New Holland LM860/LM850/LM840 Telescopic Handlers OEM Service & Repair Manual

NEW HOLLAND CONSTRUCTION SERVICE MANUAL March, 2000 N/A LM860 LM850 LM840

©1999 NEW HOLLAND CONSTRUCTION OWNER ASSISTANCE We at New Holland Construction and your New Holland Construction 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. Sometimes, 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 Ph # (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. MANUAL CORRECTIONS If a page in this manual is found to need correction, please fax a marked page to (630)260-4565 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

©1999 NEW HOLLAND CONSTRUCTION INTRODUCTION This service manual provides the technical obtaining the most from your investment and will be glad to answer any questions you may have about your New Holland machine. When major service is required, your dealer’s staff of trained service technicians is ready to serve you. When in need of parts, always order genuine New Holland service parts from your New Holland Construction dealer. Be prepared to give your dealer the model and serial number of the engine. Record the serial numbers here. Model _____________________________ Serial Number _______________________ Engine Model _____________________________ Engine Serial Number ______________________ CAUTION: THIS SYMBOL IS USED THROUGHOUT THIS BOOK WHENEVER YOUR OWN PERSONAL SAFETY IS INVOLVED. TAKE TIME TO BE CAREFUL! This service manual provides the technical information needed to properly service and maintain your machine. Use it in conjunc- tion with the operator’s manual which is supplied with the loader. Keep both manu- als available for ready reference. Whenever working on New Holland Con- struction equipment, left and right sides of the machine are determinedby standing behind the unit, looking in the direction of travel. The easiest and least time-consuming removal, disassembly, and reassembly procedures are detailed in the manual. Modifying these procedures is not recom- mended. New Holland Construction machines are designed with emphasis on safety for operator protection. However, careless and negligent operation can still result in serious injury to persons or damage to property. Be sure to read and follow all safety instructions in this manual. ABOUT IMPROVEMENTS New Holland Construction is continually striving to improve its products. We must, therefore, 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. ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

©1999 NEW HOLLAND CONSTRUCTION PRECAUTIONARY STATEMENTS PERSONAL SAFETY Throughout this manual and on machine decals, you will find precautionary statements (“CAUTION”, “WARN- ING”, and “DANGER”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them. CAUTION: THE WORD “CAUTION” IS USED WHERE A SAFE BEHAVIORAL PRACTICE ACCORDING TO OPERATING AND MAINTENANCE INSTRUCTIONS AND COMMON SAFETY PRACTICES WILL PROTECT THE OPERATOR AND OTHERS FROM ACCIDENT INVOLVEMENT. WARNING: THE WORD WARNING DENOTES A POTENTIAL OR HIDDEN HAZARD WHICH HAS A POTENTIAL FOR SERIOUS INJURY. IT IS USED TO WARN OPERATORS AND OTHERS TO EXERCISE EVERY APPROPRIATE MEANS TO AVOID A SURPRISE INVOLVEMENT WITH MACHINERY. DANGER: THE WORD “DANGER” DENOTES A FORBIDDEN PRACTICE IN CONNECTION WITH A SERIOUS HAZARD. FAILURE TO FOLLOW THE “CAUTION”, “WARNING”, “DANGER”, AND “STOP” INSTRUCTIONS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH. MACHINE SAFETY Additional precautionary statements (“ATTENTION” and “IMPORTANT”) are followed by specific instructions. These statements are intended for machine safety. ATTENTION: The word “ATTENTION” is used to warn the operator of potential machine damage if a certain procedure is not followed. IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed.

