New Holland LM series LM5040 LM5060 LM5080 Complete Workshop Service Repair Manual

87755314 5/08 1st Printing © 2008 CNH America LLC Printed In U.S.A. LM5040, LM5060, LM5080 REPAIR MANUAL COMPLETE CONTENTS SECTION 00 - GENERAL INFORMATION 2 .............................. SECTION 10 - ENGINE 4 .............................................. SECTION 21 - POWERSHIFT GEARBOX 4 .............................. SECTION 25 - FRONT AXLE 7 ......................................... SECTION 27 - REAR AXLE 8 ........................................... SECTION 33 - BRAKES 9 .............................................. SECTION 35 - HYDRAULIC SYSTEM 10 .................................. SECTION 50 - CAB CLIMATE CONTROL 13 .............................. SECTION 55 - ELECTRICAL SYSTEM 14 ................................ The following pages are the collation of the contents pages from each section and chapter of the LM5040, LM5060, LM5080 Repair manual. Complete Repair part # 87755311. The sections used through out all New Holland product Repair manuals may not be used for each product. Each Repair manual will be made up of one or several books. Each book will be labeled as to which sections are in the overall Repair manual and which sections are in each book. The sections listed above are the sections utilized for the LM5040, LM5060, LM5080 Telehandlers.

2 SECTION 00 - GENERAL INFORMATION BOOK 1 - 87755312 Chapter 1 - General Information CONTENTS Section Description Page General Instructions 3 ........................................................... Important Notice 3 ........................................................... Shims 3 .................................................................... Seals For Rotating Shafts 3 ................................................... O--Rings 3 .................................................................. Sealants 3 .................................................................. Bearings 3 .................................................................. Roll Pins 3 .................................................................. Spare Parts Notice 4 ......................................................... Tool Notices 4 ............................................................... Warnings 4 ................................................................. How to Move a Vehicle Without Batteries 4 ...................................... Health and Safety 5 ............................................................. Avoid Accidents 5 ........................................................... Safety Rules 5 .............................................................. General 5 ............................................................... Starting 6 ............................................................... Engine 6 ................................................................ Electrical Systems 7 ...................................................... Hydraulic Systems 7 ...................................................... Wheels and Tires 7 ....................................................... Removals and Installs 7 ................................................... Product Identification 8 .......................................................... Chassis Number 8 ........................................................... Vehicle Identification Data Plates 8 ............................................. Engine Identification F4GE9484J*J600 8 ....................................... Front Axle Identification 9 ..................................................... 4x3 Power Shift Identification 9 ................................................ Rear Axle Identification 9 ..................................................... Cab Identification Data Plate 10 ............................................... Identification of Attachments 11 ................................................

3 SECTION 00 - GENERAL INFORMATION BOOK 1 - 87755312 Chapter 1 - General Information (Continued) CONTENTS Section Description Page Environmental Considerations 12 ................................................. Useful Indications 12 ..................................................... Maintenance Techniques 13 ...................................................... General 13 ................................................................. Hoses And Pipes 13 ......................................................... Fittings With Front Sealing O--rings 13 .......................................... Specific Sealing Compounds 14 ............................................... Tightening Values For Threaded Fasteners 14 ................................... Specifications 17 ................................................................ General 17 ................................................................. Engine Data 22 .............................................................. Cooling System 22 ........................................................... Fuel System 22 ............................................................. Transmission 23 ............................................................. Electrical System 23 ......................................................... Brakes 23 .................................................................. Steering 23 ................................................................. Front Axle 23 ............................................................... LM5040--LM5060 23 ...................................................... LM5080 23 .............................................................. Rear Axle 23 ................................................................ Hydraulic System 24 ......................................................... Torques 24 ................................................................. Four Wheel Drive Tire Combinations 24 ......................................... Weight of Machines 24 ....................................................... Tire Pressures 25 ............................................................ Lubricants and Coolants 26 ...................................................

4 SECTION 10 - ENGINE BOOK 1 - 87755312 Chapter 1 - Engine CONTENTS Section Description Page F4 GE 9484 Engine 2 ............................................................ Engine Specifications 3 ........................................................ Sectional Views 6 ................................................................ Overhaul 11 ..................................................................... Engine and Transmission 11 ................................................... Pre-removal 11 ........................................................... Removal 20 ............................................................. Installation 21 ............................................................ Troubleshooting 23 .............................................................. Tightening Torques 36 ........................................................... SECTION 21 - POWERSHIFT GEARBOX BOOK 1 - 87755312 Chapter 1 - Powershift Gearbox CONTENTS Section Description Page Description of Operation 3 ........................................................ Powershift Gearbox 4 x 3 3 .................................................... Gearshift Control 3 ........................................................ Driving with the Powershift Gearbox 3 ........................................ Disconnection of Gearbox 5 ................................................ Transmission Power Flows 6 ................................................... Layout of Gears and Clutches 7 ............................................. Drop Box Assembly 8 ...................................................... Operation of Gearbox 9 .................................................... Converter, Pump Drive Section and Pressure Control Valve 10 .................

