PDF Service Repair Manual New Holland LW80 Wheel Loader - 1 MB
This is the complete service and repair manual for the New Holland LW80 Wheel Loader.
It contains detailed, step-by-step instructions for all aspects of maintenance, troubleshooting, and major repairs.
Written for professional technicians, this manual includes diagrams and specifications for systems like the engine, transmission, and hydraulics.
It's the ultimate resource for keeping your LW80 in optimal working condition.
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--- Page 3 ---
TECHNICAL HANDBOOK LW 80
Repair work - safety instructions 2801063
Operating instructions Pressurized or spring loaded units
Never carry out repair work without hav- Never open defective pressurized or
ing read and understood the operating spring loaded units but replace them as
instructions. an entirety.
Pay special attention to: In exceptional cases, open only when the
system and the operating sequence are
"Fundamental Safety Instructions",
precisely known and any special tools re-
"Inspection and servicing - safety instruc-
quired are available.
tions" and all warnings and safety instruc-
tions attached to the machine. The technical handbook contains no in-
formation on this point.
The descriptions of job sequences pro-
vide only experienced personnel with the
necessary instructions.
The operating manual must be kept with Never remove lead seals
the machine at all times.
Never change rated pressure of pressure
relief valves without the explicit authoriza-
tion of NEW HOLLAND CONSTRUCTION.
Repair personnel Never remove lead seals from pressure
Repair personnel must have know-how relief valves and accumulators.
and experience relevant to repairing this
or comparable machines.
Working at greater heights
Always wear safety harnesses when work-
ing at greater heights.
Wear an approved safety harness; it must
be equipped with stabilizers and safety
cables.
8 01 73179332
--- Page 4 ---
SERVICE DATEN / SERVICE DATA
2 2 801 850.00 de/us
--- Page 5 ---
SERVICE DATEN / SERVICE DATA
Nm 0 1 2 3 4 5 6 7 8 9
2110 1556.251 1556.989 1557.727 1558.464 1559.202 1559.939 1560.677 1561.414 1562.152 1562.889
2120 1563.627 1564.365 1565.102 1565.840 1566.577 1567.315 1568.052 1568.790 1569.528 1570.265
2130 1571.003 1571.740 1572.478 1573.215 1573.953 1574.690 1575.428 1576.166 1576.903 1577.641
2140 1578.378 1579.116 1579.853 1580.591 1581.328 1582.066 1582.803 1583.541 1584.279 1585.016
2150 1585.754 1586.491 1587.229 1587.967 1588.704 1589.442 1590.179 1590.917 1591.654 1592.392
2160 1593.129 1593.867 1594.604 1595.342 1596.080 1596.817 1597.555 1598.292 1599.030 1599.768
2170 1600.505 1601.243 1601.980 1602.718 1603.455 1604.193 1604.930 1605.668 1606.406 1607.143
2180 1607.881 1608.618 1609.356 1610.093 1610.831 1611.568 1612.306 1613.043 1613.781 1614.519
2190 1615.256 1615.994 1616.731 1617.469 1618.207 1618.944 1619.682 1620.419 1621.157 1621.894
2200 1622.632 1623.369 1624.107 1624.844 1625.582 1626.320 1627.057 1627.795 1628.532 1629.270
2210 1630.007 1630.745 1631.482 1632.220 1632.958 1633.695 1634.433 1635.170 1635.908 1636.646
2220 1637.383 1638.121 1638.858 1639.596 1640.333 1641.071 1641.808 1642.546 1643.283 1644.021
2230 1644.759 1645.496 1646.234 1646.971 1647.709 1648.447 1649.184 1649.922 1650.659 1651.397
2240 1652.134 1652.872 1653.609 1654.347 1655.084 1655.822 1656.560 1657.297 1658.035 1658.772
2250 1659.510 1660.247 1660.985 1661.722 1662.460 1663.198 1663.935 1664.673 1665.410 1666.148
2260 1666.885 1667.623 1668.361 1669.098 1669.836 1670.573 1671.311 1672.048 1672.786 1673.523
2270 1674.261 1674.999 1675.736 1676.474 1677.211 1677.949 1678.686 1679.424 1680.162 1680.899
2280 1681.637 1682.374 1683.112 1683.849 1684.587 1685.324 1686.062 1686.800 1687.537 1688.275
2290 1689.012 1689.750 1690.487 1691.225 1691.962 1692.700 1693.437 1694.175 1694.913 1695.650
