NEW HOLLand LM1340-LM1745 LOADALL Service Manual

LM1340 TURBO LM1343 TURBO LM1345 TURBO LM1443 TURBO LM1445 TURBO LM1745 TURBO TELEHANDLERS Workshop Manual Print N. 87682524 (V -- 2007) THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY. Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to safeguard your health and your safety. You will find this symbol in the text of this Manual referred to the following key words: WARNING -- Cautions directed to avoid improper repair interventions involving potential consequences for the operator’s safety. DANGER -- These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved. IMPORTANT NOTICE All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service Organization of the Manufacturer , observing strictly the instructions explained using, whenever necessary, the recommended specific tools. Whoever performs the operations reported without following exactly the precautions is responsible on his own, for the damages that may result. Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national, regional or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or merchandized by the Factory. In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or merchandized by the Factory, when failures are caused by the use of parts and/or components not approved by the Factory.

AVOID ACCIDENTS Most accidents and injuries occurring in industry, on the farm, at home or on the road, are caused by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason, MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the necessary precautions, before the accident occurs. Regardless of the care used in design and construction of any type of equipment, there may be conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation. A careful operator is the best insurance against accidents. The complete observance of one simple rule would prevent many thousands serious injuries each year. This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion. WARNING On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment. MODEL CODES The complete range of telescopic handlers (Telehandler) described in this manual is identified in the text by reference to the maximum extension of the telescopic arm. The vehicles listed below may not be available in all countries or markets, therefore for the latest information consult your authorised dealer. Model LM1340 LM1343 LM1345 LM1443 LM1445 LM1745 Stabilisers no small large small large large Engine 88 kW (120 CV -- 118 HP) Turbo Aftercooler Max. lifting height (m) 12.300 12.450 12.450 13.550 13.550 16.600 Max. capacity (kg) at 500 mm from fork stop 4000 4300 4500 4300 4500 4500 Capacity at max. height (kg) 2600 3600 4000 3000 3600 2500 Extension at max. height (m) 1.200 0.500 0.000 0.500 0.300 1.000 Max. longitudinal extension (m) 8.650 9.330 12.540 Capacity at max. extension (kg) 700 1700 1800 1400 1500 450 Weight (kg) 10480 10780 11760 Length (m) 5.850 6.070 6.135

Workshop Manual LM1340 TURBO -- LM1343 TURBO -- LM1345 TURBO LM1443 TURBO -- LM1445 TURBO LM1745 TURBO TELESCOPIC HANDLERS 87682524 - 05 - 2007 GENERAL LIST OF CONTENTS SECTION 00 -- GENERAL Description Page .............................................................................. General instructions 1 ........................................................................... Safety rules 3 .................................................................................. Product identification 6 ........................................................................... Environmental considerations 9 ................................................................... Maintenance techniques 10 ....................................................................... SECTION 10 -- ENGINE Description Page Main specifications of engine 3 .................................................................. General engine specification 4 ................................................................... Generalities engine F4GE9484J*J600 6 ........................................................... Removal and installation of the motor and the radiator 11 ............................................ Troubleshooting 23 ............................................................................. Tightening torques 36 ...........................................................................

2 GENERAL LIST OF CONTENTS 87682524 - 05 - 2007 SECTION 21 -- POWERSHIFT GEARBOX Description Page Powershift Gearbox 4x4 2 ........................................................................ Driving with the powershift gearbox 2 .............................................................. Gearbox assembly 5 ............................................................................ Idler gear case assembly 7 ...................................................................... Gearbox operation 8 ............................................................................. Transmission and Hydraulic oil circuit diagrams 15 ................................................... Modulation valve operation 31 .................................................................... Torque converter and heat exchanger hydraulic oil circuit 34 .......................................... Troubleshooting guide 35 ......................................................................... Troubleshooting procedures 35 ................................................................... Pressure testing clutch and high pressure circuit 38 .................................................. Pressure testing torque converter and cooler circuit 39 ............................................... Check points 40 ................................................................................. Assembly instructions 42 ......................................................................... Overhaul 45 .................................................................................... Special tools 104 ................................................................................ SECTION 25 -- FRONT AXLE Description Page Specifications 1 ................................................................................. Description 2 ................................................................................... Operation 3 .................................................................................... Troubleshooting 4 ............................................................................... Wheel toe--in check 5 ............................................................................ Component overhaul 5 ........................................................................... Front axle removal procedure 6 ................................................................... Front axle overhaul 7 ............................................................................ Axle drive pinion bearing adjustment 52 ............................................................ How to install and adjust the axle drive pinion 54 .................................................... Front drive shaft 57 ..............................................................................