©1999 NEW HOLLAND CONSTRUCTION SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1. FOR SERVICING, THE LOADER SHOULD BE ON LEVEL TERRAIN, ENGINE STOPPED WITH THE WHEELS BLOCKED OR THE ENTIRE MACHINE SOLIDLY SUPPORTED WITH THE WHEELS OFF THE GROUND BEFORE SERVICING ANY COMPONENT OF THE DRIVETRAIN. 2. FOR SERVICING UNDER THE OPERATOR’S SEAT, RAISE THE SEAT AND PAN ASSEMBLY TO THE RAISED LATCHED POSITION AND SECURELY LATCH. 3. DO NOT OPERATE THE MACHINE UNLESS THE SEAT IS LATCHED IN THE OPERATE POSITION. 4. DO NOT SERVICE THE MACHINE WITH A RAISED BOOM UNLESS THE BOOM IS RESTING ON BOOM LOCK PINS OR CYLINDER LOCKING TOOLS OR FIXTURES. 5. DO NOT SERVICE THE LOADER WITH THE ENGINE RUNNING UNLESS THE LOADER IS PROPERLY AND SECURELY SUPPORTED WITH ALL FOUR WHEELS OFF THE GROUND. 6. USE CAUTION WHEN SERVICING THE UNIT AROUND MOVING PARTS. 7. DO NOT TILT THE BOOM AND CAB WITHOUT PROPER INSTRUCTION. 8. DO NOT TILT THE BOOM AND CAB WITHOUT USING THE PROPER CAB TILTING TOOL. 9. REINSTALL ALL SHIELDS REMOVED FOR SERVICE. 10. NEVER LOOSEN ANY HYDRAULIC CONNECTIONS BEFORE RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM. 11. WEAR EYE PROTECTION SUCH AS GOGGLES, ETC. 12. WEAR EAR PROTECTION SUCH AS EARPLUGS, ETC. WHEN YOU FEEL THE NOISE LEVEL IS UN- COMFORTABLE. 13. IF ANY SERVICING OR ADJUSTMENTS REQUIRE THE BATTERY TO BE DISCONNECTED, DISCON- NECT THE (-) NEGATIVE GROUND CABLE. 14. WHEN SERVICING ELECTRICAL COMPONENTS, DISCONNECT THE (-) NEGATIVE GROUND CABLE. 15. IF AN ELECTRONIC INSTRUMENT CLUSTER (EIC) REQUIRES REMOVAL FROM THE DASH AREA OR THE MACHINE, DISCONNECT THE (-) NEGATIVE GROUND BATTERY CABLE. THIS WILL SHUT OFF POWER TO THE EIC AND PREVENT DAMAGE TO THE EIC BOARD OR BLOWING FUSES IF THE BOARD IS ACCIDENTALLY GROUNDED. 16. IF WELDING IS REQUIRED ON THE MACHINE, DISCONNECT THE (-) NEGATIVE GROUND CABLE. FAILURE TO DISCONNECT THE BATTERY MAY RESULT IN DAMAGE TO THE EIC (ELECTRONIC INSTRUMENT CLUSTER) MONITORING SYSTEM AND OTHER ELECTRICAL COMPONENTS. 17. IF WELDING IS REQUIRED ON AN ATTACHMENT, REMOVE THE ATTACHMENT FROM THE MA- CHINE.