5 SECTION 21 - POWERSHIFT GEARBOX BOOK 1 - 87755312 Chapter 1 - Powershift Gearbox (Continued) CONTENTS Section Description Page Input Shaft and Directional Clutches 11 ....................................... Gear Speed Clutches 12 .................................................. Output Section 12 ........................................................ Transmission Controls (Refer to Hydraulic Diagram) 13 ........................ Solenoid Valve/Clutch Combination 14 ...................................... Transmission and Hydraulic Oil Circuit Diagrams 16 ........................... Operation of Modulating Valve 32 ........................................... Torque Converter and Oil Cooler Hydraulic Circuit 35 .......................... Troubleshooting Guide 36 ........................................................ Procedures 36 .............................................................. Stall Test 36 ............................................................. Transmission Pressure Checks 37 .......................................... Mechanical and Electrical Checks 37 ....................................... Hydraulic Checks 37 ...................................................... Testing 38 .................................................................. Low Clutch Pressure 38 ................................................... Charge Pump Efficiency Low 38 ............................................ Overheating 38 .......................................................... Converter Noisy 38 ....................................................... Lack of Power 38 ........................................................ Pressure Tests on Clutch and High Pressure Circuit 39 ........................ Pressure Tests on Torque Converter and Oil Cooler Hydraulic Circuit 40 ....................................................... Test Points 41 ............................................................... Overhaul 43 .................................................................... Service Points 43 ............................................................ Gearbox 46 ................................................................. Disassembly 46 .......................................................... Modulating Valve 55 ......................................................... Removal 55 .............................................................

6 SECTION 21 - POWERSHIFT GEARBOX BOOK 1 - 87755312 Chapter 1 - Powershift Gearbox (Continued) CONTENTS Section Description Page A and B Clutches 56 ......................................................... Disassembly of Clutch A (Reverse) 56 ...................................... Disassembly of Clutch B (Forward) 57 ...................................... Assembly of Clutch A (Reverse) 59 ......................................... Assembly of Clutch B (Forward) 61 ......................................... C and D Clutches and Shaft 64 ................................................ Disassembly of Clutch C (4th Speed) 64 ..................................... Disassembly of Clutch D (3rd Speed) 66 .................................... Assembly of Clutch C (4th Speed) 67 ....................................... Assembly of Clutch D (3rd Speed) 70 ....................................... E and F Multi-disk Clutches 72 ................................................ Disassembly of Clutch E (1st Speed) 72 ..................................... Disassembly of Clutch F (2nd Speed) 74 .................................... Assembly of Clutch E (1st Speed) 76 ....................................... Assembly of Clutch F (2nd Speed) 79 ....................................... Regulating Valve 81 .......................................................... Disassembly 81 .......................................................... Assembly 81 ............................................................ Modulating Valve 82 ......................................................... Disassembly 82 .......................................................... Assembly 83 ............................................................ Manifold Plate 84 ............................................................ Disassembly 84 .......................................................... Assembly 86 ............................................................ Converter Housing 87 ........................................................ Disassembly 87 .......................................................... Assembly 88 ............................................................ Drop Box 89 ................................................................ Disassembly 89 .......................................................... Assembly 92 ............................................................ Assembly of Gearbox 93 .................................................. Special Tools 105 ...............................................................

7 SECTION 25 - FRONT AXLE BOOK 1 - 87755312 Chapter 1 - Front Axle CONTENTS Section Description Page Specifications 3 .................................................................. Sectional Views 3 ................................................................ Description of Operation 7 ........................................................ Wheel Toe--in Check 8 ........................................................ Troubleshooting 9 ................................................................ Overhaul 10 .................................................................... Front Axle 10 ............................................................... Removal 11 .............................................................. Steering Knuckle 12 ......................................................... Removal 12 ............................................................. Installation 14 ............................................................ Axleshaft Double Universal Joint 16 ............................................ Removal 16 ............................................................. Installation 18 ............................................................ Planetary Reduction Gear 20 .................................................. Disassembly 20 .......................................................... Assembly 25 ............................................................ Steering Cylinder 30 ......................................................... Removal 30 ............................................................. Installation 32 ............................................................ Steering Angle Adjustment 36 .............................................. Disassembly 37 .......................................................... Assembly 39 ............................................................ Differential Unit 42 ........................................................... Removal 42 ............................................................. Disassembly 43 .......................................................... Assembly 47 ............................................................ Axle Drive Pinion 53 ......................................................... Removal 53 ............................................................. Shim Selection 57 ........................................................ Installation 59 ............................................................

