New Holland CE LV80 Service Manual
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SERVICE MANUAL
NEW HOLLAND
CONSTRUCTION
LV80
TRACTOR
LOADER
El
I\EW HOLLAI\D
LV80
TRACTOR LOADER
SERVICE MANUAL
SECTION 2 - 439 DIESEL ENGINE
Part Number: 86641267
SECTION 2 - 439 DIESEL ENGINE
SECTION 3 - FUEL SYSTEM
SECTION 4 - ELECTRICAL SYSTEM
SECTION 5 - STEERING
SECTION 6 - POWER TRAIN
SECTION 7 - BRAKES
SECTION 8 - HYDRAULIC SYSTEM
SECTION 9 - MOUNTED EQUIPMENT
Issued February, 2002 • 86641267 Bur
Copyright© 2002 New Holland Construction. All Rights Reserved.
SECTION 2
439 DIESEL ENGINE
TABLE OF CONTENTS
GENERAL INFORMATION
Proprietary Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Company Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Model Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Owner Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
To The Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Improvements ...................................................................... VII
Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
Machine Safety ..................................................................... VIII
Safety Rules ....................................................................... IX
California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
CHAPTER 1
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
Table of Contents ..................................................................... 1-1
Special Tools ........................................................................ 1-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Radiator Removal .................................................................... 1-3
Engine Removal ...................................................................... 1-6
Installing the Front Engine Support ...................................................... 1-22
CHAPTER2
STALL TESTS
Table of Contents ..................................................................... 2-1
Specifications ........................................................................ 2-3
General Information ................................................................... 2-3
Preparing the Machine for the Stall Test ................................................... 2-3
Procedure to Heat Torque Converter and Hydraulic Oil ....................................... 2-4
Stall Test Procedure .................................................................. 2-4
Check Sheet - NA Engine .............................................................. 2-5
Check Sheet - Turbo Engine ............................................................ 2-6
CHAPTER3
SPECIFICATIONS
Table of Contents ..................................................................... 3-1
Run-in Instructions .................................................................... 3-3
Identification Marks ................................................................... 3-5
Engine Specification Details ............................................................ 3-6
Special Torques ..................................................................... 3-13
CHAPTER4
AFTERCOOLER
Table of Contents ..................................................................... 4-1
Specifications ........................................................................ 4-3
Special Torque ....................................................................... 4-3
Special Tools ........................................................................ 4-3
Removing the Aftercooler .............................................................. 4-4
Inspecting the Aftercooler .............................................................. 4-8
Installing the Aftercooler ............................................................... 4-9
86641267 Feb 02 Bur
CHAPTERS
CYLINDER HEAD AND VALVE TRAIN
Table of Contents .................................................................... 5-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Identification Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Special Tools ....................................................................... 5-6
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 7
Cylinder Head Disassembly ........................................................... 5-15
Checking and Resurfacing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Valve Guide Replacement ............................................................ 5-18
Inspection of the Valves and Valve Seats ................................................. 5-21
Valve Seat Installation ............................................................... 5-25
Refacing Intake and Exhaust Valves and Valve Seats ....................................... 5-26
Diagnosis of Different Dye Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Rocker Arm Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Locating Top Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Adjusting the Rocker Arm to Valve Clearance ............................................. 5-50
CHAPTERS
II
CYLINDER BLOCK
Table of Contents .................................................................... 6-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Special Tools ....................................................................... 6-7
Front Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Front Oil Seal and Wear Sleeve Installation ............................................... 6-16
Rear Oil Seal and Wear Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Cylinder Wall Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Reconditioning the Engine Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Piston and Connecting Rod Disassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Piston and Connecting Rod Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Crankshaft ......................................................................... 6-47
Crankshaft and Main Bearings ......................................................... 6-52
