NEW HOLLAND
Repair Manual
LM--A -- LoaderMultipurpose
604.55.181.01 09 -2004
CONTENTS
SECTION00 -- HEALTH, SAFETY, MAINTENANCE
CHAPTER 1 -- General Safety & Product Identification
CHAPTER 2 -- Specifications & Tooling
SECTION 10 -- ENGINE OVERHAUL
CHAPTER 1 -- Engine & Fuel System
CHAPTER 2 -- Engine Removal
SECTION 21 -- TRANSMISSIONS
CHAPTER 1 -- 4X4 Compact Shuttle
CHAPTER 2 -- Powershift Operating Lever
CHAPTER 3 -- Powershift Overhaul
SECTION23 -- DRIVE LINES
CHAPTER 1 -- Drive Shafts
SECTION 25 -- FRONT AXLE
CHAPTER 1 -- Front Axle
SECTION 27 -- REAR AXLE
CHAPTER 1 -- RearAxle
SECTION33 -- BRAKES
CHAPTER1 -- Brakes
CHAPTER 2 -- TrailerBrake Valve
CONTENTS 2
604.55.181.01 09 -2004
SECTION 35 -- HYDRAULIC SYSTEMS
CHAPTER 1 -- Hydraulic Circuits & Components, Mechanical & Monoramp System
CHAPTER 2 -- Hydraulic Circuits & Components, Flow Sharing System
CHAPTER 3 -- Casappa Hydraulic Pump
CHAPTER 4 -- Hydraulic Cylinders
CHAPTER 5 -- Smooth Ride Control System
CHAPTER 6 -- Auxiliary Hydraulics
SECTION39 -- CHASSIS
CHAPTER 1 -- Frame, Chassis and Attachments
SECTION41 -- STEERING
CHAPTER 1 -- Hydrostatic Steering System
SECTION 50 -- CAB ENVIRONMENT
CHAPTER1 -- Heating System
CHAPTER 2 -- Air Conditioning
SECTION 55 -- ELECTRICAL SYSTEM
CHAPTER 1 -- Electrical System Introduction
CHAPTER 2 -- Wiring Diagrams, Harnesses and Connectors
CHAPTER 3 -- Starting System
CHAPTER 4 -- Charging System
CHAPTER 5 -- Battery
CHAPTER 6 -- Load Status System
CHAPTER 7 -- Monoramp Control System
CHAPTER 8 -- Flow Sharing Control System
CHAPTER 9 -- Smooth Ride Control System
SECTION82 -- LOADER
CHAPTER 1 -- Overhaul
SECTION90 -- CAB
CHAPTER 1 -- Overhaul
SECTION 00 -- MAINTENANCE -- CHAPTER 1 1
604.55.181.00 09--2003
SECTION 00 -- MAINTENANCE
Chapter 1 -- General Instructions
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by NEW
HOLLAND authorised workshops. All instructions detailed should be carefully observed and special equipment
indicated should be used if necessary.
Everyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible of deriving damages.
SHIMMING
At each adjustment, select adjusting shims, measure them individually using a micrometer and then sum up re-
corded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on rated value indi-
cated for each shim.
ROTATING SHAFT SEALS
To correctly install rotating shaft seals, observe the following instructions:
-- Let the seal soak into the same oil as it will seal for at least half an hour before mounting;
-- Thoroughly clean the shaft and ensure that the shaft working surface is not damaged;
-- Place the sealing lip towards the fluid. In case of a hydrodynamic lip, consider the shaft rotation direction and
orient grooves in order that they deviate the fluid towards the inner side of the seal;
-- Coat the sealing lip with a thin layer of lubricant (oil rather than grease) and fill with grease the gap between
the sealing lip and the dust lip of double lip seals;
-- Insert the seal into its seat and press it down using a suitable tool. Do no tap the seal with a hammer or a drift;
-- Take care to insert the seal perpendicularly to its seat while you are pressing it. Once the seal is settled, ensure
that it contacts the thrust element if required.;
-- To prevent damaging the sealing lip against the shaft, place a suitable protection during installation.
