New Holland LB90.B Instruction manual

ECN
A
M
R
O
F
REP
NEVORP
LB90.B
LB95.B
LB110.B
LB115.B
Workshop
Manual
Workshop
Manual
LB90.B
LB95.B
LB110.B
LB115.B
Print No. 604.13.547
English - Printed in Italy

1
INDEX
SECTION 00 - SAFETY PRECAUTIONS
SECTION 01 - MAINTENANCE
SECTION 02 - TECHNICAL SPECIFICATIONS
1. MODELS....................................................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. TECHNICAL SPECIFICATIONS................................................................................................................... 5
4. LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ................................................................ 9
5. BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE ........................................................... 13
6. LIFTING CAPACITIES................................................................................................................................ 18
7. LOADER BUCKET WITH FORKS DIMENSIONS AND PERFORMANCE................................................. 23
8. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS.............................................................. 24
SECTION 17 - TORQUE CONVERTERS
1. POWERSHUTTLE TORQUE CONVERTER ................................................................................................3
1.1 DESCRIPTION AND OPERATION........................................................................................................ 3
1.2 TECHNICAL SPECIFICATIONS............................................................................................................ 4
1.3 OVERHAUL ........................................................................................................................................... 4
1.4 INSPECTION......................................................................................................................................... 4
1.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.6 STALL TEST.......................................................................................................................................... 5
1.7 FAULT FINDING.................................................................................................................................... 6
2. POWERSHIFT TORQUE CONVERTER ...................................................................................................... 7
2.1 DESCRIPTION AND OPERATION........................................................................................................ 7
2.2 TECHNICAL SPECIFICATIONS............................................................................................................ 8
2.3 OVERHAUL ........................................................................................................................................... 8
2.4 INSPECTION......................................................................................................................................... 9
2.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 9
2.6 STALL TEST........................................................................................................................................ 11
2.7 FAULT FINDING.................................................................................................................................. 12
SECTION 21 - TRANSMISSION
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025” ................................................... 3
1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 TIGHTENING TORQUES ...................................................................................................................... 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 2WD COMPONENTS.............................................................................................. 23
1.9 TRANSMISSION 4WD COMPONENTS.............................................................................................. 26
1.10 TRANSMISSION REMOVAL ............................................................................................................. 31
1.11 DISASSEMBLY AND ASSEMBLY..................................................................................................... 32

2
1.12 FAULT FINDING ................................................................................................................................ 90
1.13 SPECIAL TOOLS............................................................................................................................... 93
2. POWERSHIFT TRANSMISSION “DANA T16000” ..................................................................................... 94
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 94
2.2 TRANSMISSION CONTROLS............................................................................................................. 95
2.3 LUBRICATION ................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER................................................................................................................ 108
2.6 TRANSMISSION HYDRAULIC DIAGRAM ........................................................................................ 109
2.7 OPERATION ...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION REMOVAL AND INSTALLATION ........................................................................ 133
2.11 TRANSMISSION COMPONENTS ................................................................................................... 137
2.12 DISASSEMBLY AND ASSEMBLY................................................................................................... 155
2.13 SPECIAL TOOLS............................................................................................................................. 264
2.14 FAULT FINDING .............................................................................................................................. 265
2.15 FAULT FINDING .............................................................................................................................. 267
SECTION 25 - FRONT AXLES
1. FRONT AXLE 2WD “CARRARO” ................................................................................................................. 3
1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.3 FAULT FINDING .................................................................................................................................. 23
2. FRONT AXLE 4WD “CARRARO” ............................................................................................................... 25
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 25
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 31
2.3 FAULT FINDING .................................................................................................................................. 77
3. FRONT AXLE 4WS “CARRARO” ............................................................................................................... 80
3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 80
3.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 84
3.3 FAULT FINDING ................................................................................................................................ 137
4. SPECIAL TOOLS...................................................................................................................................... 140
SECTION 27 - REAR AXLE
1. REAR AXLE 2WS ......................................................................................................................................... 3
1.1 DESCRIPTION AND OPERATION....................................................................................................... 3
1.2 TECHNICAL SPECIFICATIONS............................................................................................................ 6
1.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8
1.4 FAULT FINDING .................................................................................................................................. 27
2. REAR AXLE 4WS “CARRARO”.................................................................................................................. 28
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 28
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 32
2.3 FAULT FINDING .................................................................................................................................. 81
3. SPECIAL TOOLS........................................................................................................................................ 84
SECTION 33 - BRAKES SYSTEM
1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. HAND BRAKE............................................................................................................................................... 6

