New Holland LS160 Skid Steer Loader Manuals

Manuals and User Guides for New Holland LS160 Skid Steer Loader. We have 2 New Holland LS160 Skid Steer Loader manuals available for free PDF download: Manual, Workshop Manual

New Holland LS160 Manual

New Holland LS160 Manual (742 pages)

Brand: New Holland | Category: Mini Skid Steers | Size: 11.49 MB

Table of Contents

Contents
1
Model Codes
3
Safety Information
4
Avoid Heating Near Pressurized Fluid Lines
7
Handle Fluids Safety
7
Use Care Around High-Pressure Fluid Lines
7
Use Care in Handling and Servicing Batteries
7
Controls
8
Safe Service Procedures
8
Machine Model and Serial Number Location
9
Hardware Identification
10
Minimum Hardware Tightening Torques
10
Installation of Adjustable Fittings in Straight Thread O Ring Bosses
12
Standard Torque Data for Hydraulic Tubes and Fittings
12
Lubricants and Coolants
13
Pipe Thread Fitting Torque
13
Sealants
13
Properly Support a Raised Machine
14
Properly Support Boom on Boom Lock Pins
14
Raising Boom Without Hydraulic Oil Flow
14
Raising Boom Without Battery Voltage (12 Volts)
16
Reattaching Cylinders after Repair with Boom Resting on Boom Lock Pins
17
Major Unit Overhaul
18
Cab and Boom Tilt Procedure
19
Craning the Skid Steer
25
Special Tools Table
28
General Information
29
Basic Weight
31
Operating Capacity
31
Tire Sizes and Inflation
31
Specifications
32
Dimensions
35
Table of Contents
37
Engine
37
Crankshaft
39
Cylinder Block
39
Engine Component Descriptions
39
General Description
39
General Engine Information
39
- Camshaft
  40
- Cylinder Head
  40
- Lubricating System
  40
- Pistons and Connecting Rods
  40
Engine Model and Serial Number Location
41
Turbocharger Lubrication
41
Safety Precautions - Engine
42
General Engine Specifications
43
LS170 - Excessive Oil Consumption
51
Engine Specifications
53
Torque Specifications
57
Engine Components Electrical Diagram
58
Engine Removal
59
Engine Disassembly Sequence
64
- Engine Component Maintenance
  72
  - Rocker Assembly
    72
  - Cylinder Head Assembly
    73
  - Valve Guide and Valve Stem
    74
  - Thickness of Valve Head
    74
  - Valve to Valve Guide Clearance
    74
Valve Seat
75
Piston and Piston Rings
78
- Connecting Rod
  81
Bearing Holder
83
- Crankshaft Bearing (Bushing)
  84
- Thrust Clearance
  84
- Crankshaft Bushing Replacement
  85
- Crankshaft Journal (Bushing)
  85
- Crankshaft Maintenance
  86
Camshaft Assembly
88
Flywheel and Ring Gear
88
Camshaft Gear and Bearing Assembly
89
- Timing Gear
  89
Oil Pump
90
Oil Filter
91
Thermostat Removal
91
Water Pump Assembly and Thermostat Housing
91
Governor
93
- Governor Operation
  95
Engine Reassembly Sequence
97
- Crankshaft and Bearing Holder Assembly
  98
- Rear Oil Seal
  98
- Backplate/Flywheel Housing
  99
- Piston and Connecting Rod
  99
- Idler Gear and Oil Pump Assembly
  100
- Oil Intake and Oil Strainer
  100
- Oil Sump
  100
- Dipstick and Tube
  100
- Front Plate
  100
- Crankshaft Pulley
  102
- Injection Pump Installation
  102
- Timing Gear Case Installation
  102
- Adjusting the Fuel Injection Timing
  103
- Spill Timing Procedure
  104
  - Oil Pipe
    108
  - Cap, Push Rod, and Rocker Arm Assembly
    109
  - Valve Clearance Adjustment
    109
  - Cylinder Head Cover
    109
  - Connect the Thermostat Housing and Hoses
    110
