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SERVICE MANUAL F106.7 / F106.7A / F156.7 / F156.7A Grader Tier III

Print No. 84329014A


Repair manual Grader

F106.7 / F106.7A F156.7 / F156.7A

Š 2010 CNH Baumaschinen GmbH Printed in Germany

84329014A

Edition 07-2010


CNH Baumaschinen GmbH

THE REPRINTING OR COPYING OF THIS REPAIR MANUAL EITHER WHOLELY OR PARTIALLY, REQUIRES PERMISSION IN WRITING FROM THE PUBLISHER

The information contained in these instructions are related to the time at which the manual is published. As we are constantly striving to improve our products and make additional options available, modifications may be made which affect the procedures described in these repair instructions. If you find descriptions or information that differ from your product, please contact your dealer.


REPAIR INSTRUCTIONS FOREWORD

F106.7 / F106.7A F156.7 / F156.7A

TO THE READER

mechanical assembly:

This repair manual is intended for professional repair technicians. It contains important information, needed for carrying out specialised repair work. Please read carefully through the repair manual, and also the operating instructions, before undertaking any repair work. Even if you are already familiar with the technology used in graders, please use this repair manual, but also use the operating instructions and parts catalogue for reference and guidance. The repair manual will allow the experienced construction machine mechanic to carry out the necessary repair work correctly.

technical description and information regarding the operation of essential systems and equipment;

information about performance tests on the machine;

troubleshooting and information for identifying faults on the machine;

technical information necessary for repair operations on the machine, the equipment necessary for carrying out repairs, information about maintenance standards, procedures for removal/installation and for disassembly/ assembly.

USE This repair manual refers to the machine version originally supplied. It does not describe any attachments that may be added or modifications that may be made at a later time. The repair manual contains the following information:

• • • • • •

Safety information Technical data and special tools Function description Performance test Troubleshooting and fault correction Repair instructions

The Safety Instructions section describes the recommended procedures for preventing the risk of injuries to the operator and the personnel responsible for maintaining and working on the machine. The Specifications section contains service data, conversion tables and lists of special tools and maintenance materials required. The other sections contain the following information for each

Edition 07-2010

You can use the list of contents to find the necessary information easily. The illustrations are partially simplified to make them more easily understood. Although it may result in apparent differences with your particular grader model, this is intended to make the information clearer.

REPAIR Carry out the required repair operations as soon as possible. Doing so will reduce repair costs and increase the availability of your grader. In all repair work, always follow the instructions in the workshop manual and operating instructions. Customer service will be pleased to assist you with a considerable number of work operations not described in the workshop manual. Always use only original replacement parts.

FURTHER REFERENCE MATERIAL In addition to the present manual, please also refer to the following documentation:

• •

84329014A

Operators Manual Parts catalogue

1


REPAIR INSTRUCTIONS OVERVIEW OF CHAPTERS

F106.7 / F106.7A F156.7 / F156.7A

OVERVIEW OF CHAPTERS

SAFETY INFORMATION

1

SPECIFICATIONS

2

ENGINE

3

TRANSMISSION

4

REAR AXLE

5

FRONT AXLE

6

EQUIPMENT

7

HYDRAULIC SYSTEM

8

BRAKES

9

STEERING SYSTEM

10

ELECTRICAL SYSTEM

11

CAB AND CAB FLOOR

12

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1

Chapter 1 SAFETY INFORMATION

CNH Baumaschinen GmbH Product documentation 13581 Berlin, Staakener Str. 53-63

84329014A

© 2010 CNH Baumaschinen GmbH July 2010


REPAIR INSTRUCTIONS SAFETY INFORMATION

F106.7 / F106.7A F156.7 / F156.7A

CHAPTER 1 TABLE OF CONTENTS

1

GRUNDLEGENDE SICHERHEITSHINWEISE ...................................................1-3

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.7.1 1.7.2 1.7.3 1.7.4 1.7.5 1.8