3
2.1 HAND BRAKE ADJUSTMENT .............................................................................................................. 7
3. BRAKE CYLINDERS .................................................................................................................................... 8
4. OIL BRAKE TANK....................................................................................................................................... 13
5. BLEEDING PROCEDURE.......................................................................................................................... 13
SECTION 35 - HYDRAULIC SYSTEM
1. HYDRAULIC DIAGRAMS ............................................................................................................................. 3
1.1 HYDRAULIC DIAGRAM - 2WS CENTRE PIVOT MECHANICAL MODELS ......................................... 3
1.2 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS................................................. 5
1.3 HYDRAULIC DIAGRAM - 2WS CENTRE PIVOT PILOT MODELS ...................................................... 7
1.4 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS ............................................................ 10
1.5 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT MECHANICAL MODELS ....................................... 13
1.6 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS............................................... 15
1.7 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT PILOT MODELS .................................................... 17
1.8 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODEL .............................................................. 20
2. HYDRAULIC PUMP.................................................................................................................................... 23
2.1 DESCRIPTION AND OPERATION...................................................................................................... 23
2.2 TECHNICAL SPECIFICATIONS.......................................................................................................... 24
2.3 LOAD SENSING VALVE ..................................................................................................................... 26
2.4 REMOVAL ........................................................................................................................................... 28
2.5 COMPONENTS ................................................................................................................................... 29
2.6 DISASSEMBLY AND ASSEMBLY....................................................................................................... 30
3. CONTROL VALVES ................................................................................................................................... 34
3.1 CONTROL VALVES “HUSCO” (LB110.B CENTRE PIVOT MECHANICAL MODELS) ...................... 34
3.2 CONTROL VALVES “REXROTH” (MECHANICAL MODELS) ............................................................ 71
3.3 CONTROL VALVES “REXROTH” (PILOT MODELS) ......................................................................... 87
4. HYDRAULIC SWING SYSTEM ................................................................................................................ 111
4.1 DESCRIPTION AND OPERATION.................................................................................................... 111
4.2 HYDRAULIC OIL FLOW .................................................................................................................... 112
4.3 PRECISION SWING CONTROL ....................................................................................................... 114
5. HYDRAULIC CYLINDERS........................................................................................................................ 117
5.1 LOADER CYLINDER ......................................................................................................................... 118
5.2 LOADER BUCKET CYLINDER ......................................................................................................... 124
5.3 4X1 BUCKET CYLINDER.................................................................................................................. 130
5.4 BACKHOE BOOM CYLINDER .......................................................................................................... 133
5.5 BACKHOE DIPPER CYLINDER........................................................................................................ 137
5.6 BACKHOE BUCKET CYLINDER....................................................................................................... 141
5.7 SHORT AND LONG TELESCOPIC CYLINDER................................................................................ 145
5.8 STABILIZER CYLINDER (CENTRE PIVOT MODELS)..................................................................... 149
5.9 STABILIZER CYLINDER (SIDESHIFT MODELS)............................................................................. 153
5.10 SWING CYLINDER.......................................................................................................................... 157
5.11 BACKHOE SIDESHIFT LOCKING CYLINDER (SIDESHIFT) ......................................................... 161
5.12 SPECIAL TOOLS............................................................................................................................. 163
6. CONTROL LEVERS ................................................................................................................................. 164
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 164
6.2 DESCRIPTION AND OPERATION.................................................................................................... 165
6.3 DISASSEMBLY AND ASSEMBLY..................................................................................................... 168
6.4 CONTROL LEVER VALVE................................................................................................................ 171
7. FAULT FINDING AND FLOW TESTING .................................................................................................. 174
7.1 PRELIMINARY CHECKS................................................................................................................... 174