8 SECTION 25 - FRONT AXLE BOOK 1 - 87755312 Chapter 1 - Front Axle (Continued) CONTENTS Section Description Page Front Drive Shaft 62 ......................................................... Removal 62 ............................................................. Front Driveshaft Universal Joint 63 ............................................. Removal 63 ............................................................. Installation 64 ............................................................ Special Tools 65 ................................................................ Front And Rear Axles 65 ..................................................... SECTION 27 - REAR AXLE BOOK 1 - 87755312 Chapter 1 - Rear Axle CONTENTS Section Description Page Specifications 2 .................................................................. Sectional Views 2 ................................................................ Description of Operation 5 ........................................................ Overhaul 6 ...................................................................... Rear Drive Shaft 6 ............................................................ Removal 6 ............................................................... Rear Axle 7 .................................................................. Removal 8 ............................................................... Pivot Bushings 8 ............................................................. Inspection 8 .............................................................. Special Tools 9 .................................................................. Front and Rear Axles 9 ........................................................

9 SECTION 33 - BRAKES BOOK 1 - 87755312 Chapter 1 - Brakes CONTENTS Section Description Page Specifications 2 .................................................................. Description of Operation 3 ........................................................ Service Brakes 3 ............................................................. Brake Pump 4 ............................................................... Trailer Brake 5 ............................................................... Trailer Brake Valve 6 .......................................................... Dynamic Selector Valve 7 ...................................................... Parking Brake 8 .............................................................. Troubleshooting 9 ................................................................ Overhaul 10 .................................................................... Brakes 10 .................................................................. Disassembly 10 .......................................................... Assembly 13 ............................................................ Brake Disk Adjustment 16 .................................................... Brake Bleeding Procedure 17 ................................................. Necessary Conditions 17 .................................................. Equipment Required 17 ................................................... Bleeding Steps 17 ........................................................

10 SECTION 35 - HYDRAULIC SYSTEM BOOK 2 - 87755313 Chapter 1 - Hydraulic System CONTENTS Section Description Page Technical Data 4 ................................................................. Description and Operation 5 ....................................................... Hydraulic System 5 ........................................................... Introduction 5 ............................................................. Steering Valve 5 .............................................................. Hydraulic Diagram 5 ....................................................... Telescopic Boom 6 ........................................................... Basic Hydraulic Circuit Operation 6 .......................................... Tool Distributor 6 .......................................................... Auxiliary Control Distributor 6 ............................................... Telescopic Boom Hydraulic Circuit 6--7 M (20--23 ft) for On--Off Distributor and Fixed Displacement Pump (Cab Models) 9 ...................... Telescopic Boom Hydraulic Circuit 10 M (33 ft) for On--Off Distributor and Fixed Displacement Pump (Cab Models) 10 .................... Telescopic Boom Hydraulic Circuit 6--7 M (20--23 ft) for Proportional Solenoid Distributor and Fixed Displacement Pump (Cab Models) 11 .................................................... Telescopic Boom Hydraulic Circuit 10 M (33 ft) for Proportional Solenoid Distributor and Variable Displacement Pump (Cab Models) 12 ......................................................... Telescopic Boom Hydraulic Circuit 10 M (33 ft) for On--Off Distributor and Fixed Displacement Pump (ROPS Models) 13 .................. Hydraulic Gear Pump 15 ..................................................... Hydraulic Diagram 15 ..................................................... Hydraulic Piston Pump 17 .................................................... Pressure Reduction Valve (6--7 M [20--23 ft] version) 18 ........................... Hydraulic Diagram 18 ..................................................... Detail of Pressure Reduction Valve Ports 18 ................................. Pressure Reduction and Stabilizer Valve (10 M [33 ft] Version) 19 .................. Solenoid Valve 4th--5th Hydraulic Function on Boom 20 ........................... Front Loader Controls (Cab Models) 21 ......................................... Operation 21 ............................................................ Telehandler On--Off Control Joystick 21 ..................................... Proportional Control Telehandler Joystick 21 .................................

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New Holland LM series LM5040 LM5060 LM5080 Complete Workshop Service Repair Manual

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