  - Nozzle/Holder Assembly
    110
  - Return Pipe and Injection Pipe
    110
  - Alternator Assembly
    110
Reinstallation of Engine into Skid Steer Frame
111
- How to Operate the Engine after Overhaul
  113
- Cooling System Operation
  114
- Water Pump Assembly and Thermostat Housing
  115
- Radiator
  116
- Fuel System
  118
- Fuel Specifications
  118
- Diesel Fuel Storage
  118
- Fuel System Components
  119
- Filling the Tank
  119
- Fuel Guage
  120
- Cold Start Aid
  121
- Fuel Filter System
  121
- Priming the Fuel System
  122
- Fuel System Testing
  123
  - Fuel Flow
    125
  - Fuel Tank
    126
- Fuel System Components
  126
  - Fuel Lever Sender
    127
  - Fuel Tank Pickup Tube
    127
  - Electric Fuel Pump
    127
  - Governor Description
    128
  - Nozzle and Holder
    130
  - Air Cleaner Description
    132
Fuel Injection Timing
132
- Turbocharger - LS170 N844T Engine
  137
  - Turbocharger Description
    137
  - Turbocharger Troubleshooting
    137
Turbocharger Removal
139
- Turbocharger Disassembly
  141
- Turbocharger Reassembly
  146
- Checking the Rotor for Movement
  149
- Turbocharger Lubrication System
  150
- Glow Plug
  152
- Miscellaneous Engine Electrical
  152
  - Fuel Shut-Off Solenoid
    153
  - Oil Pressure Switch
    153
  - Maximum Circuit Resistance
    154
- Special Tools
  155
  - Engine Overhaul
    156
  - Engine Removal from Skid Steer
    156
  - Labor Guide (Engine)
    156
  - Oil Consumption Rectification
    156
  - Rear Drive Axle (Gearboxes)
    161
  - Gearboxes Specifications
    164
  - Final Drive System
    165
  - Gearboxes Troubleshooting
    165
  - Gearboxes Testing
    167
  - Gearboxes Removal and Inspection
    168
  - Gearbox Disassembly
    172
  - Gearbox and Related Parts
    173
  - Gearbox Reassembly
    174
  - Gearbox Reinstallation
    176
  - Reassemble the Parking Brake
    177
  - Gearboxes - Labor Guide
    179
  - Hydrostatic Transmission
    181
  - Neutralizer, Pumps, Motors
    181
- General Information
  183
- Operation
  183
- Hydrostatic Drive System Testing
  188
- Hydrostatic System Oil Flow
  191
  - Hydrostatic Pump and Motor Charge Pressure Oil Flow
    192
  - Hydrostatic Pump and Motor Case Drain Flow
    193
- Hydrostatic Charge System Pressure Test
  194
- Hydrostatic Pump Case Drain Test
  195
- Pump Case Drain (Oil Flow) Test Procedure
  197
- Hydrostatic Pump High Pressure Test
  198
- Hydrostatic Pump Efficiency Test
  200
- Hydrostatic Motor Case Drain Test
  202
- Hydrostatic Motor Efficiency Test
  203
- Hydraulic, Hydrostatic System Air Ingress Test
  205
  - Hydrostatic Pumps Removal
    207
  - Hydrostatic Pumps Disassembly
    211
  - Pump Housings Inspection
    216
  - Pump Shafts Inspection
    217
  - Cam Plates Inspection
    218
  - Piston and Shoe Assemblies Inspection
    218
  - Rotating Group Inspection
    218
  - Piston Block Inspection
    219
  - Replaceable Bearing Plate Inspection
    219
  - Back Plate Inspection
    220
  - Hydrostatic Pumps Reassembly
    221
- Hydraulic System Pump Installation (Without High Flow)
  227
- Hydraulic System Pump/High Flow Pump Installation
  229
  - The High Flow Pump Components
    230
  - The Hydraulic System Pump Components
    230
- Hydrostatic Motor Disassembly
  238
- Hydrostatic Motor Removal
  238
- Hydraulic System Cleaning Procedure