GENERAL LIST OF CONTENTS 3 87682524 - 05 - 2007 SECTION 27 -- REAR AXLE Description Page Specifications 1 ................................................................................. Description 2 ................................................................................... Operation diagram 3 ............................................................................ Component overhaul 5 ........................................................................... Rear axle removal procedure 5 ................................................................... Overhaul 6 ..................................................................................... Special tools 7 .................................................................................. SECTION 33 -- BRAKES Description Page Specifications 1 ................................................................................. Power brakes 2 ................................................................................. Parking brake 3 ................................................................................ Brake disc adjustment 6 ......................................................................... Troubleshooting 7 ............................................................................... Brakes disassembly 8 ........................................................................... SECTION 35 -- HYDRAULIC SYSTEM Description Page Technical data 2 ................................................................................ Description and operation 3 ...................................................................... Introduction 3 ................................................................................... Steering system hydraulic circuit 3 ................................................................ Steering valve 4 ................................................................................ Telescopic boom hydraulic circuit 6 ................................................................ Component operation 11 ......................................................................... Hydraulic pump 11 .............................................................................. Delivery side divider valve 11 ..................................................................... Pressure reduction valve 13 ...................................................................... Front loader controls 15 .......................................................................... Power steering (OSPQ) 19 ....................................................................... Telescopic boom distributor 21 .................................................................... Auxiliary control distributor 24 ..................................................................... Cylinders 25 .................................................................................... Arms 35 ....................................................................................... Working platform 61 ............................................................................. Procedure for the calibration of the personnel carrier platform electronic controller 65 ..................... Special tools 71 .................................................................................

4 GENERAL LIST OF CONTENTS 87682524 - 05 - 2007 SECTION 55 -- ELECTRICAL SYSTEM Description Page Chapter 1 – Electrical system general Electrical equipment specifications 1 ............................................................... Electrical system and fuses 2 ..................................................................... Controls and instruments 6 ....................................................................... Use of the tip--over prevention system 16 ........................................................... Bulb replacement 23 ............................................................................. Protecting the electrical systems during charging or welding 26 ........................................ Starting the machine using jump leads 27 .......................................................... Temporary wiring repairs 28 ...................................................................... Electrical system--general fault finding 30 ........................................................... Working platform 31 ............................................................................. Special tools 46 ................................................................................. Chapter 2 – Circuit diagrams List of connectors 48 ............................................................................ List of components 49 ........................................................................... How to use the circuit diagrams 50 ................................................................ Diagram 1: Starter/Recharge/Warning/Indicators lights 53 ............................................ Diagram 2: Transmission 55 ...................................................................... Diagram 3: Wheel alignment/Hydraulic solenoids/Brake system 57 ..................................... Diagram 4: Arm control 59 ........................................................................ Diagram 5: Stabiliser 61 .......................................................................... Diagram 6: Lights/Windscreen wiper 63 ............................................................ Diagram 7: Work lamps/Roof beacon light 65 ....................................................... Diagram 8: Tilting prevention system/Roof wiper 67 .................................................. Diagram 9: Heating/Sound system/Electric socket/Interior lamp 69 ..................................... Diagram 10: Air conditioner 71 .................................................................... Chapter 3 -- Wiring list Instrument panel wiring 75 ....................................................................... Cab wiring 79 ................................................................................... Front wiring 80 .................................................................................. Rear wiring 81 .................................................................................. Engine wiring 82 ................................................................................

SECTION 00 -- GENERAL 1 87682524 - 05 - 2007 GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair interventions listed in this Manual must be performed exclusively by the Service Network of the Manufacturer, complying strictly with the indications herein and using, when required, the prescribed special tools. Whoever performs service operations described herein without complying strictly with the instructions becomes solely responsible for any consequential damage that could occur. ADJUSTING SHIMS For each adjustment select the adjusting shims, measuring them one by one with a micrometer and adding to gether subsequently, the values measured. Do not rely on the measurement of the entire pack, that could be wrong, or the nominal value indicated on each ring. SEALS FOR ROTATING SHAFTS For correct installation of the seals for rotating shafts, please comply with the following precautions: -- prior to installation, keep the seals soaking for at least half an hour in the same oil they are going to seal; -- clean thoroughly the shaft and make sure that its working face is undamaged; -- direct the sealing lip toward the fluid; in the event the lip is of the hydro dynamic type, the grooves must be directed so that, in relation to the rotating direction of the shaft, they tend to return the fluid toward the inside of the sealing device; -- smear the sealing lip with a film of lubricant (oil to be preferred to grease) and fill with grease the gap between sealing lip and dust lip in twin lip seals; -- insert the seal in its seat, pressing it with a punch with a flat face; never strike it with a hammer or mallet; -- when pressing in the seal, make sure that it is inserted perpendicularly in relation to the seat and, once in position, make sure that, when required, it contacts the shoulder; -- to prevent the sealing lip of the seal being damaged by the shaft, insert appropriate protection during the installation of the two parts. “0--RING” TOROIDAL SEALS Lubricate O--rings before inserting them in the relevant seats to prevent them becoming twisted and rolled during installation, thus jeopardising their sealing capacity. SELAING COMPOUNDS Mating surface marked X must be smeared with a sealing compound recommended by the Manufacturer or an adequate equivalent. Prior to applying the compound, prepare the surfaces in the following manner: -- remove all possible scaling with a metal brush; -- degrease the surfaces thoroughly using the degreesing agent recommended by the Manufacturer or an adequate equivalent. BEARINGS When installing bearings, it is recommended to: -- warm them up to 80 – 90 C (176 – 194 F) before installing them on the relevant shafts; -- cool them down before inserting them in the relevant seats with an outer fitting. SPLIT PINS When installing split pins, make sure that the cut is pointing in the direction of the load on the pin. On the other hand, spiral elastic pins do not require any installation orientation.