4
7.2 FAULT FINDING (WITH “HUSCO” CONTROL VALVES) - LB110.B CENTRE PIVOT..................... 175
7.3 PRESSURE TESTING (WITH “HUSCO” CONTROL VALVES) - LB110.B CENTRE PIVOT............ 180
7.4 FAULT FINDING (WITH “REXROTH” CONTROL VALVES)............................................................. 188
7.5 PRESSURE TESTING (WITH “REXROTH” CONTROL VALVES).................................................... 192
SECTION 39 - CHASSIS
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. REMOVAL AND INSTALLATION COMPONENTS....................................................................................... 6
2.1 COMPONENTS WITHIN THE CHASSIS...............................................................................................6
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 7
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS ....................................................................... 9
2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS......................................................................... 10
2.5 TIGHTENING TORQUES .................................................................................................................... 12
SECTION 41 - STEERING SYSTEM
1. STEERING SYSTEM 2WS ........................................................................................................................... 4
2. STEERING SYSTEM 4WS ........................................................................................................................... 7
3. POWER STEERING ................................................................................................................................... 12
3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 13
3.2 COMPONENTS ................................................................................................................................... 15
3.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 16
3.4 SPECIAL TOOLS................................................................................................................................. 33
3.5 FAULT FINDING .................................................................................................................................. 33
SECTION 50 - CAB HEATING AND AIR CONDITIONING
1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. CAB HEATING.............................................................................................................................................. 5
2.1 DESCRIPTION AND OPERATION........................................................................................................ 5
3. AIR CONDITIONING................................................................................................................................... 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 16
3.3 DESCRIPTION AND OPERATION...................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 25
3.5 FLUSHING THE SYSTEM ................................................................................................................... 43
3.6 EVACUATING THE SYSTEM.............................................................................................................. 45
3.7 CHARGING THE SYSTEM.................................................................................................................. 46
3.8 COMPONENTS OVERHAUL............................................................................................................... 47
3.9 COMPRESSOR ................................................................................................................................... 51
3.10 SPECIAL TOOLS............................................................................................................................... 65
SECTION 55 - ELECTRICAL SYSTEM
1. GENERALITIES ............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING .................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB ........................................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHIFT CAB ............................................................................... 24
2.3 ELECTRICAL DIAGRAMS - 4WS........................................................................................................ 43
2.4 ELECTRICAL DIAGRAMS - ROPS ..................................................................................................... 62

5
3. CONTROLS AND INSTRUMENTS ............................................................................................................ 77
3.1 FRONT INSTRUMENT PANEL ........................................................................................................... 77
3.2 SIDE INSTRUMENT PANEL ............................................................................................................... 79
3.3 DIAGNOSTIC SIGNALING .................................................................................................................. 81
3.4 CALIBRATION OF SPEEDOMETER ..................................................................................................83
3.5 IMMOBILISER CIRCUIT...................................................................................................................... 84
4. STARTING SYSTEM .................................................................................................................................. 85
4.1 DESCRIPTION AND OPERATION...................................................................................................... 85
4.2 FAULT FINDING.................................................................................................................................. 86
4.3 STARTER MOTOR.............................................................................................................................. 89
5. ALTERNATOR............................................................................................................................................ 95
5.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 95
5.2 DESCRIPTION AND OPERATION...................................................................................................... 95
5.3 COMPONENTS ................................................................................................................................... 97
5.4 REMOVAL ........................................................................................................................................... 98
5.5 PRELIMINARY CHECK AND TESTS.................................................................................................. 99
5.6 FAULT FINDING................................................................................................................................ 108
6. BATTERY ................................................................................................................................................. 109
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 109
6.2 DESCRIPTION AND OPERATION.................................................................................................... 109
6.3 BATTERY REPLACEMENT .............................................................................................................. 110
6.4 MAINTENANCE................................................................................................................................. 112
6.5 TESTS ............................................................................................................................................... 114
6.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 116
6.7 BATTERY MASTER SWITCH (optional LB90.B - LB95.B) ............................................................... 116
7. COMPONENT TESTING .......................................................................................................................... 117
7.1 GENERAL INTRODUCTION ............................................................................................................. 117
7.2 COMPONENT TESTING ................................................................................................................... 118
7.3 GROUND POINTS............................................................................................................................. 118
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 4
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 7
3. LOADER ATTACHMENT SAFETY STRUT................................................................................................ 10
4. LOADER BUCKET REMOVAL ................................................................................................................... 12
5. LOADER REMOVAL (2WS) ....................................................................................................................... 15
6. LOADER REMOVAL (4WS) ....................................................................................................................... 17
SECTION 84 - BACKHOE
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. BACKHOE ATTACHMENT MECHANICAL CONTROL VERSION .............................................................. 6
3. BACKHOE ATTACHMENT PILOT CONTROL VERSION.......................................................................... 12
4. REMOVAL AND INSTALLATION ............................................................................................................... 14
5. TELESCOPIC DIPPER REVISION............................................................................................................. 24