Warnhinweise und Symbole .......................................................................................................... 1-3 Intended use .................................................................................................................................. 1-3 Organizational procedures ............................................................................................................. 1-4 Personnel selection and qualifications - basic responsibilities ...................................................... 1-5 Safety information for specific phases of operation ........................................................................ 1-6 Special operations when using the machine, servicing and fault repair work as part of working procedure, waste disposal .............................................................................................................. 1-7 Notes on special types of hazard.................................................................................................... 1-8 Electrical energy ............................................................................................................................. 1-8 Gas, dust, vapour, smoke .............................................................................................................. 1-8 Hydraulic, pneumatic system.......................................................................................................... 1-8 Noise .............................................................................................................................................. 1-8 Oil, grease and other chemical substances ................................................................................... 1-8 Transport, towing and restarting .................................................................................................... 1-9

2

WARNING AND INSTRUCTION PLATES ........................................................1-10

2.1 2.2

Left side of vehicle ....................................................................................................................... 1-10 Right side of vehicle ..................................................................................................................... 1-12

3

OPERATION .....................................................................................................1-15

3.1 3.2 3.3 3.4 3.5 3.5.1 3.5.2 3.5.3 3.6 3.7 3.8 3.9

General information ..................................................................................................................... 1-15 Fuelling ........................................................................................................................................ 1-17 Fuelling system (optional) ............................................................................................................ 1-18 Driving .......................................................................................................................................... 1-19 Machine recovery / towing ........................................................................................................... 1-21 Towing device............................................................................................................................... 1-21 Transport ..................................................................................................................................... 1-21 Crane loading .............................................................................................................................. 1-21 Work operations ........................................................................................................................... 1-22 Using the grader .......................................................................................................................... 1-22 Attachments ................................................................................................................................. 1-23 SECURING THE MACHINE ........................................................................................................ 1-24

4

INSPECTION AND MAINTENANCE ................................................................1-25

4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.4 4.5 4.6 4.7 4.8 4.9

General information ..................................................................................................................... 1-25 Fuel system ................................................................................................................................. 1-29 Electrical system .......................................................................................................................... 1-30 Before working on the electrical system ...................................................................................... 1-30 Alternator ..................................................................................................................................... 1-30 Power relay (K10.1), start relay (K1.5) and grid heater power relay (K1.7) ................................. 1-31 Power shift transmission .............................................................................................................. 1-31 Hydraulic system ......................................................................................................................... 1-31 Brakes .......................................................................................................................................... 1-32 Wheels and tyres ......................................................................................................................... 1-33 Air conditioning (optional) ............................................................................................................ 1-35 Repair .......................................................................................................................................... 1-36

5

PROTECTING ELECTRONIC UNITS DURING WELDING WORK .................1-38

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5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5

Disconnect the connectors of the electronic units ....................................................................... 1-38 Transmission control “EST37A” (XA1) and front wheel drive control “FWD” (XA8.1) .................. 1-38 AIC connections ........................................................................................................................... 1-39 Engine control .............................................................................................................................. 1-39 Cab connector ............................................................................................................................. 1-40 Alternator connector .................................................................................................................... 1-40

6

VACUUM PUMP ................................................................................................1-41

6.1 6.2 6.3

General information ..................................................................................................................... 1-41 Scope of supply ........................................................................................................................... 1-41 Connecting the vacuum pump ..................................................................................................... 1-41

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1

BASIC SAFETY INFORMATION

1.1

Warning notes and symbols

The following symbols are used in the operating instructions to indicate particularly important information: ATTENTION: Safety rules and procedures, designed to protect the driver and others from mortal dangers or injuries, and to prevent serious damage to property. NOTE: Notes and precautions to avoid damage to machinery and property.

1.2

Proper use

This machine is constructed according to the recognized mechanical safety regulations, and using state-of-the-art technology. Nevertheless, when in operation, situations can occur that present serious or mortal dangers to the operator and others, or risks of damage to the machine and other property. The machine should be used only if it is in proper operating condition, and only by operators who are aware of the dangers, know the safety procedures, and have read the operating instructions! The important notes are placed at the start of this section. Immediately repair any faults (or have them repaired) if these could have a prejudicial effect on safety.

Only implements approved by CNH Baumaschinen should be used. No extensions or conversions may be made to units supplied. Only implements approved by CNH Baumaschinen should be used. Proper use of the machine also means following the operating instructions and applying the inspection and maintenance conditions. Using the grader for any other purpose, for example:

• • •

carrying passengers, as a working platform, towing or carrying loads without using the proper attachments, is considered improper use.