2300 1696.388 1697.125 1697.863 1698.601 1699.338 1700.076 1700.813 1701.551 1702.288 1703.026
2310 1703.763 1704.501 1705.239 1705.976 1706.714 1707.451 1708.189 1708.926 1709.664 1710.401
2320 1711.139 1711.876 1712.614 1713.352 1714.089 1714.827 1715.564 1716.302 1717.040 1717.777
2330 1718.515 1719.252 1719.990 1720.727 1721.465 1722.202 1722.940 1723.677 1724.415 1725.153
2340 1725.890 1726.628 1727.365 1728.103 1728.841 1729.578 1730.316 1731.053 1731.791 1732.528
2350 1733.266 1734.003 1734.741 1735.479 1736.216 1736.954 1737.691 1738.429 1739.166 1739.904
2360 1740.641 1741.379 1742.116 1742.854 1743.592 1744.329 1745.067 1745.804 1746.542 1747.280
2370 1748.017 1748.755 1749.492 1750.230 1750.967 1751.705 1752.442 1753.180 1753.917 1754.655
2380 1755.393 1756.130 1756.868 1757.605 1758.343 1759.080 1759.818 1760.555 1761.293 1762.031
2390 1762.768 1763.506 1764.243 1764.981 1765.719 1766.456 1767.194 1767.931 1768.669 1769.406
2400 1770.144 1770.881 1771.619 1772.356 1773.094 1773.832 1774.569 1775.307 1776.044 1776.782
2410 1777.520 1778.257 1778.995 1779.732 1780.470 1781.207 1781.945 1782.682 1783.420 1784.157
2420 1784.895 1785.633 1786.370 1787.108 1787.845 1788.583 1789.320 1790.058 1790.795 1791.533
2430 1792.271 1793.008 1793.746 1794.483 1795.221 1795.958 1796.696 1797.434 1798.171 1798.909
2440 1799.646 1800.384 1801.121 1801.859 1802.596 1803.334 1804.072 1804.809 1805.547 1806.284
2450 1807.022 1807.759 1808.497 1809.234 1809.972 1810.710 1811.447 1812.185 1812.922 1813.660
2460 1814.397 1815.135 1815.873 1816.610 1817.348 1818.085 1818.823 1819.560 1820.298 1821.035
2470 1821.773 1822.510 1823.248 1823.986 1824.723 1825.461 1826.198 1826.936 1827.674 1828.411
2480 1829.149 1829.886 1830.624 1831.361 1832.099 1832.836 1833.574 1834.312 1835.049 1835.787
2490 1836.524 1837.262 1837.999 1838.737 1839.474 1840.212 1840.949 1841.687 1842.425 1843.162
2500 1843.900 1844.637 1845.375 1846.113 1846.850 1847.588 1848.325 1849.063 1849.800 1850.538
2510 1851.275 1852.013 1852.750 1853.488 1854.226 1854.963 1855.701 1856.438 1857.176 1857.914
2520 1858.651 1859.389 1860.126 1860.864 1861.601 1862.339 1863.076 1863.814 1864.552 1865.289
2530 1866.027 1866.764 1867.502 1868.239 1868.977 1869.714 1870.452 1871.189 1871.927 1872.665
2540 1873.402 1874.140 1874.877 1875.615 1876.353 1877.090 1877.828 1878.565 1879.303 1880.040
2550 1880.778 1881.515 1882.253 1882.990 1883.728 1884.466 1885.203 1885.941 1886.678 1887.416
2560 1888.153 1888.891 1889.628 1890.366 1891.104 1891.841 1892.579 1893.316 1894.054 1894.792
2570 1895.529 1896.267 1897.004 1897.742 1898.479 1899.217 1899.954 1900.692 1901.429 1902.167
2580 1902.905 1903.642 1904.380 1905.117 1905.855 1906.593 1907.330 1908.068 1908.805 1909.543
2590 1910.280 1911.018 1911.755 1912.493 1913.230 1913.968 1914.706 1915.443 1916.181 1916.918
2600 1917.656 1918.393 1919.131 1919.868 1920.606 1921.344 1922.081 1922.819 1923.556 1924.294
2610 1925.031 1925.769 1926.507 1927.244 1927.982 1928.719 1929.457 1930.194 1930.932 1931.669
2620 1932.407 1933.145 1933.882 1934.620 1935.357 1936.095 1936.832 1937.570 1938.307 1939.045
2630 1939.783 1940.520 1941.258 1941.995 1942.733 1943.470 1944.208 1944.946 1945.683 1946.421
2640 1947.158 1947.896 1948.633 1949.371 1950.108 1950.846 1951.583 1952.321 1953.059 1953.796
2650 1954.534 1955.271 1956.009 1956.747 1957.484 1958.222 1958.959 1959.697 1960.434 1961.172
2660 1961.909 1962.647 1963.385 1964.122 1964.860 1965.597 1966.335 1967.072 1967.810 1968.547
2670 1969.285 1970.022 1970.760 1971.498 1972.235 1972.973 1973.710 1974.448 1975.186 1975.923
2680 1976.661 1977.398 1978.136 1978.873 1979.611 1980.348 1981.086 1981.823 1982.561 1983.299
2690 1984.036 1984.774 1985.511 1986.249 1986.986 1987.724 1988.462 1989.199 1989.937 1990.674
2700 1991.412 1992.149 1992.887 1993.625 1994.362 1995.100 1995.837 1996.575 1997.312 1998.050