6
SECTIONS INDEX
Where disassembly of a specific component is required refer to the relevant repair manual section.
SECTION 17: TORQUE CONVERTER
SECTION 21: TRANSMISSION
SECTION 25: FRONT AXLE
SECTION 27: REAR AXLE
SECTION 33: BRAKES SYSTEM
SECTION 35: HYDRAULIC SYSTEM
SECTION 39: CHASSIS
SECTION 41: STEERING SYSTEM
SECTION 50: CAB HEATING AND AIR CONDITIONING
SECTION 55: ELECTRICAL SYSTEM
SECTION 82: LOADER
SECTION 84: BACKHOE

LB90.B
LB95.B
LB110.B
LB115.B
SECTION 00 - SAFETY PRECAUTIONS

4 SECTION 00 - SAFETY PRECAUTIONS
SAFETY RULES
ZCarefully follow specified repair and maintenance
procedures.
ZDo 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, hel-
mets, etc.
ZNever carry out any repair on the machine if some-
one is sitting on the operator’s seat, except if they
are certified operators to assist in the operation to
be carried out.
ZNever operate the machine or use attachments
from a place other than sitting at the operator’s
seat.
ZNever carry out any operation on the machine
when the engine is running, except when specifi-
cally indicated.
ZStop the engine and ensure that all pressure is re-
lieved from hydraulic circuits before removing
caps, covers, valves, etc.
ZAll repair and maintenance operations should be
carried out with the greatest care and attention.
ZService stairs and platforms used in a workshop or
in the field should be built in compliance with the
safety rules in force.
ZDisconnect the batteries and label all controls to
warn that the Machine is being serviced. Block the
machine and all equipment which should be
raised.
ZNever check or fill fuel tanks and accumulator bat-
teries, nor use starting liquid if you are smoking or
near open flames as such fluids are flammable.
ZBrakes are inoperative when they are manually re-
leased for maintenance purposes. In such cases,
the machine should be kept constantly under con-
trol using blocks or similar devices.
ZThe fuel filling gun should remain always in contact
with the filler neck.
Maintain this contact until the fuel stops flowing
into the tank to avoid possible sparks due to static
electricity buildup.
ZUse exclusively specified towing points for towing
the machine. 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.
ZTo transfer a failed machine, use a trailer or a low
loading platform trolley if available.
ZTo load and unload the machine from the transpor-
tation mean, select a flat area providing a firm sup-
port to the trailer or truck wheels. Firmly tie the
machine to the truck or trailer platform and block
wheels as required by the forwarder.
ZFor electrical heaters, battery-chargers and similar
equipment use exclusive auxiliary power supplies
with a efficient ground to avoid electrical shock
hazard.
ZAlways use lifting equipment and similar of appro-
priate capacity to lift or move heavy components.
ZPay special attention to bystanders.
ZNever pour gasoline or diesel oil into open, wide
and low containers.
ZNever use gasoline, diesel oil or other flammable
liquids as cleaning agents. Use non-flammable
non-toxic proprietary solvents.
ZWear protection goggles with side guards when
cleaning parts using compressed air.
ZDo not exceed a pressure of 2.1 bar, in accordance
with local regulations.
ZDo not run the engine in a closed building without
proper ventilation.
ZDo not smoke, use open flames, cause sparks in
the nearby area when filling fuel or handling highly
flammable liquids.
ZDo not use flames as light sources when working
on a machine or checking for leaks.
ZMove with caution when working under a Machine,
and also on or near a Machine. Wear proper safety
accessories:
helmets, goggles and special footwear.
ZDuring checks which should be carried out with the
engine running, ask an assistant to sit at the oper-
ator’s seat and keep the service technician under
visual control at any moment.
In case of operations outside the workshop, drive
the machine to a flat area and block it. If working
on an incline cannot be avoided, first block the Ma-
chine carefully. Move it to a flat area as soon as
possible with a certain extent of safety.
ZRuined or plied cables and chains are unreliable.
Do not use them for lifting or trailing. Always han-
dle them wearing gloves of proper thickness.
ZChains should always be safely fastened. Ensure
that fastening device is strong enough to hold the
load foreseen. No persons should stop near the
fastening point, trailing chains or cables.
ZThe working area should be always kept CLEAN
and DRY. Immediately clean any spillage of water
or oil.
ZDo 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 Machine
or its attachments, check, adjust and block the op-
erator’s seat. Also ensure that there are no per-
sons within the Machine or attachment operating
range.
ZDo not keep in your pockets any object which
might fall unobserved into the Machine’s inner
compartments.