Improper use of the machine can present a mortal danger to operating personnel and others, and may cause physical injuries or extensive damage to property. The manufacturer/supplier will not be liable for any damage resulting from improper use. In this case, the user alone will be responsible. Noise emission data as stated in statutory order 3 pursuant to Equipment Safety Law of 18/01/1991 or EC Machinery Directive 89/392/EWG.

This Grader is principally designed for:

• • • • • •

Creating a finish grade surface Clearing top soils Scarifying old road surfaces and hard ground Cutting embankments Clearing ice and snow

Using earth-moving equipment properly, with driver seats that meet standard ISO 7096, 2008 EM 4 Class < 1.1 as described in ISO 7096:2008 Table 1, will ensure that the measured vibration frequencies (measured as described in ISO 2631 Part 1) meet the requirements regarding protection from wholebody vibrations.

Placing, spreading, mixing, and compressing materials.

The Grader can also be used in conjunction with other attachments for special applications. The Specifications provide clear information on this subject.

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Organizational procedures

Keep the operating instructions stored at the location where the machine is used, and in a place where they can be easily accessed, for example in the holder provided! In addition to the operating instructions, follow and draw attention to the general legal regulations and other obligatory requirements regarding accident prevention and environmental protection! These obligations and requirements may also apply to the handling of dangerous goods, the providing and wearing of personal protective equipment, or road traffic regulations. Supplement the operating instructions with additional instructions, including supervision and reporting requirements, in order to take account of the specific operating conditions, for example in relation to work planning, work procedures, and the personnel employed. Before starting work, personnel appointed to carry out work on the machine must have read the operating instructions, and particularly the Safety Information section. It will be too late to do this once the actual work has begun. This particularly applies to personnel who only work occasionally on the machine, e.g. for the purpose of setting up or maintenance. You must check, at least occasionally, that personnel can demonstrate safety and risk awareness, while following the operating instructions!

Check that all safety information and warning notices at or on the machine remain fully and clearly legible! If there are any changes that affect safety or the operating behaviour of the machine, stop the machine immediately and inform the person or department responsible! No modifications, conversions or retrofits that might affect safety must be made to the machine without the approval of the supplier! This also applies to the installation or re-adjustment of safety devices and valves, or welding work on load-bearing parts. Replacement parts must meet the technical requirements stated by the manufacturer. This can be ensured by always using original replacement parts. Replace hydraulic hoses at the stated or appropriate intervals, even if no defects affecting safety are visible. Carry out periodic checks / inspections at the intervals specified by regulations or in the operating instructions! When maintenance work is being carried out, fire extinguishers and their operating instructions must be displayed at a suitable place! Pay attention to fire detection and firefighting devices!

Loose or long hair must be tied up, and personnel must not wear loose clothing or jewellery, including rings. These cause a risk of injury, as they may be caught up or pulled into the machine. Where necessary, or when specified by the regulations, personal protective equipment must be worn! Pay attention to the safety information and warning notices on the machine!

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Personnel selection and qualifications - basic responsibilities

Only trained and reliable personnel should be allowed to work on or with the machine. Apply the minimum age required by law! Only use personnel who have been suitably trained or instructed, and clearly set out the responsibilities assigned for operating, setting up, maintenance, and repair!

Work on the machine's electrical equipment should only be carried out by a qualified electrician, or a trained technician under the supervision and guidance of a qualified electrician, in accordance with the electrical regulations. Work on the chassis and suspension, and the brake and steering systems should only be carried out by personnel trained for this purpose! Only personnel with the necessary skills and experience should be allowed to work on the hydraulics!

Ensure that only the personnel appointed for the task concerned is allowed to work on or with the machine! Define the responsibilities of the driver (also in relation to road traffic regulations) and authorize him/her to reject third-party instructions that would lead to a breach of safety regulations! Personnel being trained, instructed or briefed, or persons undergoing general training, must only be allowed to work on or with the machine if they are kept under constant supervision by an experienced person!

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F106.7 / F106.7A F156.7 / F156.7A

Safety information for specific phases of operation

Normal Mode Refrain from any working methods that might be prejudicial to safety! Before starting work, familiarize yourself with the particular working environment at the location concerned. This may concern obstacles in the work/ traffic area, the load-bearing capacity of the ground, and safety barriers necessary to close off the worksite from public traffic areas. Take steps to ensure that the machine is only operated when in a safe and operating condition! Only operate the machine if all protection devices and safety-related equipment, e.g. removable guards, emergency shut-off devices, noise insulation, and extractor systems, are present and in functional condition. The machine must be inspected at least once in each shift for visible damage and defects! Any changes that occur (including changes in operating behaviour) must be reported immediately to the department or person responsible! Stop the machine immediately and secure it! If there is a malfunction, stop the machine immediately and secure it! Faults must be repaired immediately!