  266
- Start-Up Procedure after Rebuild (after Pump or Motor Replacement)
  269
- Charge Check Valve Removal and Replacement
  271
- Hydrostatic System Controls
  272
- Steering System
  272
- Control Linkage Removal
  274
- Neutralizer Assembly
  274
  - Neutralizer Parts Inspection
    274
  - Neutralizer Removal
    274
  - Control Linkage Parts Inspection
    275
- Left Control Handle with no Boom Hand Control
  278
- Left Control Handle with Boom Hand Control
  281
- Right Control Handle with Auxiliary or Bucket Control
  287
- Bucket Control Handle
  289
- Drive Control Adjustment Procedure
  296
- Neutral Adjustment
  297
  - Control Lever Parallel Adjustment
    298
  - Control Lever Stop Adjustment
    298
  - Hydrostatic System and Steering System Labor Guide
    299
  - Brakes and Controls
    300
  - Parking Brake
    300
- General Information
  301
  - Brakes and Controls Specifications
    303
  - Brakes and Controls Troubleshooting
    304
  - Parking Brake Testing
    306
  - Parking Brake Operation
    307
  - Parking Brake Removal and Inspection
    308
  - Brake Control Linkage Removal
    309
  - Parking Brake Control Linkage and Related Parts
    310
  - Inspection of Control Linkage Parts
    311
  - Installation of Brake Control Linkage
    312
  - Spring Reassembly
    312
  - Brake Caliper and Disc Removal
    313
  - Brake Caliper and Disc Parts Inspection
    314
  - Brake Caliper and Disc Reassembly
    316
  - Parking Brake and Linkage Adjustment
    319
  - Spring Adjustment
    319
  - Caliper Adjustment
    320
  - Brakes and Controls Labor Guide
    321
  - Hydraulic System
    322
  - Valves, Gear Pump, Cylinders, and Pedal Controls
    322
- General Information
  324
- Hydraulic System Compatibility
  325
- Boom and Cylinder Pivot Pin Location and Machine Usage
  327
- Boom Cylinder Pivot Pins
  327
- Control Valve Power Beyond
  328
  - Hydraulic System Specifications
    329
  - Hydraulic System Troubleshooting
    333
- Auxiliary Boom Hydraulics Troubleshooting
  337
- Adjustments Control Handle
  338
- Hydraulic System Testing
  339
- Hydraulic System Oil Flow
  345
- Control Valve - Bucket Spool Shifted
  346
- Control Valve - Boom Spool Shifted
  347
- Auxiliary Control Operation
  348
- Control Valve - Auxiliary Spool Shifted
  348
- Main System Pressure Tests
  349
- Checking Main System Pressure at Boom Cylinders
  351
- Checking Main System Pressure at Bucket Cylinders
  352
- Check Main System Pressure at Auxiliary Boom Hydraulic Quick Couplers
  353
- Boom Circuit Relief Valve Test
  354
- Gear Pump Flow Efficiency Test
  356
- Boom and Bucket Spool Lock Solenoid Test
  360
- Hydraulic, Hydrostatic System Air Ingress Test
  362
- Control Valve Specifications
  364
- Control Valve Removal
  365
  - Control Valve Disassembly and Inspection
    366
  - Main System Relief Valve
    366
  - Lift Check Valves
    367
  - Spool Locks (Boom and Bucket)
    367
  - Spools, Caps, and O Rings
    368
  - Control Valve Parts Inspection
    370
  - Control Valve Reassembly
    371
  - Control Valve Reinstallation
    374
- Hydraulic Pump Specifications
  375
  - Hydraulic Pump Removal
    376
  - Hydraulic System Pump and High Flow Pump Removal/Disassembly
    377
- Hydraulic System Pump Removal/Disassembly (Without High Flow)