2 SECTION 00 -- GENERAL 87682524 - 05 - 2007 NOTES ON SPARE PARTS Use genuine spare parts guaranteed by the Manufacturer only. Genuine spare parts are the only ones ensuring the same quality, the same life and the same safety as the originally mounted parts, since they are the same as the ones installed in production. Only genuine parts from the manufacturer ensure this guarantee. Orders for spare parts must include the following indications: -- model of the vehicle (commercial designation) and serial number; -- type and number of the engine; -- part number for the item ordered, as provided by the “Microfiches” or the “Spare Part Catalogue”, on which the order is based. NOTES ON TOOLING The tooling that the Manufacturer recommends and illustrates in this Manual is: -- studied and designed specifically for servicing vehicles of this range; -- required to ensure a reliable repair; -- accurately developed and inspected to provide effective and long lasting working. You are also reminded that correct tooling allows you to: -- to operate under optimised technical conditions; -- to achieve the best results; -- to save time and effort; -- to work in safer conditions. WARNING The wear limits provided for some items must be considered as recommended values, but not absolutely binding. The indications “front”, “rear, “right”, “left” refer to different parts as seen seating from in the operator’s seat oriented in the normal travel direction of the vehicle. HOW TO MOVE A VEHICLE WITHOUT BATTERIES The cables of the external power supply must be connected exclusively to the respective terminals of the positive and negative cables of the vehicle, using efficient clamps providing adequate and safe contact. In the event it is necessary to check the operation of the electrical system of the vehicle, do it exclusively with the power supply connected. At the end of the inspection, disconnect all actuators and deactivate the power supply before disconnecting the cables.

SECTION 00 -- GENERAL 3 87682524 - 05 - 2007 SAFETY RULES PAY ATTENTION TO THIS SYMBOL This alert symbol announces important messages involving your safety. Read carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to 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 improper repair interventions involving potential consequences for the safety of the personnel performing the repairs. DANGER -- These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved. AVOID ACCIDENTS Most accidents, whether they occur in workshop, on the farm, at home or on the road, are caused by the failure of some individuals to follow simple and fundamental safety rules and precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs. Regardless of the care used in the design and construction of any type of equipment, there are many conditions that cannot be completely safeguarded against without hindering reasonable accessibility and efficient operation. A careful operator is the best insurance against an accident. The complete observance of one simple rule would prevent many serious accidents. DANGER. Never attempt to clean, lubricate or maintain a machine while it is in motion. SAFETY RULES SAFETY RULES  Read and heed all safety rules before any intervention.  Do not wear rings, wristwatches, jewellery, and loose or hanging apparels, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can catch on moving parts. Wear proper safety equipment as recommended for the job. Examples: hard hat, heavy gloves, ear protection, safety glasses or goggles, reflector vests, respirator. Consult your employer for specific safety equipment requirements.  Do not perform any service operation on the machine with a person seated in the operator’s compartment, unless he is an authorised operator co--operating in the operation to be performed.  Never attempt to operate the machine or its tools from any position other than seated in the operator’s seat.  Never perform any intervention on the machine with engine running unless this is prescribed.  Cut--off the engine and make sure that all pres- sures in the hydraulic systems are released before removing caps, covers, valves etc.  All service interventions must be performed with the utmost care and attention.  Shop and/or field service platforms or ladders must be constructed and maintained in accord- ance with local and national regulations.  Disconnect the batteries and tag all controls to signal that an intervention is in progress. Block the machine and all equipment that must be lifted.  Do not check nor refill fuel tanks, as well as batteries, nor use starting fluid while smoking or near open flames since these fluids are flam- mable.  Brakes are inactive when manually released for service interventions. Under such circum- stances it is necessary to maintain the control of the machine using appropriate blocks or similar devices.  The fuel--filling nozzle must be kept constantly inside the filling neck. Keep this contact from the beginning to the end of the fuelling operation to avoid the possibility that sparks due to static electricity are generated.  Use only designated towing or attaching points. Use care in making attachments. Make sure pins and/or locks are secure before pulling. Stay clear of drawbars, cables or chains under load.  To move a disabled machine, use a trailer or a low--boy, if available.

NEW HOLLand LM1340-LM1745 LOADALL Service Manual

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