Before starting work / moving off, check whether the brake, steering, lighting and signalling systems are operational! Before moving off, always check that attachments are secured to prevent accidents! If driving the machine on public roads, streets, or other areas, follow the road traffic regulations and, if necessary, bring the machine into a condition that complies with these regulations. In conditions of poor visibility or when dark, always switch on the vehicle lights! Passengers should only sit in the passenger seats provided for this purpose. When passing through underpasses and tunnels, and under bridges or under overhead lines etc., always ensure that there is sufficient headroom! Always keep at a sufficient distance from the edges of trenches and embankments! Do not use any working methods that might endanger the stability of the machine! Do not drive with overhead attachments placed in a transverse position; always drive with attachments and loads lowered and near the ground, especially when driving uphill/downhill!

Start the machine only from the driver's position! During switch-on/switch-off, pay attention to the control display as explained in the operating instructions! Before starting up the machine, ensure that no one will be at risk when the machine is started!

1-6

When on a gradient, always adapt vehicle speed to the particular conditions! Always shift to the lower gear range before coming to the gradient, never while driving on it! Before leaving the driver's seat, always secure the machine to prevent it moving off accidentally, and to prevent access by unauthorized persons! Switch off the engine!

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REPAIR INSTRUCTIONS SAFETY INFORMATION

1.6

F106.7 / F106.7A F156.7 / F156.7A

Special operations when using the machine, fault repair work and troubleshooting as part of working procedure, waste disposal

Apply the intervals specified in the operating instructions for adjustment, maintenance, and inspection tasks, and pay attention to the information and scheduled times for the replacement of parts and equipment components! These tasks should only be carried out by qualified personnel! Inform the operating personnel before starting special or repair operations! Appoint supervisors! When carrying out any tasks related to the operating, retrofitting or adjusting of the machine and its safety devices, and to maintenance, inspection or repair work, follow the switch-on/ switch-off procedures described in the operating instructions and the notes concerning repair operations! Whenever required, seal off the repair area, leaving plenty of room! If the machine is switched off completely for maintenance and repair work, it must be secured to prevent it being switched on accidentally:

â&#x20AC;˘ â&#x20AC;˘

Take out the key and

For maintenance work at greater heights, wear fallprotection! Keep all handles, steps, guard rails, landings, platforms and ladders clear of dirt, snow and ice! At the start of maintenance/repair work, clean any oil, fuel, or operating fluids from the machine, and particularly away from screw connections or other connections! Do not use aggressive cleaning agents! Use fibre-free cleaning cloths! If cleaning the machine using water or a steam jet (high-pressure cleaner) or other cleaning equipment, seal off or cover all openings where water/steam/cleaning agents should not be allowed to enter for safety or functional reasons. Electric motors and switching cabinets are particularly at risk. When carrying out cleaning work, ensure that heat sensors connected to fire detection and extinguishing systems cannot come into contact with hot cleaning fluids. These might trigger the fire extinguishing system. After cleaning, remove all covers and sealing plugs completely!

attach a warning sign.

Only carry out maintenance and repair work when the machine is parked on a level and sufficiently stable surface, and secured to prevent it moving off or buckling! When being replaced, individual components and major assemblies should be carefully fastened and secured to the lifting gear. Only use suitable and correctly functioning lifting gear and load-handling equipment, with sufficient load capacity! Do not stand or work under suspended loads! Only appoint experienced persons to attach loads and instruct crane drivers! Instructors must stand where they are visible to the operator, or be in contact with him by voice communications.

Edition 07-2010

For assembly work carried out above body height, use the appropriate safety hoists and work platforms provided for this purpose. Do not use machine parts as climbing aids!

After cleaning all fuel, engine oil, brake fluid, and hydraulic fluid pipes, examine them for leaks, loose connections, chafe marks and damage! Repair any defects immediately! When carrying out maintenance and repair work, always tighten any loose screw connections! If safety devices have to be removed for setting-up, maintenance and repair work, these should be put back in place immediately and inspected when the maintenance/repair work is completed. Dispose of operating fluids, auxiliary products and replacement parts safely, and without damage to the environment!