  377
- High Flow Pump Parts Inspection
  379
- Hydraulic System Pump Parts Inspection
  380
- Hydraulic System Pump Reassembly/Installation (Without High Flow)
  382
- Hydraulic System Pump and High Flow Pump Reassembly/Installation
  385
- New Hydraulic System Pump Installation (Without High Flow)
  391
- New Hydraulic System Pump/High Flow Pump Installation
  393
- Gear Pump Start-Up Procedure
  399
- Boom Cylinders Specifications
  400
- Cylinders, Boom and Bucket
  400
- Boom Cylinder Disassembly
  402
- Boom Cylinder Removal
  402
  - Boom Cylinder Disassembly
    404
  - Boom Cylinder Parts Inspection
    405
  - Boom Cylinder Reassembly
    406
  - Boom Cylinder Reinstallation
    408
- Bucket Cylinder Disassembly
  408
- Bucket Cylinder Removal
  408
- Hydraulic Cooling, Filter, Reservoir System
  424
- Filter Base Removal
  425
- Filter System
  425
- Filter Base Reassembly
  426
- Oil Cooler Removal
  426
  - Filter/Breather Cap Cleaning
    427
  - Oil Cooler Reassembly
    427
- Oil Reservoir
  427
- Oil Reservoir Removal
  428
  - Oil Reservoir Reinstallation
    429
  - Adapting Attachments with NH-Supplied Ball/Pin Couplers
    430
  - Hydraulic System Labor Guide
    431
  - Rear Counterweights
    432
  - Towing Hooks and Ballasting
    432
  - Frames
    434
  - Lower Main, ROPS
    434
  - ROPS Frame Removal
    435
  - ROPS Frame Reinstallation
    441
  - Frames Labor Guide
    444
  - Axles and Wheels
    446
  - Axles Specifications
    449
  - Axles Troubleshooting
    450
  - Final Drive System Troubles
    450
  - Final Drive Testing
    452
  - Axle Housing Assembly Removal
    453
  - Axle Housing Assembly Disassembly
    454
  - Axle Housing Assembly Parts Inspection
    456
  - Axle Housing Assembly Reassembly
    457
  - Axle Housing Assembly Reinstallation
    459
  - Drive Chain and Sprocket Removal
    460
  - Brake Disc Removal
    462
  - Front Drive Sprocket and Chain
    463
  - Proper Tire Inflation
    467
  - Tire Options
    467
  - Tire Pressures
    467
  - Tires/Wheels
    467
  - Tire and Track Installation
    468
  - Track Installation on Loader
    468
  - Axles Labor Guide
    469
  - Cab Climate Control
    470
  - Heater/Defroster
    470
  - Heater/Defroster (CAB)
    471
  - Relay and Fuse Block
    471
  - Switch and Control Panel
    471
  - Switch Wiring
    471
  - Heater Wiring Diagram
    472
  - Louver Replacement
    472
  - Heater Core Replacement
    473
  - Heater Core, Shutoff Valve and Fan Assembly Access
    473
  - Heater Shutoff Valve Replacement
    473
  - Heater Fan Assembly Replacement
    474
  - Heater Hose to Engine Connections
    474
  - Filter (Heater)
    475
  - Heater Core Connections
    475
  - Bleeding Air from Heater
    476
  - Heater/Defroster Labor Guide
    477
  - Advanced Warning System, Circuits, Alternator, and Starter
    478
  - Electrical System
    478
- General Electrical Information
  483
  - Electrical System - Definition of Terms
    484
  - Wire Abbreviations to Indicate Wire Color
    485
- Adapting Attachments Requiring 12V Electrical Power
  486
  - Engine Fuse Panel
    487
  - Electrical System Specifications
    489
- Electrical Diagram
  492
- Advanced Warning System
  496
- Electronic Instrument Cluster (EIC)
  496
- (EIC) Electronic Instrument Cluster Front Panel