SECTION 00 - SAFETY PRECAUTIONS 5
ZWhenever 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 proc-
ess should wear tinted eye protection. NEVER
LOOK AT THE WELDING ARC IF YOUR EYES
ARE NOT SUITABLY PROTECTED.
ZMetal cables with the use get frayed. Always wear
adequate protections (heavy gloves, eye protec-
tion, etc.).
ZHandle all parts with the greatest caution. Keep
your hands and fingers far from gaps, moving
gears and similar. Always use approved protective
equipment, such as eye protection, heavy gloves
and protective footwear.
START UP
ZNever run the engine in confined spaces which are
not equipped with adequate ventilation for exhaust
gas extraction.
ZNever bring your head, body, arms, legs, feet,
hands, fingers near fans or rotating belts.
ENGINE
ZAlways 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.
ZDo 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.
ZNever check or adjust the fan belt tension when the
engine is running. Never adjust the fuel injection
pump when the machine is moving.
ZNever lubricate the machine when the engine is
running.
ELECTRICAL SYSTEMS
ZIf 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 venti-
lation. 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 not smoke to prevent ex-
plosion hazards.
ZPrior 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. En-
sure that ventilation is appropriate to prevent acci-
dental explosion hazard due to build-up of gasses
relieved during charging.
ZAlways disconnect the batteries before performing
any type of service on the electrical system.
HYDRAULIC SYSTEMS
ZSome 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 for this
purpose. If any fluid is injected into the skin, seek
medical aid immediately. Lack of immediate medi-
cal attention, serious infections or dermatitis may
result.
ZAlways take system pressure readings using the
appropriate gauges.
WHEELS AND TYRES
ZCheck that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodi-
cally check possible damages to the rims and
tyres.
ZKeep off and stay at the tyre side when correcting
the inflation pressure.
ZCheck the pressure only when the machine is un-
loaded and tyres are cold to avoid wrong readings
due to over-pressure. Do not reuse parts of recov-
ered wheels as improper welding, brazing or heat-
ing may weaken the wheel and make it fail.
ZNever cut, nor weld a rim with the inflated tyre as-
sembled.
ZTo remove the wheels, block both front and rear
Machine wheels. Raise the Machine and install
safe and stable supports under the Machine in ac-
cordance with regulations in force.
ZDeflate the tyre before removing any object caught
into the tyre tread.
ZNever inflate tyres using flammable gases as they
may originate explosions and cause injuries to by-
standers.
REMOVAL AND INSTALLATION
ZLift 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.
ZHandle 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.
ZDo not twist chains or metal cables. Always wear
protection gloves to handle cables or chains.

