
Safety Signs Installed on Hydraulic Coupler—If Equipped 36
Operation—Operator’s Station 39
Pedals, Levers, and Panels 39
Front Switch Panel 39
Front Switch Panel Functions 40
Rear Panel 41
Horn 41
Power Dig Button 42
Pilot Shutoff Lever 42
Left Console 42
Travel Alarm and Travel Alarm Cancel Switch 43
Seat Heater Switch—If Equipped 44
Reversing Cooling Fan Switch—If Equipped 44
Cab Heater and Air Conditioner 45
Selecting Display Between Celsius and Fahrenheit 47
Operating the AM/FM Radio 47
Secondary Exit Tool 48
Opening Upper Front (Secondary Exit) Window 48
Removing and Storing the Lower Front Window 48
Opening Cab Door Window 49
Opening and Closing the Polycarbonate Type Roof Exit Cover 49
Adjusting the Mechanical Suspension Seat 50
Adjusting the Air Suspension Seat—If Equipped 50
Adjusting Pilot Control Lever Console Height 51
Operation—Monitor Operation 52
Monitor 52
Monitor Functions 52
Monitor Start-Up 53
Main Menu 54
Time Set Menu 55
Selecting an Attachment From Default Screen 55
Selecting an Attachment From Main Menu 56
Attachment Specification Screen 57
Pump 2 Flow Rate Adjustment 58
Displaying Operating Conditions 59
Maintenance Settings 60
Screen Display When Scheduled Maintenance is Due 63
Fuel Rate Display/No Display 65
Language Settings 65
Alarm Occurrence Screen 66
Operation—Operating the Machine 71
Before Starting Work 71
Operator’s Daily Machine Check Before Starting 71
Engine Break-In Period 71
Starting Engine 72
Cold Weather Start Aid—If Equipped 74
Cold Weather Warm-Up 74
Travel Pedals and Levers 75
Locking the Hydraulic Coupler to the Attachment 77
Unlocking the Hydraulic Coupler From the Attachment 78
Control Lever Pattern Operation 78
Control Lever Pattern Conversion 79
Mechanical Control Lever Pattern Selector—If Equipped 80
Operating In Water and Mud 81
Driving Up a Steep or Slippery Slope 81
Lifting 82
Lower Boom With Engine Stopped 82
Parking the Machine 83
Loading and Unloading for Transport 84
Towing 85
Lifting Machine 86
Maintenance—Machine 87
Diesel Fuel 87
Lubricity of Diesel Fuel 87
Handling and Storing Diesel Fuel 88
Biodiesel Fuel 88
Testing Diesel Fuel 90
Minimizing the Effect of Cold Weather on Diesel Engines 90
Alternative and Synthetic Lubricants 91
Diesel Engine Oil — Tier 3 and Stage IIIA 92
Diesel Engine Oil and Filter Service Intervals 92
Hydraulic Oil 93
Lubricant Storage 94
Mixing of Lubricants 95
Swing Gear Case and Travel Gear Case Oils 95
Pump Drive Gear Case Oil 95
Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease 96
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 96
Drain Intervals for Diesel Engine Coolant 97
John Deere COOL-GARD™ II Coolant Extender 98
Supplemental Coolant Additives 98
Operating in Warm Temperature Climates 99
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 99
Testing Diesel Engine Coolant 100
Maintenance—Periodic Maintenance 102
Service Machine at Specified Intervals 102
Check the Hour Meter Regularly 102
Prepare Machine for Maintenance 102
Open Access Doors for Service 102
Open Engine Hood 103
Fuel Tank 103
Hydraulic Breaker and Crusher Attachments 103
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 104
Service Intervals 104
Required Parts 107
Maintenance—As Required 108
Remove and Clean Fuel Tank Inlet Screen 108
Check and Clean Air Cleaner Dust Unloader Valve 108
Check Windshield Washer Fluid Level 108
Check and Adjust Track Sag 108
Check Coolant 110
Drain Auxiliary Fuel Filter and Water Separator—If Equipped 112
Maintenance—Every 10 Hours or Daily 113
Check Engine Oil Level 113
Check Engine Coolant Level 113
Check Hydraulic System Oil Level 114
Lubricate Hydraulic Coupler—If Equipped 114
Maintenance—Initial Service—50 Hours 116
Inspect and Re-Torque Track Hardware 116
Maintenance—Every 50 Hours or Weekly 117
Drain Water and Sediment from Fuel Tank Sump 117
Drain Water Separator Filter 117
Maintenance—Every 100 Hours 118
Lubricate Working Tool Pivots 118
Maintenance—Initial Service—250 Hours 119
Drain and Refill Engine Break-In Oil and Replace Filter 119
Maintenance—Every 250 Hours 120
Check and Adjust Air Conditioner Belt 120
Check Swing Gear Case Oil Level 120
