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New Holland LM5020 Tier 3, Service Manual, Page: 36 / 41

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New Holland LM5020 Tier 3 Service Manual Download Page 36

INTRODUCTION

Reassembling hydraulic equipment

• Clean parts in a well ventilated room.

• Remove residual oil with compressed air, and apply fresh hydraulic oil or gear oil to surfaces before reassembly.

• Replace removed o-rings, back-up rings and oil seals with new ones. Apply gear oil on them before reassembling.

• Thoroughly clean and dry surfaces on which liquid sealant must be reapplied.

• Before assembling, remove rust preventives on new parts.

• Use special tools to fit bearings, bushing and oil seal.

• Assemble parts matching to the marks.

• After completion, check that there is no omission of parts.

47787942 27/10/2014

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Summary of Contents for LM5020 Tier 3

Page 1: ...LM5020 LM5030 Tier 3 Telescopic Handler Part number 47787942 English October 2014 Copyright 2014 CNH Industrial Italia S p A All Rights Reserved SERVICE MANUAL LM5020 LM5030 Telescopic Handler 1 1 Part number 47787942 ...

Page 2: ...SERVICE MANUAL LM5020 LM5030 47787942 27 10 2014 EN Find manuals at https best manuals com ...

Page 3: ...owered rear axle 27 1 Hydrostatic drive 29 29 202 Hydrostatic transmission 29 1 Brakes and controls 33 33 120 Mechanical service brakes 33 1 33 202 Hydraulic service brakes 33 2 33 110 Parking brake or parking lock 33 3 Hydraulic systems 35 35 000 Hydraulic systems 35 1 35 106 Variable displacement pump 35 2 35 353 Hydraulic travel system 35 3 35 359 Main control valve 35 4 35 740 Telescopic arm h...

Page 4: ...1 Electrical systems 55 55 000 Electrical system 55 1 55 100 Harnesses and connectors 55 2 55 512 Cab controls 55 3 55 524 Cab controls Lift arm Boom Dipper Bucket 55 4 55 408 Warning indicators alarms and instruments 55 5 47787942 27 10 2014 Find manuals at https best manuals com ...

Page 5: ...47787942 27 10 2014 Find manuals at https best manuals com ...

Page 6: ...INTRODUCTION 47787942 27 10 2014 1 Find manuals at https best manuals com ...

Page 7: ...Basic instructions Precaution for disassembly and assembly 30 Basic instructions Electrical equipment precautions 32 Consumables 33 Consumables 34 Hydraulic contamination 35 Product identification 36 Product identification 38 Product identification Machine orientation 40 Product identification Machine orientation 42 Product identification 44 Product identification 49 Dimension 54 Dimension 57 See ...

Page 8: ...amages caused by parts and or components not approved by the manu facturer including those used for the servicing or repair of the product manufactured or marketed by the manufacturer In any case no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and or components not approved by the manufacturer The information in this...

Page 9: ...t tap the seal with a hammer or mallet 6 While you insert the seal check that the seal is perpendicular to the seat When the seal settles make sure that the seal makes contact with the thrust element if required 7 To prevent damage to the seal lip on the shaft position a protective guard during installation operations O ring seals Lubricate the O ring seals before you insert them in the seats This...

Page 10: ...e from the machine battery The electronic monitoring system and charging system will be damaged if this is not done 5 Remove the battery ground cable Reconnect the cable when you complete welding Special tools WARNING Battery acid causes burns Batteries contain sulfuric acid Avoid contact with skin eyes or clothing Antidote external Flush with water Antidote eyes flush with water for 15 minutes an...

Page 11: ...ury CAUTION used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY Machine safety NOTICE Notice indicates a situation which if not avoided could result in machine or property damage Throughout this manual you will find the signal wor...

Page 12: ...uipment from any other position than the operator s seat TULI12WEX2004AA 1 Never carry out any operation on the machine when the engine is running except when specifically 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 S...

Page 13: ...acoustic ears protections Goggles with lateral shield or masks for eyes protection Do not wear rings wristwatches jewels unbuttoned or flapping clothing such as ties torn clothes scarves open jackets or shirts with open zips which could get caught into moving parts TULI12WEX2008AA 4 Engine Radiator Never leave the engine run in closed spaces without venti lation and not able to evacuate toxic exha...

Page 14: ...move the cap with hot engine wear safety clothes and equipment then loosen the cap slowly to re lieve the pressure gradually When checking the fuel oil and coolant levels use ex clusively explosion proof classified lamps If this kind of lamps are not used fires or explosions may occur TULI12WEX2011AA 7 Hydraulic systems Splashes of fluids under pressure can penetrate the skin causing serious injur...