  497
- EIC Functional Groups
  498
- Continuously Monitored Elements
  502
- Automatic Shutdown
  503
- Engine Preheat
  503
- Operating Mode
  504
- Broken Alternator/Water Pump Belt Warning
  506
- EIC Interlocks
  507
- Fuel Level
  507
- EIC Lock Mode
  508
- EIC Engine Preheat
  509
- Electronic Instrument Cluster (EIC) Troubleshooting
  510
- Advanced Warning System (AWS)
  513
- EIC Board Self Test
  514
- Diagnostic and Setup Modes
  515
- EIC Diagnostics and Setup Items
  516
- Arrow, Open Book, and Audible Alarm Test
  517
- Diagnostic Mode EIC Circuit Tests
  517
  - Hydraulic Oil Filter Restriction Switch
    517
  - Air Cleaner Switch
    518
  - Engine Oil Pressure Sensor
    518
  - Hydrostatic Charge Pressure Switch
    518
  - Coolant Temperature Sensor
    519
  - Fuel Gauge
    519
  - Transmission/Hydraulic Oil Temperature Sensor
    519
  - Seat Belt Switch and Circuit
    520
  - Seat Switch and Circuit
    520
  - Service/Run Switch
    520
- EIC Setup Mode
  521
- Blown Fuse Symptom and Testing
  529
- Electronic Battery Fuse
  529
- Electronic Instrument Cluster (EIC) and Starter Circuits
  529
  - Key Main Fuse
    529
  - Parking Brake Light Testing
    531
  - Seat Belt Light Testing
    531
- Testing Other EIC Functions
  531
- Boom and Bucket Spool Locks Testing
  532
- EIC Board Reading Accuracy
  534
- EIC Board Claims Warranty
  536
  - Handling the EIC Board
    536
  - EIC (Electronic Instrument Cluster)
    537
  - EIC Board Ground Circuit
    537
- Electrical Circuits
  537
  - Main Power Circuit to EIC Board
    537
  - Battery Voltage
    538
- Seat Switch Circuit to EIC Board
  538
- Seat Belt Switch Circuit to EIC Board
  539
- Boom/Bucket Control Valve Spool Lock Solenoids
  585
- Boom/Bucket Control Valve Spool Lock Solenoids Installation
  585
- Boom/Bucket Control Valve Spool Lock Solenoids Removal
  585
- Main Wire Harness Removal
  587
- Main Wire Harness Installation
  592
- Road/Work Lights
  596
  - Road/Work Light Switch Wiring
    597
  - Road/Work Light Wiring Diagram
    597
  - Rear Work and Taillight
    599
- Alternator (40 Amp Version)
  600
- Alternator Charging Circuit
  600
- Alternator Service Specifications
  602
- Alternator System Testing and Troubleshooting
  603
- Alternator Removal
  607
  - Alternator Disassembly
    608
  - Alternator Component Test
    610
  - Stator Test
    611
  - Diode Trio Test
    612
  - Negative Heat Sink Test
    612
  - Positive Heat Sink Test
    612
  - Rectifier Assembly
    612
  - Brush and Brush Spring Check
    613
  - Installing Rotor
    613
  - Bench Check
    614
- Alternator Reinstallation
  615
- Starter Motor Service Specifications
  616
- Starter Motor Troubleshooting
  616
- Starter Motor Disassembly
  618
- Starter Motor Removal
  618
  - Starter Motor Description
    619
  - Starter Construction
    620
  - Starter Operation
    621
  - Drive Spring Operation
    622
  - Electric Solenoid Operation
    622
  - Starter Disassembly
    623
  - Starter Inspection and Repair
    627
  - Field Coil
    628
  - Brushes
    629
  - Overrunning Clutch
    630
  - Reduction Gears
    630
  - Electric Solenoid
    631
  - Pull-In Test
    631
  - Starter Reassembly
    632
  - Starter Performance Test
    635
- Starter Reinstallation
  636