Crankshaft Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Crankshaft Reconditioning ............................................................ 6-61
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Flywheel Housing Bore Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Flywheel Housing Face Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Tachometer Drive, If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
Expansion Plug Removal and Installation ................................................. 6-95
Crankcase Pressure Check (Blow By) .................................................. 6-104
CHAPTER7
LUBRICATION SYSTEM
Table of Contents ..................................................................... 7-1
Specifications ........................................................................ 7-3
Special Torques ...................................................................... 7-4
Lube Flow Chart ...................................................................... 7-4
Oil Pump ........................................................................... 7-5
Oil Pressure Relief Valve Service ....................................................... 7-11
Oil Filter Housing and Oil Cooler ........................................................ 7-13
Oil Pan and Oil Inlet Tube ............................................................. 7-15
CHAPTER 8
BALANCER
Table of Contents ..................................................................... 8-1
Specifications ........................................................................ 8-3
Special Torques ...................................................................... 8-3
Three Gear Balancer .................................................................. 8-4
CHAPTER 9
COOLING SYSTEM
Table of Contents ..................................................................... 9-1
Specifications ........................................................................ 9-3
Safety Rules ......................................................................... 9-3
How to Clean the Cooling System ........................................................ 9-3
Water Pump ......................................................................... 9-4
Thermostat .......................................................................... 9-6
Coolant Inlet Manifold ................................................................ 9-10
Fan Pulley Bracket ................................................................... 9-12
Belt Tensioner ...................................................................... 9-15
Thermostat Service .................................................................. 9-18
CHAPTER10
TURBOCHARGER
Table of Contents .................................................................... 10-1
Specifications ....................................................................... 10-3
Special Torques ..................................................................... 10-3
Special Tools ....................................................................... 10-3
Troubleshooting Guide for the Turbocharger ............................................... 10-4
Servicing the Turbocharger ............................................................ 10-5
CHAPTER 11
HX25W AND HX30W TURBOCHARGER
Table of Contents .................................................................... 11-1
Specifications ....................................................................... 11-3
Special Torques ..................................................................... 11-3
Troubleshooting Guide for the Turbocharger ............................................... 11-4
Turbocharger Service ................................................................ 11-5
Cleaning and Inspection ............................................................. 11-12
Turbocharger Wastegate Calibration .................................................... 11-26
86641267 Feb 02 Bur
NOTE: New Holland reserves the right to make improvements in design or changes in specifications
at any time without incurring any obligation to install them on units previously sold.
Ill
NOTES
IV
GENERAL INFORMATION - LV80 TRACTOR LOADER
GENERAL INFORMATION
PROPRIETARY NOTICE
The contents of this manual are proprietary data of New Holland Construction. Reproduction or use of any part for
other than the operation and maintenance of New Holland Construction equipment is permissible only if expressly
authorized in writing by New Holland Construction.
Additional copies may be obtained from your New Holland Construction Dealer. Address requests for copies to
your Dealer and refer to the publication number appearing on the bottom of the manual cover.
COMPANY POLICY
Company policy, which is one of continuous improvement, reserves the right to change prices and to make
changes in design and specification at any time without notice and without obligation to modify units previously
built.
All data given in this book is subject to production variations. Dimensions and weights are approximate only and
the illustrations do not necessarily show machines in standard condition. For exact information about any particular
machine please consult your New Holland Construction Dealer.
PARTS AND ACCESSORIES
Genuine parts and accessories have been specifically designed for these machines.
We would like to point out that "non-genuine" parts and accessories have NOT been examined and released by the
Company. The installation and or use of such products could have negative effects upon the design characteristics
of your machine and thereby affect its safety. The company is not liable for any damage caused by the use of
"non-genuine" parts and accessories.
MODEL CODES
The range of machines listed may not be available in all countries or markets therefore, for the latest information
consult your local New Holland Construction Dealer.
V
GENERAL INFORMATION - LV80 TRACTOR LOADER
OWNER ASSISTANCE
We at New Holland and your New Holland dealer want you to be completely satisfied with your investment.