‘O’ RINGS
Lubricate the ‘O’ rings before inserting them into their seats. This will prevent the ‘O’ rings from rolling over during
mounting which will jeopardise sealing.
SEALERS
Apply NEW HOLLAND FLEXIBLE GASKET SEALANT 82995770 or a suitable equivalent, over the mating sur-
faces marked with an X.
Before applying the sealer, prepare the surface as follows:
-- remove possible scales using a metal brush;
-- thoroughly degrease the surfaces using NEW HOLLAND DEGREASER 82995779, or a suitable equivalent.
BEARINGS
It is advisable to heat the bearings to 80 to 90°C before mounting them on their shafts and cool them down before
inserting them into their seats with external tapping.
SPRING PINS
When mounting split socket spring pins, ensure that the pin notch is oriented in the direction of the effort to stress
the pin.
Spiral spring pins should not be oriented during installation.
2 SECTION 00 -- MAINTENANCE -- CHAPTER 1
604.55.181.00 09--2003
NOTES FOR SPARE PARTS
Use exclusively genuine NEW HOLLAND spare parts, the only ones bearing this logo.
Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted
in production.
Only the NEW HOLLAND genuine spare parts can offer this guarantee.
All spare parts orders should be complete with the following data:
-- Vehicle model (commercial name) and frame number;
-- engine type and number;
-- part number of the ordered part, which can be found on the “Microfiches” or the “Spare Parts Catalogue”,
which is the base for order processing.
NOTES FOR EQUIPMENT
Equipment which NEW HOLLAND proposes and shows in this manual are as follows:
-- studied and designed expressly for use on NEW HOLLAND Vehicles;
-- necessary to make a reliable repair;
-- accurately built and strictly tested to offer efficient and long--lasting working means.
We also remind the Repair Personnel that having these equipment means:
-- work in optimal technical conditions;
-- obtain best results;
-- save time and effort;
-- work more safely.
NOTICES
Wear limits indicated for some details should be intended as advised, but not binding values. The words “front”,
“rear”, “right hand”, and “left hand” referred to the different parts should be intended as seen from the operator’s
seat oriented to the normal sense of movement of the Vehicle.
HOW TO MOVE THE VEHICLE WITH THE BATTERY REMOVED
Cables from the external power supply should be connected exclusively to the respective terminals of the Vehicle
positive and negative cables using pliers in good condition which allow proper and steady contact.
Disconnect all services (lights, wind--shield wipers, etc.) before starting the Vehicle.
If it is necessary to check the Vehicle electrical system, check it only with the power supply connected. At check
end, disconnect all services and switch the power supply off before disconnecting the cables.
SECTION 00 -- MAINTENANCE -- CHAPTER 1 3
604.55.181.00 09--2003
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL
This warning symbol points out important messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguard your safety and personal integrity.
In this manual you will find this symbol together with the following key--words:
WARNING (ATTENZIONE) -- it gives warning about improper repair operations and
deriving potential consequences affecting the service technician’s personal safety.
DANGER (PERICOLO) -- it gives specific warning about potential dangers for person-
al safety of the operator or other persons directly or indirectly involved.
TO PREVENT ACCIDENTS
Most accidents and personal injuries taking place in
workshops are due from non--observance of some
simple and essential prudential rule and safety pre-
cautions. For this reason, IN MOST CASES THEY
CAN BE AVOIDED. It suffices to foresee possible
causes and act consequently with necessary caution
and care.
The possibility that an accident might occur with any
type of machines should not be disregarded, no mat-
ter how well the machine in question was designed
and built.
A wise and careful service technician is the best pre-
cautions against accidents.
Careful observance of this only basic precaution
would be enough to avoid many severe accidents.
DANGER: Never carry out any cleaning, lubrication
or maintenance operations when the engine is run-
ning.
SAFETY RULES
GENERALITIES
◊ Carefully follow specified repair and mainte-
nance procedures.
◊ Do not wear rings, wristwatches, jewels, unbut-
toned or flapping clothing such as ties, torn
clothes, scarves, open jackets or shirts with open
zips which could get hold into moving parts. We
advise to use approved safety clothing such as
anti--slipping footwear, gloves, safety goggles,
helmets, etc.
