1996–2005 New Holland LM430, LM640 Telehandler Operation and Maintenance Manual

This New Holland operator’s manual covers operation and maintenance of the 1996–2005 LM430 and LM640 telehandlers, detailing daily operations, routine maintenance points, and cabin control layouts. It distinguishes the LM430’s turbocharged Iveco 8045.25.575 engine from the LM640’s naturally aspirated Iveco 8045.05.576.

Text search and illustrated references: The PDF has an OCR text layer, although recognition errors limit searches in some passages and tables. Embedded bookmarks lead to the main sections, troubleshooting topics, and index; the “MAIN MENU” bookmark references a separate file that is not included. Small labels in the fuse-board illustration are readable when enlarged.

• Engine and fuel maintenance: Valve tappet adjustment, fuel-system priming, injector removal and replacement, air-cleaner servicing, Thermostart operation, and cooling-system flushing.

• Transmission and axles: Turner T4-2024 powershuttle operation, transmission oil and filter changes, suction-screen cleaning, and Hurth axle, hub, and transfer-box lubrication.

• Hydraulics and attachments: Reservoir filter and screen servicing, hose replacement, system bleeding, attachment removal and installation, and optional auxiliary hydraulic services.

• Brakes and steering: Parking-brake cable and tie-rod adjustment, foot-brake reservoir checks, wheel toe-in adjustment, steering stops, and steering-mode alignment.

• Electrical troubleshooting: Starting and charging fault charts, warning-light explanations, fuse and relay identification, bulb replacement, and electrical protection during welding.

• Load handling and reference data: Load-chart interpretation, boom extension scales, lubrication-point drawings, tire pressure and load tables, and model-specific dimensions.

Written to assist owners with operation and maintenance, this manual requires trained, qualified telehandler operators and reserves specified repair and adjustment work for authorized personnel.

Loader Controls, Steering, and Load Charts

The LM430 and LM640 use different lever assignments for boom extension and attachment tilt. Their illustrated control layouts help operators distinguish these functions before moving between models. Auxiliary-service coverage includes optional fourth and fifth functions and a return-to-tank connection.

Two-wheel, four-wheel, and crab steering are explained alongside wheel-alignment indicator lamps. Cab coverage includes ROPS inspection, seat belts, heater controls, and optional R-134A air conditioning.

The load-handling section relates boom angle and extension marks to load-chart limits. Its worked example is illustrative, not a capacity chart for a particular machine; lifting decisions require the chart installed in the cab for that machine and attachment.

Always review the documented safety decal locations and load chart warnings before operating the telehandler.

Engine, Fuel, and Cooling Maintenance

Scheduled maintenance covers engine oil and filters, air-cleaner elements, belt tension, the water/sediment separator, and the fuel lift-pump filter. Oil-change guidance accounts for fuel sulfur content and low-temperature operation.

Valve-clearance checking and adjustment, injector replacement, and fuel-system priming are described. Injector servicing itself is referred to an authorized dealer. Cooling coverage includes draining, flushing, refilling, and supplemental coolant additive FW-15.

The air-cleaner instructions explain how excessive handling or unsuitable cleaning can damage the element and allow abrasive dirt into the engine. Turbocharger precautions address bearing damage from inadequate lubrication after extended storage or interruption of the oil supply.

Hydraulic, Drivetrain, and Brake Service

The maintenance section includes hydraulic filters, reservoir screens, the breather, hose and tube replacement, and air bleeding after the circuit has been opened. Illustrations identify filling points and service locations.

Turner powershuttle coverage explains transmission disconnect operation and torque-converter behavior. Hurth axle and hub servicing accompanies wet multi-disc brake information, parking-brake adjustment, and hydrostatic steering specifications.

Reference tables provide fluid grades and capacities, tightening torques, valve clearances, belt settings, and hydraulic and steering pressures. These support maintenance and adjustment; the publication is not a full engine, transmission, or axle overhaul manual.

Fault Charts and Electrical Identification

Problem–cause–correction tables cover the engine, transmission, electrical system, hydraulics, brakes, and cab. They help distinguish routine checks from faults requiring dealer repair, including hydraulic pump or relief-valve problems and internal brake faults.

The Powershuttle Fuse Board table and location illustration identify protected circuits and relays. Instrument-console views explain engine and transmission warnings and the brake-reservoir low-level alert. These references support initial fault isolation before repair; they do not provide complete wiring diagrams.

Printable PDF and Included Pages

The English-language file contains 141 PDF pages: 140 manual pages plus one introductory promotional page, already included in the total. The manual includes its cover, warranty information, index, notes page, predelivery checks, delivery reports, and initial service forms. The PDF is printable.