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Notes on special types of hazard

1.7.3

Electrical energy

Use only original fuses with the correct current rating! Switch the machine off immediately if there are faults in the electrical system! Keep the machine at a sufficient distance from overhead power lines! If working close to overhead power lines, keep the equipment away from the lines. Danger of death! Find out the required safety clearances!

Hydraulics, pneumatic system

Regularly inspect all pipes, hoses, and screw connections for leaks and visible damage! Repair any damage immediately! Spurting oil can cause burns and other injuries. Before starting repair work, any system blocks and pressure lines (hydraulic, compressed air) that are to be opened must first be depressurized as indicated in the descriptions of the assemblies! Hydraulic and compressed air lines must be correctly laid out and assembled! Do not get the connections mixed up!

If contact is made with high-voltage lines:

• • •

Do not leave the machine;

• •

Have the voltage switched off;

Hose fittings, length and quality must meet the requirements.

Drive the machine out of the danger area; Warn persons on the ground not to come near, or to touch the machine; Only leave the machine when the contacted/ damaged power line has been safely deenergized!

The machine's electrical equipment should be regularly inspected. Faults such as loose connections or charred cables must be corrected immediately. 1.7.2

Gas, dust, vapour, smoke

Only operate combustion engines and fuel-driven heaters in well-ventilated areas! If using the equipment in an enclosed space, ensure there is sufficient ventilation before starting!

1.7.4

Noise

Noise insulation devices must be in the protection position during operation. Wear the prescribed personal ear protection! 1.7.5

Oil, grease and other chemical substances

If handling oil, grease or other chemical substances, follow the safety instructions for the product concerned! Be careful when handling hot operating fluids and auxiliary materials (risk of burns and scalding).

Follow the local regulations applying at the worksite! Only carry out welding, firing, or grinding work on the machine if this has been explicitly approved these bring risks of fire and explosion. Before carrying out welding, firing or grinding work, clean away dust and combustible materials from the machine and its surroundings, and provide adequate ventilation (risk of explosion)!

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Transport, towing and restarting

Only use suitable means of transport and lifting gear, with sufficient load-carrying capacity!

Towing, loading and transporting should be carried out only as described in the operating instructions!

When restarting, follow only the described in the operating instructions!

procedure

If towing, use the specified transport position, and keep to the permitted speed and distance!

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2

WARNING SIGNS AND INSTRUCTION PLATES

2.1

Left side of vehicle

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ATTENTION: Read the warning signs and instruction plates on the machine. Keep these signs and plates clean and legible. Replace these plates immediately if they are no longer legible. New warning signs and instruction plates can be obtained from the spare parts department. When ordering, part numbers can be found on the replacement parts lists for the machine.

Legend for left side of vehicle 1. 2. 4. 7. 9. 10. 1. 12.

15. 16. 18. 19. 20.

Read the operating instructions Do not start up the machine before you have read and understood the operating instructions. Equipment can be secured here to prevent accidental operation. Risk of injury due to hot or rotating parts in the engine compartment. Only open the engine compartment cover when the engine has stopped. Risk of injury due to unauthorized starting of the machine. Before working on the machine, switch off the engine and remove the key. This plate indicates the maximum speed permitted on public roads. Permitted lifting points for crane loading. Risk of injury due to hot or pressurized hydraulic fluid. Follow the operating instructions. Risk of injury by crushing. Do not start up the machine if anyone is near the articulated joint. Risk of injury by crushing. Do not start up the machine if anyone is standing between the machine and an adjoining barrier. Noise emissions plate. LWA indicates the level of noise emissions in dBA (as stated in EC standard 2000/41/EG). Windscreen washer system. Water can be added here for the windscreen washer system. Permitted anchoring points for loading. Risk of injury. Never jump off the machine. Always wear a safety belt. Bonnet release. The bonnet can be released from the cab using the Bowden cable.

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F106.7 / F106.7A F156.7 / F156.7A

Right side of vehicle

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ATTENTION: Read the warning signs and instruction plates on the machine. Keep these signs and plates clean and legible. Replace these plates immediately if they are no longer legible. New warning signs and instruction plates can be obtained from the spare parts department. When ordering, part numbers can be found on the replacement parts lists for the machine.

