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

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

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

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TABLE OF CONTENTS:

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

Contents 7
Safety 11
John Deere Excavator Safety Features 11
Recognize Safety Information 12
Understand Signal Words 12
Follow Safety Instructions 12
Avoid Injury From: Loading Machine on a Trailer, fastening Machine to Trailer, Unloading Machine from Trailer Always Use Caution when Loading and Unloading Machines on a Trailer Always 13
Avoid Injury from Backover Accidents Before Moving Machine, be Sure All Persons are Clear of Area Always be Alert for Bystanders Moving into the Work Area Use Horn or Other Signal to W 14
Avoid Injury from Rollaway Accidents To Prevent Rollaway, Always Make Sure Machine is Properly Secured Before Leaving Operator’s Seat Death or Serious Injury may Result if You Attempt to Mo 15
Inspect Machine 15
Use Handholds and Steps 16
Use Seat Belt 16
Maintain Seat Belt 17
Move and Operate Machine Safely 17
Operate Only from Operator’s Seat 18
Secondary Exits 18
Operate Machine Safely 18
Dig with Caution 19
Operate with Caution 19
Avoid Tipping 19
Avoid Power Lines 20
Drive Machine Safely 20
Beware of Exhaust Fumes 20
Park Machine Safely 21
Keep Riders off Machine 21
Operate Attachment Safely 22
Handle Fluids Safely—Avoid Fires 22
Prepare for Emergencies 23
Handle Starting Fluid Safely 23
Clean Trash from Machine 23
Protect Against Flying Debris 24
Wear Protective Clothing 24
Protect Against Noise 24
Handle Chemical Products Safely 25
Warn Others of Service Work 25
Stay Clear of Moving Parts 26
Support Machine Properly 26
Service Cooling System Safely 26
Practice Safe Maintenance 27
Remove Paint Before Welding or Heating 28
Avoid Heating Near Pressurized Fluid Lines 28
Avoid High Pressure Fluids 29
Prevent Battery Explosions 29
Clean the Machine Regularly 30
Store Attachments Safely 30
Dispose of Waste Properly 31
Safety Signs 32
Safety Signs 32
Operator’s Station 39
Pedals, Levers, and Panels 39
Right Front Panel and Right Console Panel 40
Monitor Panel 41
Engine Coolant Temperature Gauge 41
Warm Up Indicator 41
Fuel Gauge 42
H/P (High Power) Mode Indicator 42
E (Economy) Mode Indicator 42
Auto Idle Indicator 42
Hydraulic Oil Level Indicator 43
Fuel Level Indicator 43
Air Filter Restriction Indicator 43
Engine Coolant Temperature Indicator 44
Engine Oil Pressure Indicator 44
Alternator Voltage Indicator 44
Engine Oil Level Indicator 45
Engine Coolant Level Indicator 45
Switch Panel 45
Buzzer and Buzzer Stop Switch 46
Wiper Switch 46
Washer Switch 47
Operating Lights Switch 47
Cab Light 48
Key Switch 48
Engine RPM Dial 48
Horn Switch 48
Hour Meter 49
Heater 49
Control Panel Levers and Switches 50
Defroster Operation 50
Cab Heater and Air Conditioner—If Equipped 51
Control Panel Switches 52
Cab Heater Operation 53
Air Conditioner Operation 54
Defroster Operation 54
Front Console 55
Operating the AM/FM Radio 55
Setting the Clock 56
Cab Door Release Lever 56
Secondary Exit Tool 56
Opening Upper Front (Secondary Exit) Window 57
Closing Upper Front Window 57
Removing and Storing the Lower Front Window 58
Opening Side Windows 59
Opening and Closing the Roof Exit Cover 59
Adjusting the Seat 60
Adjusting the Armrest 60
Seat Belt 61
Operator’s Manual Compartment 61