©1999 NEW HOLLAND CONSTRUCTION 18. GIVE COMPLETE AND UNDIVIDED ATTENTION TO THE JOB AT HAND SO THAT COMPLETE CONTROL OF THE MACHINE IS MAINTAINED AT ALL TIMES. 19. DRIVE SLOWLY OVER ROUGH GROUND AND ON SLOPES; KEEP ALERT FOR HOLES, DITCHES AND OTHER IRREGULARITIES THAT MAY CAUSE THE MACHINE TO OVERTURN. 20. AVOID STEEP HILLSIDE OPERATION WHICH COULD CAUSE THE MACHINE TO OVERTURN. 21. NEVER TRANSPORT A LOADED BUCKET AT FULL HEIGHT. OPERATE THE MACHINE WITH THE LOAD AS LOW AS POSSIBLE UNTIL IT BECOMES NECESSARY TO RAISE THE BOOM TO DISCHARGE THE LOAD INTO A TRUCK, CONTAINER, ETC. 22. REDUCE SPEED WHEN TURNING SO THERE IS NO DANGER OF OVERTURNING. 23. NEVER DRIVE UP OR BACK UP A HILL OR INCLINE WITH A RAISED BOOM OR THE MACHINE COULD OVERTURN. 24. ALWAYS LOOK BEHIND YOU BEFORE BACKING UP THE MACHINE. 25. MAINTAIN PROPER FLUID LEVELS TO PREVENT LOSS OF POWER, BRAKING OR OTHER FUNC- TIONS. 26. DO NOT ALLOW PASSENGERS TO RIDE ON THE MACHINE AT ANY TIME. 27. DO NOT ALLOW CHILDREN TO OPERATE THE MACHINE OR RIDE ON THE MACHINE AT ANY TIME. 28. DO NOT ALLOW ANYONE TO OPERATE OR SERVICE THE MACHINE WITHOUT PROPER INSTRUC- TION. OSHA REQUIRES THAT ALL OPERATORS BE INSTRUCTED ON THE PROPER OPERATION OF THE MACHINE BEFORE THEY OPERATE THE UNIT. 29. DO NOT OPERATE THE LOADER IN ANY POSITION OTHER THAN WHILE IN THE OPERATOR’S SEAT WITH THE SEAT BELT SECURELY FASTENED. 30. BEFORE STARTING THE ENGINE, BE SURE THAT ALL OPERATING CONTROLS ARE IN NEUTRAL AND THE PARKING BRAKE IS ENGAGED. 31. NEVER OPERATE THE ENGINE IN A CLOSED BUILDING WITHOUT ADEQUATE VENTILATION. 32. REFUEL THE MACHINE OUTDOORS WITH THE ENGINE SHUT OFF. REPLACE THE FUEL CAP SECURELY. USE AN APPROVED FUEL CONTAINER. DO NOT SMOKE WHEN HANDLING FUEL. AVOID SPILLING FUEL. 33. AFTER OPERATING THE ENGINE, NEVER TOUCH THE MUFFLER, EXHAUST PIPE, ENGINE OR RADIATOR UNTIL THEY HAVE HAD TIME TO COOL. 34. DRESS APPROPRIATELY – WEAR RELATIVELY TIGHT-FITTING CLOTHING WHEN OPERATING OR SERVICING THE MACHINE. LOOSE OR TORN CLOTHING CAN CATCH IN MOVING PARTS OR CONTROLS. 35. BEFORE SERVICING THE MACHINE, OR ANY OF ITS ATTACHED EQUIPMENT, BE SURE THAT THE ATTACHMENTS ARE LOWERED TO THE GROUND OR ARE SUPPORTED. 36. DO NOT WORK UNDER OVERHANGS, ELECTRIC WIRES, OR WHERE THERE IS DANGER OF A SLIDE.

©1999 NEW HOLLAND CONSTRUCTION 37. WEAR AN APPROVED SAFETY HAT WHEN OPERATING THE MACHINE AND WHILE IN ANY WORK AREA. 38. WHEN DRIVING THE MACHINE ON A ROAD OR HIGHWAY, USE WARNING LIGHTS OR WARNING DEVICES AS MAY BE REQUIRED BY LOCAL OR STATE GOVERNMENT REGULATIONS. HEAD- LIGHTS, WARNING LIGHTS AND SMV SIGNS ARE AVAILABLE THROUGH YOUR NEW HOLLAND DEALER. 39. KEEP THE MACHINE CLEAN. DO NOT ALLOW TRASH, DEBRIS OR OTHER ARTICLES TO ACCU- MULATE IN THE CAB, FLOOR OR FOOT CONTROL PEDAL AREA THAT MAY HINDER SAFE MA- CHINE OPERATION. 40. NEVER OPERATE THE MACHINE WITH ANY OF THE SHIELDING REMOVED. 41. NEVER OPERATE THE MACHINE WITHOUT WINDOWS AND/OR SCREENS IN PLACE. 42. NEVER EXTEND ANY PART OF THE BODY OUTSIDE OF THE OPERATOR’S AREA. 43. ALWAYS PROPERLY TIE DOWN THE MACHINE TO A TRUCK OR TRAILER BEFORE TRANSPORT. 44. MAKE SURE ALL BYSTANDERS ARE AT A SAFE DISTANCE AWAY FROM THE MACHINE BEFORE STARTING THE ENGINE. 45. DO NOT ALLOW ANYONE NEAR THE MACHINE WHILE THE ENGINE IS RUNNING AND THE MA- CHINE IS OPERATIONAL. 46. WHEN USING THE MACHINE TO CRANE OBJECTS, DO NOT ALLOW ANYONE TO RIDE ON OB- JECTS BEING CRANED. 47. DO NOT USE THE MACHINE AS A WORK PLATFORM FOR SUPPORTING MATERIALS. 48. DO NOT LIFT PERSONNEL OR ALLOW PERSONNEL TO WORK WHILE STANDING IN THE BUCKET OR ON OTHER ATTACHMENTS. THIS IS NOT A MAN-LIFT. OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER’S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EM- PLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION. CAUTION! SOME PICTURES IN THIS MANUAL SHOW SAFETY SHIELDS REMOVED OR OPEN TO SHOW PARTS BEING SERVICED OR FOR CLARITY. ALL SHIELDS SHOULD BE CLOSED OR RE- PLACED PRIOR TO OPERATING THE MACHINE. DANGER! FASTEN SEAT BELT BEFORE STARTING ENGINE!

