New Holland LM5040 User manual

SERVICE MANUAL
Print No. 87471751E
LM5040 / LM5060 / LM5080
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LM5040
LM5060
LM5080
TELEHANDLERS
Repair Manual
Printout no. 87471751E (XII -- 2011)
THIS WARNING SYMBOL ACCOMPANIES IMPORTANT MESSAGES INVOLVING YOUR SAFETY.
Read the safety instructions carefully, and follow the precautions recommended in order to avoid
potential risks and safeguard your health and your safety.
You will find this symbol in the text of this Manual with the following key words:
WARNING - Cautions intended to avoid unsuitable repair operations with potential consequences
for the safety of the person performing the repair.
DANGER - Warnings specifically indicating potential dangers for the safety of the operator
or of other persons directly or indirectly involved.
IMPORTANT WARNINGS
All maintenance and repair operations listed in this Manual must be performed exclusively by the Service Network
of the Manufacturer, complying strictly with the indications herein and using the prescribed special tools where
indicated.
Any person performing service operations described in the manual and failing to abide strictly by the instructions
becomes solely responsible for any consequential damage that could occur.
The Manufacturer and all organizations in the distribution chain associated with the Manufacturer, including national,
regional and local dealers though not excluding others, decline all liability for damages attributable to abnormalities
in the operation or response of parts and/or components not approved by the Manufacturer, used in the servicing
and/or repair of a product built or marketed by the Manufacturer.
In any event, no warranty of any description is offered on or applicable to the product built or marketed by the
Manufacturer, in respect of damages resulting from abnormal operation or response of parts and/or components not
approved by the Manufacturer.
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AVOID ACCIDENTS
Most accidents and injuries that occur in and around factories, on farms, in the home or on the roads, are caused
by failure to follow some simple and fundamental rule regarding precautionary procedures and safety.
Accordingly, IN THE MAJORITY OF CASES, ACCIDENTS CAN BE AVOIDED: it is sufficient simply to foresee
the possible causes, and exercise the necessary caution and prudence.
Whatever the type of equipment, and however well designed and built, it is not possible to eliminate the risk of
accident completely without adversely affecting certain essential features instrumental in providing reasonable
levels of accessibility and ensuring smooth operation.
A careful and prudent operator is the best insurance against any accident.
The observance of just one elementary safety rule will of itself be sufficient in avoiding many serious accidents.
This rule is: never attempt any cleaning, lubrication or maintenance operation with the machine in motion.
WARNING
Before commencing any kind of maintenance, adjustment or repair work on machines equipped with
attachments operated hydraulically, mechanically or by wire ropes (such as front loaders, dozers,
scrapers, etc.) make certain the attachment is lowered and resting on the ground.
If the attachment needs to be in the raised position in order to gain access to one part of the machine
or another, it must be supported in the raised position by separate equipment, and not held with the
machine controls.
MODEL DESIGNATIONS
The models making up the range of telescopic handlers (Telehandlers) described in this manual are identified
in the text by reference to the maximum reach of the boom.
The vehicles listed below may not be available in all countries or on all markets. For up to date information on
all machines, consult your authorized dealer.
Model LM5040 LM5060 LM5080
no Stab. no Stab. no Stab.
Engine Turbocharged 88 kW Turbocharged 88 kW Turbocharged 88 kW
Maximum lifting height (m) 6.21 7.13 9.74
Maximum capacity (kg)
at 500 mm from fork rail
3500 4000 3300
Capacity at maximum height (kg) 3500 2500 2000
Reach at maximum height (m) 0.516 0.939 2.166
Maximum longitudinal reach (m) 3.189 4.191 7.053
Capacity at maximum reach (kg) 2000 1350 800
Weight (kg) 7310 7510 8400
Length (m) 6.157 6.322 6.452
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Workshop manual
LM5040 -- LM5060
LM5080
TELESCOPIC HANDLERS
87471751E -- 12 -- 2011
TABLE OF CONTENTS
SECTION 00 -- GENERAL
Description Page
..............................................................................
General instructions 1...........................................................................
Safety rules 3..................................................................................
Product identification 6...........................................................................
Environmental considerations 11..................................................................
Maintenance techniques 12.......................................................................
SECTION 10 -- ENGINE
Description Page
Main engine specifications 4......................................................................
General engine specifications 5...................................................................
General information on F4GE9484J*J600 engine 7..................................................
General information on F4GE9484J*J603 engine 12.................................................
Removal and installation of engine and radiator 17..................................................
Troubleshooting 29..............................................................................
Tightening torques 43............................................................................
Special tools 44.................................................................................
SECTION 21 -- TRANSMISSION
Description Page
Powershift transmission 2........................................................................
Transmission assembly 5........................................................................
Drop box assembly 7...........................................................................
Operation of gearbox 8..........................................................................
Transmission and hydraulic oil circuit diagrams 15...................................................
Operation of modulating valve 31..................................................................
Torque converter and oil cooler hydraulic circuit 34...................................................
Troubleshooting guide 35.........................................................................
Troubleshooting procedures 35...................................................................
Troubleshooting 37..............................................................................
Pressure tests on clutch and high pressure circuit 38.................................................
Pressure tests on torque converter and oil cooler hydraulic circuit 39...................................
Test points 40..................................................................................
Assembly instructions 42.........................................................................
Transmission overhaul 45........................................................................
APC122 electronic control with Powershift transmission (optional) 113..................................
Power Shuttle transmission (optional) 117..........................................................
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4GENERAL LIST OF CONTENTS
87471751E -- 12 -- 2011
Power shuttle transmission assembly 119..........................................................
Assembly instruction 123.........................................................................
Operation of gearbox 125........................................................................
Activated solenoids power flows and hydraulic circuit 127.............................................
Transmission overhaul 134.......................................................................
Brake pad substitution and adjustment of parking brake calliper
(Powershift and Powershuttle Transmission) 242....................................................
Special tools 253................................................................................
SECTION 25 -- FRONT AXLE
Description Page
Technical data 2................................................................................
Description 3...................................................................................
Operation 5....................................................................................
Troubleshooting 6...............................................................................
Wheel toe--in check 7............................................................................
Component overhaul 7...........................................................................
Front axle removal procedure 8...................................................................
Front axle overhaul 9............................................................................
Removing the steering cylinders 28................................................................
Dissasembly of 45% limited slip differential 53.......................................................
Installation and adjustment of axle drive pinion 65...................................................
Front drive shaft 74..............................................................................
SECTION 27 -- REAR AXLE
Description Page
Technical data 2................................................................................
Description 3...................................................................................
Operation diagram 5.............................................................................
Rear drive shaft 6...............................................................................
Component overhaul 9...........................................................................
Rear axle removal procedure 9...................................................................
Overhaul 10....................................................................................
Special tools 11.................................................................................
SECTION 33 -- BRAKING SYSTEM
Description Page
Service brakes 2................................................................................
Trailer brake 4..................................................................................
Parking brake 7................................................................................
Brake disc adjustment 10........................................................................
Troubleshooting 11..............................................................................
Brakes disassembly 12..........................................................................
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