◊ Never carry out any repair on the machine if
someone is sitting on the operator’s seat, except
if they are certified operators to assist in the op-
eration to be carried out.
◊ Never operate the machine or use attachments
from a place other than sitting at the operator’s
seat.
◊ Never carry out any operation on the machine
when the engine is running, except when specifi-
cally indicated.
◊ Stop the engine and ensure that all pressure is
relieved from hydraulic circuits before removing
caps, covers, valves, etc.
◊ All repair and maintenance operations should be
carried out with the greatest care and attention.
◊ Service stairs and platforms used in a workshop
or in the field should be built in compliance with
the safety rules in force.
◊ Disconnect the batteries and label all controls to
warn that the Vehicle is being serviced. Block the
machine and all equipment which should be
raised.
◊ Never check or fill fuel tanks and accumulator
batteries, nor use starting liquid if you are smok-
ing or near open flames as such fluids are flam-
mable.
◊ Brakes are inoperative when they are manually
released for maintenance purposes. In such
cases, the machine should be kept constantly
under control using blocks or similar devices.
◊ The fuel filling gun should remain always in con-
tact with the filler neck. Maintain this contact until
the fuel stops flowing into the tank to avoid pos-
sible sparks due to static electricity buildup.
4 SECTION 00 -- MAINTENANCE -- CHAPTER 1
604.55.181.00 09--2003
◊ Use exclusively specified towing points for tow-
ing the Vehicle. Connect parts carefully. Ensure
that foreseen pins and/or locks are steadily fixed
before applying traction. Do not stop near towing
bars, cables or chains working under load.
◊ To transfer a failed Vehicle, use a trailer or a low
loading platform trolley if available.
◊ To load and unload the machine from the trans-
portation mean, select a flat area providing a firm
support to the trailer or truck wheels. Firmly tie
the machine to the truck or trailer platform and
block wheels as required by the forwarder.
◊ For electrical heaters, battery--chargers and sim-
ilar equipment use exclusive auxiliary power
supplies with a efficient ground to avoid electrical
shock hazard.
◊ Always use lifting equipment and similar of ap-
propriate capacity to lift or move heavy compo-
nents.
◊ Pay special attention to bystanders.
◊ Never pour gasoline or diesel oil into open, wide
and low containers.
◊ Never use gasoline, diesel oil or other flammable
liquids as cleaning agents. Use non--flammable
non--toxic proprietary solvents.
◊ Wear protection goggles with side guards when
cleaning parts using compressed air.
◊ Do not exceed a pressure of 2.1 bar, in accor-
dance with local regulations.
◊ Do not run the engine in a closed building without
proper ventilation.
◊ Do not smoke, use open flames, cause sparks in
the nearby area when filling fuel or handling high-
ly flammable liquids.
◊ Do not use flames as light sources when working
on a machine or checking for leaks.
◊ Move with caution when working under a Vehicle,
and also on or near a Vehicle. Wear proper safety
accessories: helmets, goggles and special foot-
wear.
◊ During checks which should be carried out with
the engine running, ask an assistant to seat at the
operator’s seat and keep the service technician
under visual control at any moment.
◊ In case of operations outside the workshop, drive
the Vehicle to a flat area and block it. If working
on an incline cannot be avoided, first block the
Vehicle carefully. Move it to a flat area as soon as
possible with a certain extent of safety.
◊ Ruined or plied cables and chains are unreliable.
Do not use them for lifting or trailing. Always han-
dle them wearing gloves of proper thickness.
◊ Chains should always be safely fastened. En-
sure that fastening device is strong enough to
hold the load foreseen. No persons should stop
near the fastening point, trailing chains or cables.
◊ The working area should be always kept CLEAN
and DRY. Immediately clean any spillage of wa-
ter or oil.
◊ Do not pile up grease or oil soaked rags, as they
constitute a great fire hazard. Always place them
into a metal container.