  - Electrical System Labor Guide
    637
  - Buckets
    638
  - Front Loader (Boom and Mounting Plate)
    638
  - Bucket Capacity Cubic Feet
    639
  - Bucket Types
    639
- General Information
  639
- Boom Assembly Components
  640
- Boom Lock Pins and Linkage
  640
- Attachment Mounting Plate
  641
- Boom and Cylinder Pivot Pin Location and Machine Usage
  641
- Boom/Cylinder Pivot Pins Size
  642
- Pallet Fork
  643
- Tine Installation
  644
- Utility Fork
  644
- Buckets - Cutting Edge (Replacement)
  645
- Bucket Latch Plate Installation Procedure
  646
- Dirt Tooth Kit Installation
  648
  - Tooth Location and Installation
    649
  - Tooth Point Replacement
    649
  - Bucket Tooth Spacing
    650
- Boom Lock Pin/Linkage Removal
  652
  - Boom Lock Pin/Linkage Reinstallation
    653
  - Boom, Upper and Lower Link Removal
    655
  - Lower Link Removal
    656
  - Upper Link Removal
    657
  - Main Boom Removal
    658
- Front Boom Mounting Plate Pivot Hub Replacement
  661
- Boom, Upper and Lower Link Reinstallation
  662
- Attachment Mounting Plate
  666
- Latch Lever and Pin Removal/Repair
  667
- Repair/Rebuild Mounting Plate
  667
  - Latch Handle/Spring Assemblies
    669
  - Latch Pins
    669
  - Mounting Plate Assembly
    669
  - Pivot Bushings Replacement
    669
  - Latch Lever and Spring Repair/Rebuild
    670
  - Attachment Plate Over-Center Latch Pins Wear/Bend
    673
- Checking Procedure for Buckets and Attachments
  673
- Checking Procedure
  675
- Checking the Attachment
  675
- Checking the Loader Faceplate
  676
- Labor Guide
  678
  - Accessories
    680
  - Dealer Installed Options
    680
- Adapting Attachments Requiring 12V Electrical Power
  681
- General Information
  681
- Hydraulic System Compatibility
  684
- Arm Pads for Cab Side Panels
  686
- Armrests for Deluxe Seat
  686
- Forearm Rests
  687
- Back-Up Alarm
  688
- Block Heater (Engine)
  689
- Electric Power Supply (12 Volt, 15 Amp)
  690
- Electric Power Wiring
  690
- Aspirator Precleaner Muffler
  691
- Catalytic Muffler
  691
- Exhaust (Engine)
  691
- Aspirator or Spark Arrester Muffler Cleaning
  692
- High Flow Hydraulics
  693
- Attachment Case Drain
  694
- High Flow Hydraulics Troubleshooting
  695
- High Flow Hydraulics Component Replacement
  697
- Horn
  704
- Shoulder Belt (Seat)
  705
- Slow-Moving Vehicle (SMV) Sign Kit
  706
- Warning Light (Rotary Beacon)
  707
  - Beacon Switch Wiring
    708
  - Beacon Wiring Diagram
    708
  - Beacon Bulb Replacement
    709
- Warning Lights (Four-Way Flashers/Turn Signal/Horn)
  710
  - Warning Light Switch Wiring
    711
  - Warning Light (Four-Way) Wiring Diagram
    712
  - Rear Light
    713
  - Warning Light Bulb Replacement
    713
  - Accessories Labor Guide
    714
  - Cab and Seat
    716
  - Platform, Cab, Bodywork, and Decals
    716
- General Information
  717
- Seat and Seat Pan Support
  717
- Cab Inner Shell
  718
- Seat Pan Support Removal
  718
- Seat Removal
  718
- Seat, Switch and Pan Reinstallation
  720
- Safety Decals
  737
- Labor Guide
  741

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New Holland LS160 Workshop Manual

New Holland LS160 Workshop Manual (41 pages)

Brand: New Holland | Category: Front End Loaders | Size: 0.8 MB

Table of Contents

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