Pre Start Inspection 62
Inspect Machine Daily Before Starting 62
Operating the Engine 63
Check Instruments Before Starting 63
Level Check 63
Starting the Engine 64
Using Booster Batteries—24 Volt System 65
Check Instruments After Starting 66
Warming the Machine 66
Cold Weather Warm Up 67
Stopping the Engine 68
Driving the Machine 69
Steering the Machine Using Pedals 69
Steering the Machine Using Levers 71
Removing Propel Levers 72
Propel Speed Switch 72
Travel Alarm and Travel Alarm Cancel Switch 73
Parking the Machine 73
Parking Machine During Freezing Weather 74
Lock All Compartments 74
Operating the Machine 75
ISO/SAE Excavator Control Pattern 75
Control Lever Pattern Conversion 76
Deere Backhoe Control Pattern 78
Pilot Control Shut Off Lever 79
Auto Idle Switch 80
Mode Selection Switch 81
E (Economy) Mode 82
H/P (High Power) Mode 83
Standard Mode 83
Operating Tips 84
Driving Machine 84
Driving on Slopes 85
Driving Down a Slope 85
Driving Up a Slope 85
Driving Up a Steep or Slippery Slope—Boom on Uphill End of Machine 86
Driving Up a Steep or Slippery Slope—Boom on Downhill End of Machine 86
Moving Machine off an Embankment 87
Leveling Machine 88
Using Bucket 88
Planning Spoil Piles 90
Trenching 90
Backfilling 91
Truck Loading 92
Operating in Water and Mud 93
Clean Track Frame Area 93
Lifting 94
Hydraulic Breaker and Crusher Attachments 96
Lower Boom with Engine Stopped 96
Transporting 99
Loading Machine on a Trailer 99
Fasten Machine to Trailer 100
Unloading Machine from Trailer 101
Towing Machine 102
Lifting the Machine 103
Fuels and Lubricants 104
Diesel Fuel 104
Lubricity of Diesel Fuels 104
Low Sulfur Diesel Fuel Conditioner 105
Diesel Fuel Storage 105
Fuel Tank 106
Do Not Use Galvanized Containers 106
Diesel Engine Oil 107
Hydraulic Oil 108
Swing Gearbox and Propel Gearbox Oils 109
Track Roller, Front Idler, and Carrier Roller Oil 109
Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease 110
Oil Filters 110
Lubricant Storage 111
Alternative and Synthetic Lubricants 111
Mixing of Lubricants 112
Periodic Maintenance 113
Service Your Machine at Specified Intervals 113
Check the Hour Meter Regularly 113
Use Correct Fuels and Lubricants 113
Prepare Machine for Maintenance 114
Open Access Doors for Service 114
Open Hood for Service 115
Maintenance and Repair Record Keeping System 116
OILSCAN Plus,® CoolScan Plus® and 3 Way Coolant Test Kit 117
Maintenance and Repair Record Keeping System 118
Maintenance—As Required 121
Clean Fuel Tank Inlet Screen 121
Drain Fuel Tank Sump 121
Clean Radiator Air Inlet Screen 122
Drain Water Separator 122
Clean Air Cleaner Dust Unloader Valve 123
Check Track Sag 123
Adjusting Track Sag 124
Windshield Washer Fluid Level 125
Maintenance—Every 10 Hours or Daily 126
Check Engine Oil Level 126
Check Recovery Tank Coolant Level 127
Check Hydraulic Oil Level 128
Maintenance—Every 50 Hours 130
Grease Working Tool Pivots 130
Maintenance—Every 250 Hours 132
Check Swing Gearbox Oil Level 132
Drain Hydraulic Tank Sump 132
Change Engine Oil and Replace Filter 133
Check Radiator Coolant Level 135
Battery Filling Precautions 136
Checking Electrolyte Level 137
Check Propel Gearbox Oil Level 138
Clean Dusty Primary Element 139
Inspect Element 140
Maintenance—Every 500 Hours 141
Grease Swing Bearing 141
Grease Swing Bearing Gear 142
Replace Final Fuel Filter 143
Replace Primary Fuel Filter (Water Separator) 143