2710 1998.787 1999.525 2000.262 2001.000 2001.738 2002.475 2003.213 2003.950 2004.688 2005.426
2720 2006.163 2006.901 2007.638 2008.376 2009.113 2009.851 2010.588 2011.326 2012.063 2012.801
2730 2013.539 2014.276 2015.014 2015.751 2016.489 2017.226 2017.964 2018.701 2019.439 2020.177
2740 2020.914 2021.652 2022.389 2023.127 2023.865 2024.602 2025.340 2026.077 2026.815 2027.552
2750 2028.290 2029.027 2029.765 2030.502 2031.240 2031.978 2032.715 2033.453 2034.190 2034.928
2760 2035.666 2036.403 2037.141 2037.878 2038.616 2039.353 2040.091 2040.828 2041.566 2042.303
2770 2043.041 2043.779 2044.516 2045.254 2045.991 2046.729 2047.466 2048.204 2048.941 2049.679
2780 2050.417 2051.154 2051.892 2052.629 2053.367 2054.104 2054.842 2055.580 2056.317 2057.055
2790 2057.792 2058.530 2059.267 2060.005 2060.742 2061.480 2062.218 2062.955 2063.693 2064.430
2800 2065.168 2065.905 2066.643 2067.380 2068.118 2068.856 2069.593 2070.331 2071.068 2071.806
12 2 801 850.00 de/us
--- Page 6 ---
SERVICE DATEN / SERVICE DATA
Leistung, Energiestrom, Wärmestrom
Power, energy and heat flow
1 Nm/s = 1 kp m/s = 0,102 kp m/s
9,81
W kW kcal/s kcal/h kp m/s PS HP
1W=
(= 1 N m/s 1 0,001 2,39 x 10-4 0,860 0,102 0,00136 0,00134
= 1 J/s)
1 kW = 1 000 1 0,239 860 102 1,36 1,341
1 kcal/s = 4 190 4,19 1 3600 427 5,69 5,61
1 kcal/h = 1,16 0,00116 1 1 0,119 0,00158 0,00156
3600
1 kp m/s = 9,81 0,00981 0,00234 8,43 1 0,0133 0,0131
1 PS = 736 0,736 0,176 632 75 1 0,9863
1 HP = 746 0,746 0,178 641,8 76,09 1,0145 1
1 kp m/s = 3600 kp m/h 1 kp m/h = 1 kp m/s
3 600
22 2 801 850.00 de/us
--- Page 7 ---
SERVICE DATEN / SERVICE DATA
Schrauben mit metrischem Feingewinde DIN 13 - 13
Bolts with metric fine thread DIN 13 - 13
Gewinde- Festigkeits- Anziehdrehmomente MA in Nm
Nenn Ø klasse Tightening torques MA in Nm
Thread Material gesamt gesamt gesamt
nominal Ø quality total total total
1) 2)
0,10 0,12 0,16 (L)3)
M 8x1 8.8 22 24,5 30
10.9 32 36 43
12.9 38 43 51
M 10x1 8.8 45 52 62
10.9 67 76 91
12.9 78 89 107
M 10x1,25 8.8 43 49 58
10.9 64 72 86
12.9 74 84 100
M 12x1,25 8.8 77 87 104
10.9 112 125 150
12.9 130 150 180
M 14x1,5 8.8 121 135 165
10.9 175 200 240
12.9 205 235 280
M 16x1,5 8.8 180 205 250
10.9 270 300 370
12.9 310 360 430
M 20x1,5 8.8 380 430 530
10.9 540 620 750
12.9 630 720 880
M 22x1,5 8.8 510 580 700
10.9 720 820 1000
12.9 840 960 1170
M 24x2 8.8 640 730 890
10.9 920 1040 1250
12.9 1070 1220 1500
M 27x2 8.8 940 1070 1300
10.9 1350 1500 1850
12.9 1550 1800 2150
M 30x2 8.8 1370 1490 1740
10.9 1940 2120 2480
12.9 2270 2480 2900
1)
Schraube und/oder Mutter galvanisch verzinkt (A3B).
Screw and/or nut electro-galvanized.
2)
Schraube schwarz vergütet oder phosphatiert, Gewinde geölt.
Screw black-plated or phosphatized, thread oiled.
3)
Schrauben mit flüssiger Schraubensicherung z.B. Loctite 242, 243.
Screws with liquid screw fixer, e.g. Loctite 242, 243.
32 2 801 850.00 de/us
--- Page 8 ---
SERVICE DATA LW 80
Hydraulic system
Checking and setting data
Unit LW 80
No. 560 501 -
Hydr. oil temp. (oil reservoir) for checking and adjustments ˚C approx. 60 - 70
˚F approx. 140 - 160
Working hydraulic
- primary pressure relief bar / psi 230+5
-10
/ 3340+70
-145
- secondary pressure relief tip cylinder piston side bar / psi 240 +
_ 5 / 3480 +
_ 70
- secondary pressure relief tip cylinder rod side bar / psi 280 +
_ 5 / 4065 +
_ 70
Steering
- primary pressure relief bar / psi 175+20
-5
/ 2540+290
-70
- secondary pressure relief bar / psi 240+20 / 3480+290
Drive unit
- charge pressure (at speed 2200 min-1) bar / psi 25 +
_ 2 / 360 +
_ 30
-1
- beginning of control action (at speed 1100 min +
_ 100) bar / psi 50 / 725
- end of control action (at speed 2000 min-1) +
_ 100) bar / psi 400 / 5800
- pressure cut-off bar / psi 430 +
_ 10 / 6240 +
_ 145
- opening pressure high-pressure valves bar / psi 465+20
-10
/ 6750+290
-145
- inch valve
- brake pressure at inch begin bar / psi 5 / 73
