New Holland CE M427, M428, M459 Service Manual

Print No. 87755802D M427 / M428 / M459 Series M Telehandlers SERVICE MANUAL

M427/M428/M459 TELEHANDLERS Workshop Manual Print N.87755802D (VII -- 2010) 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 otherper- sons directly or indirectly involved. IMPORTANT NOTICE Allmaintenance 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. 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. 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. ATTENTION 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 mech- anical 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 authorized dealer. Model M427 M428 M459 no Stab. with Stab. with Stab. Engine 101 hp (74 kw) 120 hp (88 kw) 120 hp (88 kw) Max. lifting height ft (m) 41.8 (12.74) 41.8 (12.74) 44.6 (13.60) Max. capacity lb (kg) at 24 in (610 mm) in from fork stop 6600 (2994) 8000 (3629) 9000 (4082) Capacity at max. height lb (kg) with rear axle lock 6000 (2720) 6000 (2720) 7000 (3175) Reach at max. height ft (m) 5 (1.523) 5 (1.523) 3.45 (1.053) Max. longitudinal extension ft (m) 29 (8.800) 29 (8.800) 30.84 (9.400) Capacity at max. extension lb (kg) 1300 (544) 1600 (816) 1600 (726) Weight lb (kg) 22700 (10300) 24930 (11300) 27778 (12600) Length without forks in (m) 241.33 (6.130) 241.53 (6.135) 249.76 (6.344) Overall lenght in (m) 287.80 (7.310) 288 (7.315) 296.20 (7.524)

Workshop Manual M427/M428/M459 TELEHANDLERS 87755802D - 07 - 2010 GENERAL LIST OF CONTENTS SECTION 00 -- GENERAL Description Page .............................................................................. General instructions 1 ........................................................................... Safety rules 3 .................................................................................. Product identification 6 ........................................................................... Environmental considerations 10 .................................................................. Maintenance techniques 11 ....................................................................... SECTION10 -- ENGINE Description Page Main specifications of engines 2 ................................................................. Troubleshooting 5 ............................................................................. Generalities engine F4GE9484F*J600/F4GE9484J*J600 19 ........................................ Removal and installation of the motor and the radiator 24 ........................................... Special tools 36 ............................................................................... 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 ................................................................. Troubleshooting 37 ............................................................................ Pressure testing clutch and high pressure circuit 38 ................................................ Pressure testing torque converter and cooler circuit 39 ............................................. Check points 40 ............................................................................... Assembly instructions 42 ....................................................................... Overhaul 46 .................................................................................. Special tools 114 ..............................................................................

4 GENERAL LIST OF CONTENTS 87755802D - 07 - 2010 SECTION 25 -- FRONT AXLE Description Page Specifications 2 ............................................................................... Description front axle STD assy 3 ............................................................... Description front axle LSD assy 4 ............................................................... Operation 5 .................................................................................. Troubleshooting 6 ............................................................................. Wheel toe--in check 7 .......................................................................... Component overhaul 7 ......................................................................... Front axle removal procedure 8 ................................................................. Front axle overhaul 9 .......................................................................... How to disassemble the limited slip differential unit 51 .............................................. How to install and adjust the axle drive pinion 63 .................................................. Front drive shaft 72 ............................................................................ SECTION 27 -- REAR AXLE Description Page Specifications 2 ............................................................................... Description 3 ................................................................................. Operation diagram 5 .......................................................................... Component overhaul 7 ......................................................................... Rear axle removal procedure 7 ................................................................. Overhaul 8 ................................................................................... Special tools 9 ................................................................................ SECTION33 -- BRAKES Description Page Specifications 1 ............................................................................... Power brakes 2 ............................................................................... Parking brake 4 .............................................................................. Brake disc adjustment 8 ....................................................................... Troubleshooting 9 ............................................................................. Brakes disassembly 10 ........................................................................ SECTION 35 -- HYDRAULIC SYSTEM Description Page Technical data 2 .............................................................................. Description and operation 3 .................................................................... Introduction 3 ................................................................................. Steering valve 3 .............................................................................. Telescopic boom hydraulic circuit 4 ..............................................................

GENERAL LIST OF CONTENTS 5 87755802D - 07 - 2010 Component operation 9 ........................................................................ Hydraulic pump 9 ............................................................................. Delivery side divider valve 9 .................................................................... Pressure reduction valve (version M427) 12 ...................................................... Pressure reduction valve (version M428--M459) 13 ................................................ Pilot valve control 14 .......................................................................... Balancing valves 16 ........................................................................... Power steering (OSPQ) 18 ..................................................................... Telescopic boom distributor 19 .................................................................. Auxiliary control distributor (with stabilizer) 29 ..................................................... Auxiliary control distributor (without stabilizer) 30 .................................................. Cylinders 32 .................................................................................. Boom 54 ..................................................................................... Special tool 97 ................................................................................ SECTION 55 -- ELECTRICAL SYSTEM Description Page Chapter 1 – Electrical system general Electrical equipment specifications 1 ............................................................ Electrical system and fuses 2 .................................................................. Controls and instruments 6 .................................................................... Powershift gearbox 4x3 15 .................................................................... Switches 16 ................................................................................. Lights (optional) 19 ........................................................................... Protecting the electrical systems during charging or welding 21 ..................................... Starting the machine using jump leads 22 ....................................................... Temporary wiring repairs 23 ................................................................... Electrical system--general fault finding 25 ........................................................ Chapter 2 – Circuit diagrams List of connectors 28 ......................................................................... List of components 29 ........................................................................ How to use the circuit diagrams 30 ............................................................. Diagram 1: Starting/Recharge/Warning/Indicators lights 32 ........................................ Diagram 2: Transmission 34 ................................................................... Diagram 3: Wheel alignment/Hydraulic solenoids/Brake system 36 .................................. Diagram 4: Boom control 38 ................................................................... Diagram 5: Frame levelling/Parking brake device 40 .............................................. Diagram 6: Lights 42 ......................................................................... Diagram 7: Work lamps/Roof beacon light 44 ....................................................

6 GENERAL LIST OF CONTENTS 87755802D - 07 - 2010

SECTION 00 -- GENERAL 1 87755802D - 07 - 2010 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. “O--RING” TOROIDAL SEALS Lubricate O--rings before inserting them in the relevant seats to prevent them becoming twisted and rolled during installation, thus jeopardizing 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 87755802D - 07 - 2010 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 sufficient 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 87755802D - 07 - 2010 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 recognizing 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 authorized 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.

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New Holland CE M427, M428, M459 Service Manual

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