NEW HOLLAND CONSTRUCTION SERVICE MANUAL March, 2000 86609405 Section 21 TRANSMISSIONS LM860 LM850 LM840

21-1 SECTION 21 TRANSMISSIONS CONTENTS SECTION DESCRIPTION PAGE 21100 DESCRIPTION AND OPERATION 21-2 ..................................... GEAR RATIOS 21-2 .................................................. TRANSMISSION CONTROL 21-2 ..................................... TRANSMISSION DISCONNECT SWITCHES 21-3 ..................... TORQUE CONVERTER 21-4 ......................................... GEAR TRAIN 21-5 ................................................... GEAR SHIFT MECHANISM 21-5 ...................................... DIRECTIONAL CONTROL VALVE 21-6 ............................... TRANSMISSION OIL FLOW, DIRECTIONAL CONTROL VALVE OPERATION 21-8 ............................................... TRANSMISSION POWER FLOWS 21-10 .............................. 21200 TRANSMISSION / BEVEL GEARBOX OVERHAUL 21-13 ................... GENERAL INFORMATION 21-13 ...................................... TRANSMISSION / BEVEL GEARBOX REMOVAL 21-14 ............... TRANSMISSION / BEVEL GEARBOX INSTALLATION 21-15 .......... TORQUE CONVERTER OVERHAUL 21-16 ............................ TRANSMISSION DISASSEMBLY 21-17 ............................... TRANSMISSION REASSEMBLY 21-54 ................................ BEVEL GEARBOX DISASSEMBLY 21-64 ............................. BEVEL GEARBOX REASSEMBLY 21-70 .............................. TROUBLESHOOTING 21-79 .......................................... COMPONENT DETAIL 21-85 .......................................... SPECIFICATIONS 21-92 .............................................. TORQUE SPECIFICATIONS 21-94 .................................... SPECIAL TOOLS 21-94 .............................................. CONVERSION FACTORS 21-94 ......................................

SECTION 21 - TRANSMISSIONS 21-2 4 x 4 POWER SHUTTLE TRANSMISSION DESCRIPTION AND OPERATION The transmission consists of a torque converter, an internal rotor-type hydraulic pump, an oil distributor, a directional control valve assembly, two hydraulically operated clutches, a 4-speed synchromesh geartrain, transmission case, oil cooler, and transfer box. Gear Ratios Synchronized 4x4 Transmission Forward 1st - 6.285 Reverse 1st - 6.251 Forward 2nd - 3.325 Reverse 2nd - 3.307 Forward 3rd - 1.710 Reverse 3rd - 1.701 Forward 4th - 1.086 Reverse 4th - 1.080 NOTE: A conventional clutch is not used with this transmission. The transmission case serves as an oil reservoir for the torque converter and hydraulic clutch assemblies. The transmission, 4, receives power from the engine, 1, by means of a bevel gearbox, 2, and torque converter, 3. Transmission Control The front clutch provides power for forward travel and the rear clutch power for reverse travel. Engagement of the front and rear clutch is controlled by the operator through the movement of the hand operated power reversing lever, 1. The gearshift lever, 2, is used to select any one of four speeds through an “H” pattern synchronized gear shift. In any gear ratio the operator need only move the shuttle lever to change direction of travel, forward or reverse. However, as a clutch is not used between the engine and the transmission, the power flow from the engine to the transmission must be interrupted to shift from one gear ratio to another. This is accomplished by using a transmission disconnect switch on the gearshift lever. 19991630 1 19992870 3 1 2 4 2 H 1 2 3 4 N F R 19991628 2 1 3

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New Holland LM860/LM850/LM840 Telescopic Handlers OEM Service & Repair Manual

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