- brake pressure at inch end bar / psi 13 / 190
- control begin variable motor bar / psi 210 +
_ 10 / 3050 +
_ 145
Hydraulic cylinder lifting times (bucket empty)
- lifting 6,3
- lowering Sec. 3,8
- tipping Sec. 1,1
4 73179339
--- Page 9 ---
04 TRAVEL DRIVE .................................................................................................................................... 1
Hydraulic System, Safety Instructions.................................................................................................... 1
Explanations of circuit diagrams and illustrations ................................................................................ 1
Depressurizing the hydraulic system .................................................................................................... 2
Principle: hydrostatic travel drive .......................................................................................................... 3
Hydraulic circuit diagram - travel drive .................................................................................................. 4
Hydraulic circuit diagram, legend
Pressure measuring points ...................................................................................................................... 5
Functional description: hydrostatic travel drive of wheel loader LW 80
Travel drive installation............................................................................................................................ 9
Pressure measuring points ...................................................................................................................... 9
Adjusting work at the hydrostatic travel drive
Mechanical zero position ...................................................................................................................... 10
Checking and adjusting high pressure at travelling .............................................................................. 10
Adjusting cylinder (A13) ........................................................................................................................ 11
High-pressure relief valve (A4) .............................................................................................................. 12
High-pressure relief valve (A4), deblockable ........................................................................................ 13
Pressure cutout (A8) ............................................................................................................................ 14
Switching valve (A11), electromagnetically activated ............................................................................ 15
Feed pressure relief valve (A9) ............................................................................................................ 16
Checking and adjusting feed pressure .................................................................................................. 17
Control valve (A7).................................................................................................................................. 18
Checking and adjusting the regulation threshold (driving start) ............................................................ 19
Checking regulation end ........................................................................................................................ 19
Axial-piston oil motor (A15) .................................................................................................................. 20
Checking and adjusting the regulation threshold of the hydraulic motor (displacement switch-over).... 21
Inching valve (B10)................................................................................................................................ 22
Adjusting the inching threshold ............................................................................................................ 23
