Part of the John Deere Repair Manuals.
Wrenching on a John Deere 160DLC? This 406-page repair manual PDF (OEM TM10091) walks you through every major system on the excavator: tracks, travel gearbox, engine removal, hydraulics, swing drive, and operator's station. Inside you get page after page of torque tables for metric and unified hardware, exploded-view drawings of track rollers, idlers, and sprockets, and step-by-step teardown and rebuild procedures from final drive to boom. There is even a dealer-tools section with drawings for the track recoil spring tool and travel gearbox nut wrench, so you can fabricate them in your own shop. Torque the roller-to-frame cap screws to 460 N-m (340 lb-ft) and fill the cooling system with 19.0 L (5.0 gal). Downtime on an excavator bleeds money by the hour. Bookmarked front to back; type a spec, jump to the page, fix the machine.
What's Inside This Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 9-44 | Safety, Torque Values, Metric Bolt and Cap Screw, Unified Inch Bolt and Cap Screw, Flare and Cone Seat Connectors, Four Bolt Flange Fittings |
| Tracks | 45-78 | Track System, Track Roller, Track Carrier Roller, Track Shoe, Track Chain, Sprocket, Front Idler |
| Axles, Differentials and Suspension Systems | 79-112 | Axle Shaft, Bearings, And Reduction Gears, Hydraulic System, Travel Gearbox, Travel Motor, Park Brake, Counterbalance Valve, Crossover Relief Valve, Make-Up Check Valve |
| Engine | 113-124 | Removal and Installation, Engine Removal, Engine Installation |
| Engine Auxiliary System | 125-156 | Cooling System, Intake System, External Fuel Supply System, Radiator, Hydraulic Oil Cooler, Intercooler, Fuel Cooler, Air Cleaner, Fuel Tank |
| Dampener Drive (Flex Coupling) | 157-160 | Elements, Dampener Drive, Flex Coupling |
| Frame or Supporting Structure | 161-168 | Frame Installation, Chassis Weights, Welding, Structural Repair, Counterweight |
| Operator's Station | 169-212 | Removal and Installation, Operator Enclosure, Seat and Seat Belt, Heating and Air Conditioning |
| Excavator | 213-338 | Buckets, Frames, Hydraulic System |
| Swing or Pivoting System | 339-380 | Mechanical Drive Elements, Hydraulic System |
| Dealer Fabricated Tools | 381-406 | Lift Bracket, Track Recoil Spring Tool, Travel Gearbox Nut Wrench, Torque Adapter, Holding Bar, Pump Support |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Straight fitting or special nut torque (7/16-20 UNF) | 12 N•m (9 lb-ft) | p. 27 |
| Straight fitting or special nut torque (1/2-20 UNF) | 16 N•m (12 lb-ft) | p. 27 |
| Roller-to-Frame Cap Screw Torque | 460 N•m (340 lb-ft) | p. 48 |
| Track Roller Guard Cap Screw Torque | 460 N•m (340 lb-ft) | p. 48 |
| Cooling System—Capacity | 19.0 L (5.0 gal) | p. 127 |
| Hydraulic Oil Cooler-to-Frame Lower Cap Screw—Torque | 55 N•m (41 lb-ft) | p. 132 |
| Fuel Tank Mounting Cap Screws—Torque | 270 N•m (199 lb-ft) | p. 152 |
| Toolbox—Weight | 33 kg (72 lb) | p. 151 |
| Hydraulic Oil Tank Capacity | 120 L | p. 233 |
| Machine Weight (Approximate) | 18 151 kg | p. 47 |
| Track Roller Weight | 35 kg | p. 48 |
| Lower Track Roller Capacity | 260 mL | p. 50 |