Legend for right side of vehicle 2. 4. 5. 6. 7. 8. 9. 10. 12.

15. 18. 20. 22

At this point, the equipment can be secured against accidental start-up. Risk of injury from hot or rotating parts in the engine compartment. Only open the engine compartment cover when the engine has stopped. Risk of injury if engine hood falls shut. Close the engine hood by releasing the safety rod with the foot. Read the operating instructions before carrying out repair / maintenance work. Risk of injury due to hot coolant. Only take off the radiator cap once the radiator has cooled down. Coolant level marking. Risk of injury due to unauthorized starting of the machine. Before working on the machine, switch off the engine and remove the key. Fuel tank, diesel fuel can be added here. This plate indicates the maximum speed permitted on public roads. Permitted lifting points for crane loading. Risk of injury by crushing. Do not start up the machine if anyone is near the articulated joint. Risk of injury by crushing. Do not start up the machine if anyone is standing between the machine and an adjoining barrier. Noise emissions plate. LWA indicates the level of noise emissions in dBA (as stated in EC standard 2000/41/EG). Permitted anchoring points for loading. Indicates the emergency exit. Model plate.

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3

OPERATION

3.1

General information

F106.7 / F106.7A F156.7 / F156.7A

Do not operate the machine until you have read and understood the operating instructions. Pay particular attention to: the "Basic Safety Information" and all the warning signs and instruction plates attached to the machine. Before starting the machine, familiarize yourself with the positions, functions and operating direction of the controls. Operate the controls only from the driver's seat. Keep the operating instructions stored permanently on the machine.

OPERATING PERSONNEL Operating personnel must be experienced in working with and operating this or similar machines. The necessary know-how can be acquired through an instruction course that lasts a few days (possibly given by a technician), or by taking part in a driver training course.

PERSONAL PROTECTIVE EQUIPMENT AND WORK CLOTHES Wear a hard hat and protective shoes with non-slip soles. Smooth soles can slip on steps and pedals, thus causing injuries or operator errors. Wear close-fitting work clothes when operating the machine. Loose or wide items of clothing can cause the control lever to be operated accidentally.

SEAT BELT On machines with seat belts for operating personnel: Check the seat belt attached to the driver's seat. Replace immediately if damaged, or after an accident. Put the seat belt on before starting work.

Edition 07-2010

OPERATING CONDITION OF THE MACHINE Only operate the machine if in a reliable operating condition, and only as required by the regulations. Always follow the safety instructions. Always carry out inspections and maintenance work punctually (or have them carried out). Only operate the machine with the attachments and component combinations approved by the manufacturer. See the Specifications for clear information on this subject. Only attach and work with different equipment or component combinations if the manufacturer has checked and approved the planned type of assembly. Before starting work / driving, check whether the brake, steering, lighting and signalling systems are operational. Poor visibility can lead to accidents. Clean the windows, and the lenses on lamps, before operating the machine. Check whether all warning signs and instruction plates on the machine are present, and that they are clearly legible. GETTING IN AND OUT Face towards the machine when getting in or out. Use only the steps, platforms and handles provided when getting in or out. Keep steps, platforms and handles in a condition where they provide a secure grip. Clean them immediately if they become soiled with oil, grease, soil, mud, snow, ice, or other material. DANGER AREA The danger area is that area around the machine where anyone might come within the range of movement of the machine, its implements and attachments, swinging loads, falling loads, or lowering attachments.

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PERSONS IN THE DANGER AREA Warn bystanders with a horn signal before starting the machine. Check that no one is standing within the danger area around the machine. Stop working until all persons have moved out of the danger area.

MARSHALLER The marshaller must stand outside the danger area. You should have the marshaller assist you:

if you are unable to see the entire danger area around the machine,

• •

when reversing when manoeuvring.

Use only signs that will be understood both by you and the marshaller, or use an communication aid (e.g. radiophone / camera). The marshaller will not be able to understand unaided speech because of the operating noise from the machine. Remain in constant contact with the marshaller. Stop the machine immediately if you lose contact with the marshaller.

SECURING THE MACHINE Secure the machine as described in the section "Securing the machine", before:

• •

mounting / removing an attachment,

carrying out maintenance or repair work.

switching the machine off after everyday operations,

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3.2

F106.7 / F106.7A F156.7 / F156.7A

Fuelling

RISK OF EXPLOSION Fuel and fuel vapour are easily ignited and can explode into flame. Therefore, avoid causing sparks and do not use naked flames such as lighters or matches for illumination.