Repair instructions, hydraulic pump .................................................................................................... 25
Repair instructions, hydraulic motor .................................................................................................... 25
--- Page 10 ---
TECHNICAL HANDBOOK LW 80
Adjusting work at the hydrostatic travel drive 2800479
For all testing and adjusting work on the travel Checking and adjusting high pressure
drive, the hydraulic oil temperatur must be ca. at travelling
60 - 70˚C (140 - 160˚F).
The high pressure at travelling (PHD) is limited
Mechanical zero position both by the high-pressure relief valves (A4) and
by the pressure cutout (A8).
The mechanical zero position is not normally self-
adjusting. Control or adjustment is therefore ne- N.B.:
cessary only when:
The maximum high pressure is attained only if
- the pump has been dismantled and reassem-
the displacement switchover at the hydraulic mo-
bled,
tor (A15) is prevented. For this purpose the regu-
- the operator complains that the loader, despite lation threshold adjusting screw (A15, Part 2)
the travel direction switch being set to neutral must be unturned by ca. 3 turns. On completion
position, is moving in one direction. In this of work, the regulation threshold of the hydraulic
case, however, the functioning of the travel motor must be reset. For all high-pressure mea-
direction switch and the electromagnetically ac- surements, transmission range 2 (driving) must
tivated switching valve (A11) should first be be selected at the travel direction lever.
checked.
If resetting of the regulation threshold of the en-
To check the mechanical zero position, a pres- gine is to be avoided, a pressure drop due to
sure gauge (measuring range 600 bars / 8700 spinning wheels can generally also be avoided by
psi) must be connected to both measuring points applying the parking brake as far as the limit stop
for the high pressure at travelling (PHD). and preventing the travel drive from being
switched off with the handbrake switch.
N.B.:
The machine must now be secured with appro-
priate measures against forward or reverse move-
ment. The safety instructions must be observed.
The engine is started up, the travel direction
switch is set to neutral.
After slackening the lock nut (A13, Part 9) the
centering rod (A13, Part 5) is turned with a sock-
et wrench 5 mm (0.2 inch) until the same pres-
sure (in this case feed pressure) is read off at
both measuring points (PHD).
After adjustment, the centering rod (A13, Part 5)
must be secured with the lock nut (A13, Part 9).
The mechanical zero position is set.
10 04 73179332
--- Page 11 ---
TECHNICAL HANDBOOK LW 80
Axial-piston oil motor (A15) 2800484
Fig. 12
20 04 73179332
--- Page 21 ---
TECHNICAL HANDBOOK
Notes on working safety Assembling Procedure
The observance of all applicable safety rules and The complete overhauling of the front and rear
regulations is a prerequisite for protecting persons axles is described. According to circumstances,
against harm and injury and to prevent damage operations necessary for partial repair work can
to the product and the environment. be derived from there.
The repair personnel must have the know-how Wheel hubs including the planetary gear systems
and the experience required for the repair of as well as the rear axle transfer box may also be
these axles or of axles of a similar kind. If such repaired with the axle mounted. To repair brakes
know-how is lacking, the repair personnel must and axle drives, the axles must be completely
be trained and instructed beforehand by autho- dismantled. Then, the particular brakes or axle
rized personnel. drives can be laid open by removing the respec-
tive axle tube. The wheel hubs and planetary
Repair work must be carried out only after the gear systems remain enclosed.