6 SECTION 00 - SAFETY PRECAUTIONS
IMPORTANT ECOLOGICAL CONSIDERATIONS
The following are recommendations which may be
of assistance:
ZBecome acquainted with and ensure that you un-
derstand the relative legislation applicable to your
country.
ZWhere no legislation exists, obtain information
from suppliers of oils, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and
nature and how to safely store, use and dispose of
these substances.
Helpful hints
ZAvoid filling tanks using jerry cans or inappropriate
pressurized fuel delivery systems which may
cause considerable spillage.
ZIn general, avoid skin contact with all fuels, oils, ac-
ids, solvents, etc.
Most of them contain substances which can be
harmful to your health.
ZModern oils contain additives. Do not burn contam-
inated fuels and/or waste oils in ordinary heating
systems.
ZAvoid spillage when draining off used engine cool-
ant mixtures, engine, transmission and hydraulic
oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubri-
cants. Store them safely until they can be disposed
of in a proper way to comply with local legislation
and available resources.
ZModern coolant mixtures, i.e. antifreeze and other
additives, should be replaced every two years.
They should not be allowed to get into the soil but
should be collected and disposed of safely.
ZDo not open the Air-Conditioning system yourself.
It may contain gases which should not be released
into the atmosphere. Your air conditioning special-
ist has special equipment for discharging and
charging the system.
ZRepair any leaks or defects in the engine cooling or
hydraulic system immediately.
ZDo not increase the pressure in a pressurized cir-
cuit as this may lead to a catastrophic failure of the
system components.
ZProtect hoses during welding as penetrating weld
chips may burn a hole or weaken them, causing
the loss of oils, coolant, etc.

LB90.B
LB95.B
LB110.B
LB115.B
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025” ................................................... 3
1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 TIGHTENING TORQUES ...................................................................................................................... 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 2WD COMPONENTS.............................................................................................. 23
1.9 TRANSMISSION 4WD COMPONENTS.............................................................................................. 26
1.10 TRANSMISSION REMOVAL ............................................................................................................. 31
1.11 DISASSEMBLY AND ASSEMBLY..................................................................................................... 32
1.12 FAULT FINDING................................................................................................................................ 90
1.13 SPECIAL TOOLS............................................................................................................................... 93
2. POWERSHIFT TRANSMISSION “DANA T16000” ..................................................................................... 94
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 94
2.2 TRANSMISSION CONTROLS............................................................................................................. 95
2.3 LUBRICATION................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER ............................................................................................................... 108
2.6 TRANSMISSION HYDRAULIC DIAGRAM ........................................................................................ 109
2.7 OPERATION...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION REMOVAL AND INSTALLATION........................................................................ 133
2.11 TRANSMISSION COMPONENTS................................................................................................... 137
2.12 DISASSEMBLY AND ASSEMBLY...................................................................................................155
2.13 SPECIAL TOOLS............................................................................................................................. 264
2.14 FAULT FINDING.............................................................................................................................. 265
2.15 FAULT FINDING.............................................................................................................................. 267
SECTION 21 - TRANSMISSION

SECTION 21 - TRANSMISSION 3
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025”
This transmission is used on Powershuttle loader
backhoes models LB90.B - LB95.B - LB100.B.
The transmission consists of a torque converter, an
internal rotor-type hydraulic pump, an oil distributor,
a solenoid control valve assembly, two hydraulically
operated clutches, a 4-speed synchromesh
geartrain, transmission case and oil cooler tubes.
NOTE: a conventional clutch is not used with this
transmission.
The transmission case serves as an oil tank for the
torque converter and hydraulic clutch assemblies.
The transmission receives power from the engine (1)
by a fluid coupling in the torque converter (2) and hy-
draulic clutch assemblies in the transmission (3).
1.1 TECHNICAL SPECIFICATIONS
GEAR RATIO
COLD START BY-PASS VALVE SPRING
Free length.......................................................................................................................... 53.4 mm ± 0.96 mm
FORWARD CLUTCH SPRING
Free length............................................................................................................................................ 76.6 mm
CLUTCH PISTON SPRING
Free length............................................................................................................................................ 75.9 mm
DETENT SPRING
Free length (Approximately)................................................................................................................ 42.06 mm
Forward Reverse
12341234
4.824 2.998 1.408 0.792 4.020 2.496 1.173 0.660