POSSIBLE RISKS TO HEALTH Diesel fuel and fuel vapour can be injurious to health. Fuel should not be swallowed. Also, avoid prolonged contact with the skin. Do not inhale fuel vapour. Wear protective gloves or use a barrier cream. Do not eat, drink or smoke while fuelling.

AVOIDING DAMAGE TO THE ENVIRONMENT Avoid allowing fuel to overflow. Do not allow fuel to penetrate into the soil, as this is dangerous for the environment. Spilled fuel should be soaked up immediately with a cleaning cloth or binding agent, then disposed of in an environmentally responsible way. Fuel accidents should be reported immediately to the licensee or his agent.

FUELLING FROM CANS If the machine is mostly or regularly fuelled from cans or drums, there is a greater risk that dirt particles and water will penetrate into the fuel system. In this case:

always pour in the fuel through a fine-mesh strainer

• •

only use siphon pipes along with a fine filter

drain the water and sediment from the fuel tank more often

replace all fuel filters at shorter intervals.

drain the fuel filter more often than indicated in the maintenance plan

ATTENTION: NEVER FILL WITH BIODIESEL Biodiesel can damage the engine and injection system. Use only diesel fuel produced from mineral oil, which meets EN 590 standard. For more information, contact your dealer's service department.

SECURING THE MACHINE When fuelling, secure the machine to prevent unauthorized start-up:

• • •

Park the machine on level and stable ground,

• • •

switch off the engine,

Fuelling always takes place from the ground, with the operator in a standing position.

lower the attachment to the ground, switch off fuel-driven auxiliary heaters and air conditioning systems, apply the parking brake. take the key out of the key switch for the electrical system

FUELLING Read and apply the "Fuelling safety instructions" before filling up with fuel.

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Fuelling system (optional)

RISK OF EXPLOSION! Do not smoke, and keep away from naked flames. Fuel and fuel vapour are inflammable; Danger of fire. Switch off fuel-driven auxiliary heaters and air conditioning systems.

PROTECTING HEALTH AND THE ENVIRONMENT Fuel can be harmful to the skin, so wear protective gloves or use a barrier cream. Do not allow fuel to penetrate into the soil, as this is dangerous for the environment. Spilled fuel should be soaked up immediately with a cleaning cloth or binding agent, then disposed of in an environmentally responsible way. Fuel accidents should be reported immediately to the licensee or his agent.

SECURING THE MACHINE When fuelling, secure the machine to prevent unauthorized start-up:

• • •

lower the attachment to the ground Switch off the engine take the key out of the key switch for the electrical system.

INCREASED RISK OF CONTAMINATION If the machine is mostly or regularly fuelled from cans or drums, there is a greater risk that dirt particles and water will penetrate into the fuel system. In this case, the fuel prefilter must be drained and cleaned more often than indicated in the maintenance plan. The fuel filter must also be replaced at shorter intervals.

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Driving

BEFORE MOVING OFF Before operating the machine, clean your work shoes to remove clinging soil, mud, snow, ice, grease and oil. These could cause the shoes to slip on the steps or pedals, thus causing unwanted movements.

DRIVING OVER LONGER DISTANCES The blade should not extend into the steering area of the front wheels, or of the steering linkage. The central warning lamp should not flash when the driver enters, otherwise determine the cause and switch off. If driving on public roads:

Before moving off, adjust the driver's seat, steering column and mirror, and fasten your seat belt.

Keep to the conditions operating licence.

Do not carry passengers on the machine.

• •

Close the driver cab doors.

Check the content of the first-aid box. Replace items that have been used, or which have become unusable.

Warn bystanders with a horn signal before starting the machine.

NO TOWING This machine is not suitable for towing trailers or other vehicles; Doing so would cause damage to axles and gears. The tow coupling is intended only for towing or recovering the machine from hazard areas, or for lashing onto transport vehicles; see "Towing/recovery".