Page 15: ...der pressure can accidentally be pierced when the heat expands beyond the area immediately heated Arrange for fire resistant temporary shields to protect hoses or other components during welding Have any visible leakage repaired immediately Escaping oil pollutes the environment Soak up any oil that has escaped with a proper binding agent Sweep up binding agent and dispose of it separately from oth...

Page 16: ... outer sheath will allow the water pen etration Concealed corrosion of the wire reinforcement will subsequently occur along the hose length with resul tant hose failure Ballooning of the hose indicates an internal leakage due to structural failure This condition rapidly deteriorates and total hose failure soon occurs Kinked crushed stretched or deformed hoses generally suffer internal structural d...

Page 17: ... water to rinse your mouth Consult a doctor EYES Rinse abundantly with water for 15 min and con sult a doctor When the electrolyte of a battery is frozen it can ex plode if you attempt to charge the battery or if you try to start the engine using a booster battery Always keep the battery charged to prevent the electrolyte freezing Provide good ventilation when changing a battery or using a battery...

Page 18: ... oil splashes can cause slipping and therefore acci dents clean immediately and accurately the areas even tually smeared Always tighten the safety plugs of fuel tank and hydraulic oil tank firmly Never use fuel to clean the machine parts eventually smeared with oil or dust Use a non inflammable product for cleaning parts Always perform fuel or oil refilling in well aired and venti lated areas TULI...

Page 19: ...pistol complete with extension and pressure switch of control TULI12WEX2020AA 17 Cleaning Clean the exterior of all components before carrying out any form of repair Dirt and dust can reduce the efficient working life of a component and lead to costly replace ment Solvents should be checked that they are suitable for the cleaning of components and also that they do not risk the personal safety of ...

Page 20: ...ation rests and pure an tifreeze Fuel Filter elements oil and fuel filters Filter elements air filters Battery Also polluting rags paper sawdust and gloves must be disposed in compliance with the same procedures Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerant...

Page 21: ...ntain substances that may be harmful to your health Modern oils contain additives Do not burn contaminated fuels and or waste oils in ordinary heating systems Avoid spillage when draining off used engine coolant mixtures engine gearbox and hydraulic oils brake fluids etc Do not mix drained brake fluids or fuels with lubricants Store them safely until they can be disposed of in a proper way to comp...

Page 22: ... appropriate for the work to be done Makeshift tools and procedures can create safety haz ards For loosening and tightening nuts and bolts use the correct tools Avoid bodily injury caused by slipping wrenches TULI12ECX0475AA 1 47787942 27 10 2014 17 ...

Page 23: ...INTRODUCTION Bolts with fine pitch A Friction coefficient B Preload N C Fastening torque Nm LEIL14TLH0374GA 2 47787942 27 10 2014 18 ...

Page 24: ...se bolts of correct length Bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of the bolt hole Bolts that are too short cannot develop sufficient tightening force 4 The torques given in the chart are for general use only Do not use these torques if a different torque is given for a specific application 5 Make sure that the nut and bolt threads are clean ...

Page 25: ...hen tightening two or more bolts tighten them alternately as shown to ensure even tightening SMIL13CEX0149EA 4 A Equally tighten upper and lower alternately B Tighten diagonally C Tighten from center and diagonally 47787942 27 10 2014 20 ...

Page 26: ... a groove use grease to hold it in place 3 Loosely assemble split flange halves Make sure that the split is centrally located and perpendicular to the port Hand tighten the bolts to hold the parts in place Take care not to pinch the O ring 4 Tighten bolts alternately and diagonally as shown to ensure even tightening 5 Do not use air wrenches Using an air wrench often causes tightening of one bolt ...

Page 27: ...t reuse cotter pins Match the holes in the bolt and nut while tightening not while loosening Lock wire NOTICE Apply wire to bolts in the bolt tightening direc tion not in the bolt loosening direction A RIGHT B WRONG C Bend along edge sharply D Do not bend it round E Tighten F Loosen SMIL13CEX0151BA 8 SMIL13CEX0152AA 9 47787942 27 10 2014 22 ...

Page 28: ...s 2 Scratches or other damage to sealing surfaces 4 or 5 will cause oil leakage at the joint Take care not to damage them when connecting disconnecting A Joint body B Male Union Joint C Female Union Joint SMIL13CEX0153AB 10 SMIL13CEX0154AA 11 Type Wrench size Union nut Joint body Tightening torque 37 Union joint 19 mm 17 mm 29 N m 21 lb ft 22 mm 19 mm 39 N m 29 lb ft 27 mm 22 mm 78 5 N m 58 lb ft ...