4 SECTION 21 - TRANSMISSION
END FLOAT
Input forward Primary Shaft ...................................................................................................... 0.0508-0.41 mm
Input reverse Primary Shaft ...................................................................................................... 0.0508-0.41 mm
Output shaft................................................................................................................ 1st Gear - 0.33-0.508 mm
..................................................................................................................................2nd Gear - 0.35-0.558 mm
...................................................................................................................................3rd Gear - 0.38-0.838 mm
...................................................................................................................................4th Gear - 0.20-0.558 mm
Four Wheel Drive Shaft............................................................................................................... 0.050-0.28 mm
Bearing End Floats.................................................................................................................... 0.025-0.076 mm
Bearing End Float Shims available ................................................... 0.050/0.076/0.127/0.177/0.381/0.508 mm
HYDRAULIC TESTS
Tachometer setting .......................................................................................................................2000 revs/min
Test temperature, oil ............................................................................................................................. 80-85 °C
Cold Start Valve (For reference only)........................................................................................................ 26 bar
System Pressure Test....................................................................................................................13.7-15.2 bar
Torque Converter ...................................................................................................................................7-11 bar
Reverse Clutch...............................................................................................................................13.7-15.2 bar
Forward Clutch...............................................................................................................................13.7-15.2 bar
Four Wheel Drive Supply ...............................................................................................................13.7-15.2 bar
COOLER FLOW TEST
Oil temperature 80-85 °C ..............................................Revs/min .........................................Oil Flow Litres/min
...............................................................................................700 .......................................................12.5 litres
.............................................................................................1000 .......................................................18.2 litres
............................................................................................ 1500 .......................................................22.1 litres
............................................................................................ 2000 .......................................................24.0 litres
............................................................................................ 2200 .......................................................24.5 litres
.............................................................................................2500 .......................................................25.0 litres

SECTION 21 - TRANSMISSION 5
1.2 TIGHTENING TORQUES
Strainer bolts....................................................................................................................................18 to 31 Nm
Pump retaining bolts ........................................................................................................................ 18 to 31 Nm
Output Yoke bolts ............................................................................................................................68 to 88 Nm
Pressure test plugs ..........................................................................................................................41 to 54 Nm
Main transmission case bolts........................................................................................................... 45 to 64 Nm
Shift detent plug ...............................................................................................................................41 to 54 Nm
Shift fork screws...............................................................................................................................18 to 25 Nm
Shift lever assembly screws.............................................................................................................16 to 24 Nm
Drain plugs.......................................................................................................................................34 to 54 Nm
Relief valve ......................................................................................................................................23 to 30 Nm
Pressure regulator valve ..................................................................................................................46 to 60 Nm
Cold start valve ................................................................................................................................46 to 60 Nm
4WD solenoid valve spool................................................................................................................20 to 27 Nm
4WD Solenoid coil retaining nut...............................................................................................................5.4 Nm
Control valve retaining screws .......................................................................................................6.8 to 8.5 Nm
4WD hydraulic pipe connections..................................................................................................6.8 to 10.2 Nm
Filter housing bolts...........................................................................................................................45 to 64 Nm
Oil filter...............................................................................................................................................7 to 10 Nm
Temperature sender ........................................................................................................................20 to 27 Nm
RECOMMENDED SEALANTS
Transmission case joint ...................................................................................................................Loctite 5203
4WD Output gear ...............................................................................................................................Loctite 649
4WD gear (Permanent 4WD assy) ....................................................................................................Loctite 649
4WD clutch supply pipe .....................................................................................................................Loctite 542
Gear lever housing...................................................................................................................Loctite 5900 RTV
Shimming access plug .......................................................................................................................Loctite 649

6 SECTION 21 - TRANSMISSION
1.3 TRANSMISSION CONTROLS
4X4 POWERSHUTTLE TRANSMISSION CONTROLS
1. GEAR LEVER: Four gears are selectable for the
required ground speeds in both forward or re-
verse travel.
2. TRANSMISSION DISCONNECT BUTTON: Prior
to changing gear depress and hold down this
switch which disengages transmission drive, se-
lect the required gear with the gear lever and re-
lease the switch to re-engage drive.
3. LOADER ATTACHMENT CONTROL LEVER
4. MECHANICAL DIFFERENTIAL LOCK PEDAL:
Depressing this pedal will lock both rear wheels
together giving equal drive and will disengage
when wheel torque equalizes or foot brakes are
applied.
5. TRANSMISSION SHUTTLE DIRECTION LE-
VER: Movement of this lever from the neutral
position will engage forward or rearward travel.
NOTE: in reverse gear an audible alarm device
sounds.
6. WARNING HORN BOTTON
7. TRANSMISSION DISCONNECT BUTTON (on
the loader attachment control lever)
8. ROLLER FOR THE PROPORTIONAL CON-
TROL OF LOADER BUCKET 4X1

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