Normally any problems with your equipment will be handled by your dealer's Service Department; However,
misunderstandings can occur. If your problem has not been handled to your satisfaction, we suggest the following.
1. Contact the owner or General Manager of the dealership, explain the problem, and request assistance. When
additional assistance is needed, your dealer has direct access to our office.
2. If you cannot obtain satisfaction by doing this, contact the New Holland Construction office and provide them
with:
• Your Name, Address, and Telephone number
• Machine Model and Serial Number
• Dealership Name and Address
• Machine purchase date and amount of use
• Nature of problem
NEW HOLLAND CONSTRUCTION
245 E North Ave
Carol Stream, IL 60188
Phone Number: 630-260-4000
When contacting New Holland, be aware that your problem will likely be resolved in the dealership using the
dealer's facilities, equipment, and personnel. So it is important that your initial contact be with the dealer.
SPARE PARTS
To maintain operating efficiency, use NEW HOLLAND original spare parts.
When ordering parts, give the following information:
• Machine Model
• Machine and Engine Serial Numbers
• Part Number from the Parts Catalog
VI
GENERAL INFORMATION - LV80 TRACTOR LOADER
TO THE OWNER
The warranty coverage that is extended to your machine is explained in the Warranty and Limitation of Liability
form. Your dealer will provide you with a copy of the warranty and retain a copy which you have signed. After you
read the warranty, ask your dealer to explain any points that you may not understand.
The machine was designed to power and propel itself. It is intended to move material in the normal and customary
applications.
Do not modify or alter or permit anyone else to modify or alter this machine or any of its components mechanical
function with first consulting an authorized New Holland Construction dealer. If you have any questions regarding
machine modifications, contact New Holland Construction, 245 E. North Ave., Carol Stream, IL 60188.
Your safety and the safety of those around you depend upon the care and good judgment you use while operating
this equipment. Read the safety precautions carefully.
After you have operated the machine for 50 hours, take your machine and this manual to your selling dealer. He
will perform the factory recommended 50-hour service. You will be responsible for the cost of lubricants, fluids,
filters and other items replaced as part of normal maintenance. Prior to taking the machine to your selling dealer
for service, it is recommended that you contact them to determine any other charges for which you may be
responsible.
All data given in this book is subject to product variations. Dimensions and weights are approximate only and the
illustrations do not necessarily show machines in standard condition. For exact information about any particular
machine, please consult your New Holland Construction dealer.
A
CAUTION: THIS SYMBOL IS USED THROUGHOUT THIS BOOK WHENEVER PERSONAL
SAFETY IS INVOLVED. TAKE TIME TO READ AND FOLLOW THE INSTRUCTIONS. BE
CAREFUL!
CAUTION: PICTURES IN THIS MANUAL MAY SHOW PROTECTIVE SHIELDING OPEN OR
REMOVED TO BETTER ILLUSTRATE A PARTICULAR FEATURE OR ADJUSTMENT.
BE CERTAIN, HOWEVER, TO CLOSE OR REPLACE ALL SHIELDING BEFORE OPERATING THE
MACHINE.
IMPROVEMENTS
New Holland Construction is continually striving to improve its products. We reserve the right to make
improvements or changes when it becomes practical and possible to do so, without incurring any obligation to
make changes or additions to the equipment sold previously.
VII
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The New Holland CE LV80 Tractors Repair Manual is a comprehensive guide suitable for professional mechanics and tractor enthusiasts alike. It contains detailed step-by-step instructions for the removal, installation, disassembly, and assembly of various components of the LV80 tractor. Additionally, the manual includes an electrical wiring diagram and a hydraulic schematic for easy troubleshooting of electrical or hydraulic issues.
Furthermore, the manual provides valuable diagnostic information, specifications, and torque values, ensuring accurate and efficient repairs. The included models in this manual are:
- New Holland CE LV80 Tractor