Page 29: ...ts against the end face of adaptor 7 to seal pressure oil O ring procedures 1 Be sure to replace O ring 6 with a new one when reconnecting 2 Before tightening union nut 9 confirm that O ring 6 is seated correctly in O ring groove 8 Tightening union nut 9 with O ring 6 displaced will damage O ring resulting in oil leakage 3 Take care not to damage O ring groove 8 or sealing face 10 Damage to O ring...

Page 30: ...36 mm 157 N m 116 lb ft 41 mm 205 N m 151 lb ft 50 mm 320 N m 236 lb ft 60 mm 410 N m 302 lb ft Seal tape application Seal tape is used to seal clearances between male and female threads so as to prevent any leakage between threads Be sure to apply just enough seal tape to fill up thread clearances Do not overwrap Application procedure Confirm that the thread surface is clean free of dirt or damag...

Page 31: ...fers de pending on the type of clamp See below for correct tightening torque of each type of low pressure hose clamp T bolt type band clamp 4 4 N m 3 25 lb ft Worm gear type band clamp 5 9 6 9 N m 4 4 5 1 lb ft SMIL13CEX0159AA 16 A T Bolt Type SMIL13CEX0160AA 17 A Worm Gear Type 47787942 27 10 2014 26 ...

Page 32: ...se rupture or separation of fit ting Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked 3 If hoses rub against each other wear to the hoses will result leading to hose rupture Take necessary measures to protect hoses from rubbing against each other Take care that hoses do not come into contact with moving parts or sharp objects A WRONG B RIGHT C Rubbing ...

Page 33: ...tly prohibited to use the machine over the specified values SERVICE LIMIT This is the limit value at which reconditioning is impossible without replacement of parts If the value is expected to exceed the service limit before next inspection and correction are performed replace the parts immediately The operation over the specified values causes increase of damage and requires the down time of mach...

Page 34: ... Out of critical hoses that are necessary to secure safety we designate Very Important Parts V I P and recommend that they should be replaced regularly INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance it is necessary for the user to familiarize himself with how to handle the machine safely cautions to be exercised and inspection lubrication procedures Refer to the Operators...

Page 35: ...Disassembling and assembling hydraulic equipment Before removing lines release the pressure of hydraulic oil tank or open the cover on the return side to tank and take out the filter Drain the oil in removed lines into an appropriate container to prevent oil contamination Protect open connections with plugs or caps to prevent oil from leaking and debris from contaminating the system Thoroughly cle...

Page 36: ... removed o rings back up rings and oil seals with new ones Apply gear oil on them before reassembling Thoroughly clean and dry surfaces on which liquid sealant must be reapplied Before assembling remove rust preventives on new parts Use special tools to fit bearings bushing and oil seal Assemble parts matching to the marks After completion check that there is no omission of parts 47787942 27 10 20...

Page 37: ...le equipment with care so as not to drop it or bump it Connector should be removed by unlocking while hold ing the connector Never disconnect electrical plugs by pulling on the wires Always use only the electrical connectors to make the disconnection Check that connector is connected and locked com pletely Engine key off before removing and connecting connec tor Engine key off before touching term...

Page 38: ...0 L 1 06 US gal NEW HOLLAND AMBRA HYPOIDE 90 LS Reduction gear oil rear wheels 0 90 L 0 24 US gal NEW HOLLAND AMBRA HYPOIDE 90 LS Gearbox oil 4 0 L 1 06 US gal NEW HOLLAND AMBRA HYPOIDE 90 LS Brake fluid 0 8 L 0 2 US gal NEW HOLLAND AMBRA SYNTFLUID 4 Cooling fluid 12 L 3 2 US gal NEW HOLLAND AMBRA ACTIFULL OT EXTENDED LIFE COOLANT Grease 4 kg 8 8 lb NEW HOLLAND AMBRA GR 75 MD Hydraulic oil 70 L 18...

Page 39: ...8 L 1 0 US gal NEW HOLLAND AMBRA HYPOIDE 90 LS Reduction gear oil rear wheels 0 90 L 0 24 US gal NEW HOLLAND AMBRA HYPOIDE 90 LS Gearbox oil 1 5 L 0 4 US gal NEW HOLLAND AMBRA HYPOIDE 90 LS Brake fluid 1 0 L 0 3 US gal NEW HOLLAND AMBRA SYNTFLUID 4 Cooling fluid 14 5 L 3 8 US gal NEW HOLLAND AMBRA ACTIFULL OT EXTENDED LIFE COOLANT Grease 4 kg 9 lb NEW HOLLAND AMBRA GR 75 MD Hydraulic oil 130 L 34 ...

Page 40: ...elief valves or check valves held open by dirt Quick failure of components that have been repaired Slow cycle times are slow The machine does not have enough power If your machine has any of these problems check the hydraulic oil for contamination There are two types of contamination microscopic and visible Microscopic contamination occurs when very fine particles of foreign material are suspended...

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