Check Air Intake Hoses 144
Replace Hydraulic Oil Filter 145
Check Coolant In Radiator 147
Maintenance—Every 1000 Hours 148
Change Swing Gearbox Oil 148
Change Pilot Control Oil Filter 148
Change Air Cleaner Elements 149
Inspect Fan Belt 150
Replace Air Cleaner Dust Valve 150
Maintenance—Every 2000 Hours 151
Change Hydraulic Tank Oil 151
Drain Cooling System 154
Diesel Engine Coolant 156
Cooling System Fill and Deaeration 157
Change Propel Gearbox Oil 158
Clean the Engine Crankcase Ventilation Tube 159
Check and Adjust Engine Valve Lash (Clearance) 159
Firing Order 4—Cylinder Engine 161
Check Engine Speeds 162
Engine Control Motor and Sensor 162
Adjustment 162
Engine Speed Learning Procedure 164
Maintenance 165
Do Not Service Injection Nozzles 165
Do Not Adjust Injection Pump 165
Bleeding the Fuel System 166
Precautions for Alternator and Regulator 166
Service Batteries Carefully 167
Checking Electrolyte Specific Gravity 169
Using Battery Charger 170
Replacing Batteries 171
Removing Batteries 171
Welding on Machine 172
Adding 12—Volt Accessories 172
Replacing Fuses 173
Fuse (Blade Type) Color Codes 174
Checking Travel Alarm System 174
Replacing Bucket Teeth 175
Replacing Bucket Tooth Tip—Heavy Duty Bucket 176
Adjusting Bucket Linkage 176
Removing the Bucket 178
Do Not Service Control Valves, Cylinders, Pumps or Motors 178
Track Sag General Information 179
Hardware Torque Specifications 179
Check Track Shoe Torque 180
Unified Inch Bolt and Cap Screw Torque Values 181
Metric Bolt and Cap Screw Torque Values 182
Additional Metric Cap Screw Torque Values 183
Check Oil Lines And Fittings 185
Service Recommendations for O Ring Boss Fittings 186
Service Recommendations for Flat Face O Ring Seal Fittings 188
Service Recommendations for 37° Flare and 30° Cone Seat Connectors 189
Service Recommendations For Flared Connections—Straight or Tapered Threads 190
Service Recommendations For Inch Series Four Bolt Flange Fittings 191
Service Recommendations for Metric Series Four Bolt Flange Fitting 192
Operational Checkout 193
Operational Checkout 193
Operator Station Checks—Key Switch On, Engine Off 193
Operator Station Checks—Engine On 195
Hydraulic System Checks 198
Undercarriage Checks 204
Accessories Checks 206
Seat, Doors, Windows, Latches, and Locks Checks 208
Coolant Checks 213
Troubleshooting 216
Using Troubleshooting Charts 216
Engine 217
Electrical System 224
Hydraulic System 230
Storage 235
Prepare Machine for Storage 235
Monthly Storage Procedure 237
Machine Numbers 240
Record Product Identification Number (PIN) 240
Record Engine Serial Number 240
Record Propel Motor Serial Numbers 240
Record Swing Motor Serial Number 240
Record Hydraulic Pump Serial Number 241
Specifications 242
160 Excavator 242
Working Ranges 244
Engine Specifications 246
Drain and Refill Capacities 246
Lift Capacity—KG (LB) 247
Lift Capacity—KG (LB) 248
Lift Capacity—KG (LB) 249
Lift Capacity—KG (LB) 250
Crime Prevention Tips 251
Help Prevent Crime 251
Record Identification Numbers 251
Keep Proof of Ownership 251
Park Indoors Out of Sight 251
When Parking Outdoors 252
Reduce Vandalism 252
Report Thefts Immediately 253
Checklists 261
Maintenance and Repair Record Keeping System 261
John Deere Service Literature Available 265
Technical Information 265
John Deere Service Keeps You On The Job 267
AT YOUR SERVICE WHEN YOU NEED IT 267

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