Technical Handbook has been read and under-
stood.
Secure the machine before carrying out work on
installed axles:
- Park the machine on level and firm ground.
- Stand the working equipment on the ground.
- Apply the parking brake.
- Block the articulated joint or the superstructure.
- Shut off the engine.
- Withdraw the key.
- Secure the machine against inadvertent move-
ments by placing chocks under the wheels.
- Observe the warning and instruction signs on
the machine.
All tools and auxiliary means must be in a safe Fig. 1
state of operation.
For dismantling and reassembling, removed axles
are put in a vertical position, the lower axle tube
being held in a fixture. Wheel hub assembling
should be done on the vertically placed axle
tubes.
All assembling illustrations show the axle in verti-
cal position.
Weights
Front axle, complete: approx. 185 kg (408 lb)
Rear axle incl. transfer box
approx. 265 kg (585 lb)
2 800 920.00 en 3
--- Page 22 ---
TECHNICAL HANDBOOK
Axle Drive Assembly
Item Quantity Description
11 1 Axle drive assembly
12 2 Differential pin
13 4 Bevel gear
14 4 Washer
15 2 Bevel gear
19 2 Washer
20 1 Differential housing
21 1 Bevel gear set
22 12 Fillister-head screw, M 12 - 10.9
MA = 120 Nm (89 lbft), LOCTITE 243
23 2 Tapered roller bearing
24 Spacing washer, 0.1 mm
25 Spacing washer, 0.3 mm
26 Spacing washer, 0.5 mm
27 1 Housing
28 1 Cap screw
29 1 Screw cap
30 2 Packing ring
31 2 Collar bush
32 Spacing washer
33 Spacing washer
34 1 Cap
35 6 Hex screw
36 1 Tapered roller bearing
37 Spacing washer, 0.1 mm
38 Spacing washer, 0.3 mm
39 Spacing washer, 0.5 mm
40 1 Bush
41 1 Bush
42 1 Bush
43 1 Bush
44 Spacing washer, 0.1 mm
45 Spacing washer, 0.3 mm
46 Spacing washer, 0.5 mm
47 1 Tapered roller bearing
48 1 Shaft ring
49 1 Cap
50 1 Flange
51 1 Collar unit
MA = 200 Nm (148 lbft), LOCTITE 243
52 1 Gear
53 2 Housing
54 3 O-ring
55 6 Hex screw
MA = 53 Nm (39 lbft), LOCTITE 243
56 2 Screw cap
57 2 Packing ring
2 800 920.00 en 13
--- Page 23 ---
TECHNICAL HANDBOOK
• Slacken hex screws (120), loosen ring gear • Close hole in axle tube (101) with suitable
(119) and carrier (118) by mounting lever, see washer and pull off hub (113) with suitable
Fig. 2, and lift off. extractor.
Recommended: Extract hub (113) with conven-
tional hydraulic press (Lukas). Refer to Fig. 3.
Fig. 2
• Unlock snap ring (117), push carrier (118) out
of ring gear (119). Fig. 3
• Remove spacing washers (114 - 116). • Remove tapered roller bearing (110), lift shaft
ring (109) and remove second tapered roller
bearing (110) from hub (113).
• Drive outer rings of bearings (110) out of hub,
if bearings are to be replaced.
• Unscrew vent plug (102) and clean.
2 800 920.00 en 23
--- Page 24 ---
TECHNICAL HANDBOOK
Fig. 8
Turn over hub.
Insert outer ring of tapered roller bearing (110).
Fig. 9
Press in bearing ring.
Fig. 10
Place axle tube (101) in vertical position.
Apply grease to hub carrier.
Fig. 11
Put hub on axle tube.
2 800 920.00 en 33
--- Page 25 ---
TECHNICAL HANDBOOK
Fig. 43
Insert bevel gears (15).
Fig. 44
Put bevel gears (13) and washers (14) on dif-
ferential pin (12).
Bevel gears and washers should be slightly oiled.
Fig. 45
Insert complete differential cross and press down.
Pins must fully rest.
Fig. 46
Attach second housing half so that markings