Drain Hydraulic Tank Sump 120
Check Pump Drive Gear Case Oil Level 121
Check Battery Electrolyte Level and Terminals 121
Check Travel Gear Case Oil Level 123
Clean Primary Air Cleaner Element 125
Inspect and Re-Torque Track Hardware 126
Take Engine Oil Sample 126
Maintenance—Every 500 Hours 127
Lubricate Front End Pin Joints 127
Lubricate Swing Bearing 127
Lubricate Swing Bearing Gear 128
Replace Water Separator Filter 129
Replace Final Fuel Filter 129
Replace Auxiliary Fuel Filter and Water Separator—If Equipped 130
Drain and Refill Engine Oil and Replace Filter 131
Check Air Intake Hoses 131
Clean Cab Fresh Air and Cab Recirculation Air Filters 131
Take Fluid Samples 132
Maintenance—Every 1000 Hours 133
Drain and Refill Swing Gear Case Oil 133
Replace Hydraulic Oil Tank Oil Filter 133
Clean Engine Crankcase Ventilation Tube 134
Replace Pilot Control Oil Filter 134
Inspect Serpentine Belt 135
Drain and Refill Pump Drive Gear Case Oil 136
Replace Air Cleaner Elements 136
Replace Air Cleaner Dust Unloader Valve 138
Check Coolant 138
Maintenance—Every 2000 Hours 139
Adjust Engine Valve Lash 139
Drain and Refill Travel Gear Case Oil 139
Maintenance—Every 4000 Hours 140
Replace Engine Crankshaft Damper 140
Maintenance—Every 5000 Hours 141
Drain and Refill Hydraulic System Oil 141
Replace Hydraulic Tank Vent Cap Filter 143
Maintenance—Every 6000 Hours 145
Drain Cooling System 145
Cooling System Fill and Deaeration Procedure 146
Miscellaneous—Machine 148
Bleed Fuel System 148
Cleaning Radiator, Oil Cooler, Charge Air Cooler, Air Conditioner Condenser, and Fuel Cooler 148
Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump 149
Do Not Service Control Valves, Cylinders, Pumps, or Motors 149
Precautions for Alternator and Regulator 149
Handling, Checking, and Servicing Batteries Carefully 149
Using Battery Charger 150
Using Booster Batteries—24-Volt System 151
Replacing Batteries 152
Location of Fluid Sampling Test Ports—If Equipped 152
Welding On Machine 152
Clean the Machine Regularly 153
Adding 12-Volt Accessories 153
JDLink™ Machine Monitoring System (MMS)—If Equipped 153
Replacing Fuses 153
Replacing Bucket Teeth 156
Replacing Bucket Tooth Tip—Heavy-Duty Bucket 157
Replacing Bucket Teeth—TK Series 158
Removing the Bucket 158
Track Sag General Information 159
Unified Inch Bolt and Screw Torque Values 159
Metric Bolt and Screw Torque Values 160
Miscellaneous—Operational Checkout 162
Operational Checkout 162
Diagnostic Trouble Codes Check 162
Operational Checks—Key Switch OFF, Engine OFF Checks 162
Operational Checks—Key Switch ON, Engine OFF Checks 163
Operational Checks—Key Switch ON, Engine ON Checks 168
Miscellaneous—Troubleshooting 193
Troubleshooting Procedure 193
Engine 193
Electrical System 196
Hydraulic System 198
Miscellaneous—Storage 201
Prepare Machine for Storage 201
Monthly Storage Procedure 201
Miscellaneous—Machine Numbers 203
Record Product Identification Number (PIN) 203
Record Engine Serial Number 203
Record Travel Motor Serial Numbers 203
Record Swing Motor Serial Number 203
Record Hydraulic Pump Serial Number 204
Hydraulic Coupler Serial Number—If Equipped 204
Keep Proof of Ownership 204
Keep Machines Secure 205
Miscellaneous—Specifications 206
160DLC Engine Specifications 206
160DLC Drain and Refill Capacities 206
160DLC Machine Specifications 206
160DLC Working Ranges 208
Lift Capacity—160DLC, Arm: 2 58 m (8 ft 5 in ), Shoe: 600 mm (24 in ) 210
Lift Capacity—160DLC, Arm: 3 10 m (10 ft 2 in ), Shoe: 600 mm (24 in ) 210
Lift Capacity—160DLC, Arm: 2 58 m (8 ft 5 in ), Shoe: 700 mm (28 in ) 211
Lift Capacity—160DLC, Arm: 3 10 m (10 ft 2 in ), Shoe: 700 mm (28 in ) 212
Page Number 15
Section 1-1 19
Section 1-2 20
Section 1-3 27
Section 1-4 32
Section 1-5 35
Section 2-1 39
Section 2-2 52
Section 2-3 71
Section 3-1 87
Section 3-2 102
Section 3-3 108
Section 3-4 113
Section 3-5 116
Section 3-6 117
Section 3-7 118
Section 3-8 119
Section 3-9 120
Section 3-10 127
Section 3-11 133
Section 3-12 139
Section 3-13 140
Section 3-14 141
Section 3-15 145
Section 4-1 148
Section 4-2 162
Section 4-3 193
Section 4-4 201
Section 4-5 203
Section 4-6 206

S.V 03/24