Before starting the Vehicle or its attachments,
check, adjust and block the operator’s seat. Also
ensure that there are no persons within the Ve-
hicle or attachment operating range.
◊ Do not keep into your pockets any object which
might fall unobserved into the Vehicle’s inner
compartments.
◊ Whenever there is the possibility of being
reached by ejected metal parts or similar, use
protection eye mask or goggles with side guards,
helmets, special footwear and heavy gloves.
◊ Wear suitable protection such as tinted eye
protection, helmets, special clothing, gloves and
footwear whenever it is necessary to carry out
welding procedures. All persons standing in the
vicinity of the welding process should wear tinted
eye protection. NEVER LOOK AT THE WELD-
ING ARC IF YOUR EYES ARE NOT SUITABLY
PROTECTED.
◊ Metal cables with the use get frayed. Always
wear adequate protections (heavy gloves, eye
protection, etc.)
◊ Handle all parts with the greatest caution. Keep
your hands and fingers far from gaps, moving
gears and similar. Always use approved protec-
tive equipment, such as eye protection, heavy
gloves and protective footwear.
SECTION 00 -- MAINTENANCE -- CHAPTER 1 5
604.55.181.00 09--2003
START UP
◊ Never run the engine in confined spaces which
are not equipped with adequate ventilation for ex-
haust gas extraction.
◊ Never bring your head, body, arms, legs, feet,
hands, fingers near fans or rotating belts.
ENGINE
◊ Always loosen the radiator cap very slowly before
removing it to allow pressure in the system to dis-
sipate. Coolant should be topped up only when
the engine is stopped or idle if hot.
◊ Do not fill up fuel tank when the engine is running,
mainly if it is hot, to avoid ignition of fires in case
of fuel spilling.
◊ Never check or adjust the fan belt tension when
the engine is running.
Never adjust the fuel injection pump when the Ve-
hicle is moving.
◊ Never lubricate the Vehicle when the engine is
running.
ELECTRICAL SYSTEMS
◊ If it is necessary to use auxiliary batteries, cables
must be connected at both sides as follows: (+) to
(+) and (--) to (--). Avoid short--circuiting the termi-
nals. GAS RELEASED FROM BATTERIES IS
HIGHLY FLAMMABLE. During charging, leave
the battery compartment uncovered to improve
ventilation. Avoid checking the battery charge by
means of “jumpers” made by placing metallic ob-
jects across the terminals. Avoid sparks or flames
near the battery area. Do no smoke to prevent ex-
plosion hazards.
◊ Prior to any service, check for fuel or coolant
leaks. Remove these leaks before going on with
the work.
◊ Do not charge batteries in confined spaces.
Ensure that ventilation is appropriate to prevent
accidental explosion hazard due to build--up of
gases releaved during charging.
◊ Always disconnect the batteries before perform-
ing any type of service on the electrical system.
HYDRAULIC SYSTEMS
◊ Some fluid slowly coming out from a very small
port can be almost invisible and be strong enough
to penetrate the skin. For this reason, NEVER
USE YOUR HANDS TO CHECK FOR LEAKS,
but use a piece of cardboard or a piece of wood
to this purpose. If any fluid is injected into the skin,
seek medical aid immediately. Lack of immediate
medical attention, serious infections or dermato-
sis may result.
◊ Always take system pressure readings using the
appropriate gauges.
WHEELS AND TYRES
◊ Check that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodi-
cally check possible damages to the rims and
tyres.
◊ Keep off and stay at the tyre side when correcting
the inflation pressure.
◊ Check the pressure only when the Vehicle is un-
loaded and tyres are cold to avoid wrong readings
due to over--pressure. Do not reuse parts of re-
covered wheels as improper welding, brazing or
heating may weaken the wheel and make it fail.
◊ Never cut, nor weld a rim with the inflated tyre as-
sembled.
◊ To remove the wheels, block both front and rear
Vehicle wheels. Raise the Vehicle and install safe
and stable supports under the Vehicle in accor-
dance with regulations in force.
◊ Deflate the tyre before removing any object
caught into the tyre tread.
◊ Never inflate tyres using flammable gases as they
may originate explosions and cause injuries to by-
standers.
REMOVAL AND INSTALLATION
◊ Lift and handle all heavy components using lifting
equipment of adequate capacity. Ensure that
parts are supported by appropriate slings and
hooks. Use lifting eyes provided to this purpose.
Take care of the persons near the loads to be
lifted.
◊ Handle all parts with great care. Do not place your
hands or fingers between two parts. Wear ap-
proved protective clothing such as safety
goggles, gloves and footwear.
◊ Do not twine chains or metal cables. Always wear
protection gloves to handle cables or chains.
6 SECTION 00 -- MAINTENANCE -- CHAPTER 1
604.55.181.00 09--2003
PRODUCT IDENTIFICATION
Your machine and its major components are
identified by various numbers and letters for
recognition in After Sales Service. The following
information provides the locations of these
identification plates, stamped numbers and
examples of what can be found on your machine.
VEHICLE SERIAL NUMBER (1)
The Serial Number is stamped at the front on the top
of the right hand main frame. Example: *041716103*
NOTE: The Serial Number and identification
numbers of components may be required by your
dealer when requesting parts or service. These
numbers will also be required as an aid to identifying
the machine if it is ever stolen, keep them safe.
1
1
VEHICLE IDENTIFICATION PLATE (2)
The machine identification plate is located on the left
hand of the seat pod. Record the data of your
machine below.
MODEL/TECHNICAL TYPE
UNIT SERIAL NO.
YEAR
2
2
ENGINE IDENTIFICATION (3)
The engine identification information is located on
the left hand side of the engine block. Record the
information below for quick reference.
MODEL NO.
SERIAL NO.
DATE CODE.
3
SECTION 00 -- MAINTENANCE -- CHAPTER 1 7
604.55.181.00 09--2003
FRONT AXLE IDENTIFICATION
The serial number and axle type is printed on the
plate (1), located on the front of the axle housing.
Record the information below for quick reference.
AXLE TYPE
SERIAL NO.
DATE CODE
1
TRANSMISSION IDENTIFICATION 4x4
POWER SHUTTLE
The serial number and type is printed on the plate (1),
on the lower right side of the transmission. Record
the information below for quick reference.
MODEL NO.
SERIAL NO.
DATE CODE
1
2
TRANSMISSION IDENTIFICATION 4x3
POWER SHIFT
The serial number and type is printed on the plate (1),
on the lower part of the transmission. Record the
information below for quick reference.
MODEL NO.
SERIAL NO.
DATE CODE
1
0007001
3
8 SECTION 00 -- MAINTENANCE -- CHAPTER 1
604.55.181.00 09--2003
REAR AXLE IDENTIFICATION
The serial number is stamped on the plate (1)
attached to the rear axle housing. Record the serial
number below for quick reference.
AXLE TYPE.
SERIAL NUMBER.
DATE CODE
4
IDENTIFICATION PLATES IN THE CAB
The Cab Identification Plate with serial number and
details are printed on the plate to the rear left hand
side of the seat. Record the serial number below for
quick reference.
Serial No.
Date Code
The ROPS and Fops details are printed on the
certification plate and mounted with the Cab Plate.
Record the serial number below for quick reference.
Serial No.
Date Code
The Engine details are printed on the certification
plate‘s and mounted with the Cab Plate. Record the
serial number below for quick reference.
Serial No.
Date Code
5
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New Holland LM A Loader Repair Manual
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Description
The New Holland LM 415A, LM425A, LM435A, LM445A Loader Repair Manual is a comprehensive guide for maintaining and repairing these loader models. This manual is an invaluable resource for both professional mechanics and DIY enthusiasts. It provides detailed technical information, including diagrams, specifications, and step-by-step procedures for troubleshooting, maintenance, and repair tasks.
With its English language format, this manual ensures accessibility to a wide range of users, making it an essential tool for anyone working with or maintaining these loader models. Whether you're looking to perform routine maintenance or tackle more complex repairs, this manual equips you with the knowledge and guidance needed to keep your New Holland loaders in optimal working condition.