DRIVING WITH HANGING LOADS Ensure that the wheels provide sufficient ground adhesion; only this will ensure braking/steering effectiveness. Do not drive with hanging loads positioned cross-wise. Do not attempt a U-turn with such loads. Do not attempt to position such loads using the articulated joint

REVERSING When reversing, the view of the danger area is reduced. Therefore, obtain assistance from an experienced marshaller. Agree on the meaning of signals with the marshaller, to ensure that the signals from the marshaller are correctly understood.

of

the

general

Take along a first-aid box, hazard warning triangle and warning lamp.

With the engine running, check:

That the steering wheel moves easily, by turning it briefly to the left and right, and that the steering gear responds.

Drive a short distance and operate the brake to check that the service brake is working effectively.

Never allow the machine to move with the gear lever in the "N" position, for example when driving downhill. If driving with the door open, this should be engaged in the end position. Before moving off, bring the machine up to operating temperature as described in the "Operating instructions - warming up". Only then should the engine be placed under full load.

PARKING THE MACHINE Machines parked on slopes can move off by themselves. Therefore, always park the machine on an even, horizontal surface, lower the attachment and its support to the ground.

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SEAT BELT Fasten your seat belt before every trip. Do not pass the seat belt over rigid or breakable objects, for example a bunch of keys or spectacles. This could result in bodily injuries. The seat belt must always lie firmly against the body and should not catch on anything. The belt buckle guide should not be obstructed (for example, with papers), otherwise the buckle tongue will not engage. Seat belts that are damaged, or which were stressed during an accident and have therefore been stretched, must be replaced.

ADJUSTING THE STEERING COLUMN Do not adjust the steering column while driving. Your attention will be distracted - RISK OF ACCIDENT! Before adjusting the steering column:

• • •

Stop the machine Gear lever in neutral position Apply the parking brake.

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F106.7 / F106.7A F156.7 / F156.7A

Towing /recovery

3.5.2

Transporting

Tow the machine with the tow bar or tow rope only.

Only load up and transport the machine if all the requirements of the safety regulations are met.

The tow bar / tow rope should not be damaged. It must be designed so that the calculated load at rupture is three times the tractive force of the towing machine.

Arrange the loading and transport with a company that is experienced in the transport of abnormal loads.

The towing vehicle must have sufficient tractive force. Drive slowly and carefully. No one should be standing near the tow bar/rope. Only tow the machine if the brakes and steering are functional and the machine cannot be transported any other way. If these are not functional, only tow the machine as far as is necessary to recover the machine from danger areas. After recovery, the machine must be secured to prevent it rolling, and prevent unauthorized start-up.

Responsibility for the loading and transport is borne by the transport company or their agent. To reduce the risk of slipping, clean the drive-on ramps and loading area on the transport vehicle and the wheels of the machine, in order to remove oil, grease, soil, mud, snow, ice and other materials. Use anchoring equipment with sufficient load capacity (for the weight specifications of the machine, see the "Specifications" section). 3.5.3

Crane loading

If loading with a crane, lock the articulated joint.

Before transporting over long distances, either repair the machine or load it onto a transport vehicle Towing speed should not go above 10 km/h. Tow the machine out of the danger area only, otherwise tow it on a low-bed trailer. Towing any further can cause damage to the transmission. 3.5.1

Towing devices

The towing devices should not be used for towing trailers.

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Everyday operation

3.7

Read carefully through the sections "Basic safety information" and "Operation - General information" and follow the instructions given. Before starting work, examine the worksite for embedded gas and water pipes, and electrical power lines. Damaging these lines can cause a lifethreatening situation! Before operating the machine, clean your work shoes to remove clinging soil, mud, snow, ice, grease and oil. These could cause the shoes to slip on the steps or pedals, thus causing unwanted movements of the machine.

Using the grader

Due to the versatility of the grader and the diversity of the materials, there are many possible applications and working methods. We therefore recommend having the driver instructed by the manufacturer. Read and pay attention to: “Operating instructions Warming up”. Do not exceed the machine's permitted transverse/ longitudinal tilt angle. Doing so will reduce or interrupt the engine lubrication. The permitted tilt angles of the machine are:

Transverse tilt: Left / right 35° 35°

If driving with the door open, this should be locked in the end position.

Longitudinal tilt: Downward / upward 35° 35°

Warn bystanders with a horn signal before starting the machine.

If the engine temperature, oil pressure or alternator warning lamps come on, lower the attachment immediately and switch the engine off.

Do not drive with hanging loads positioned crosswise. Do not attempt a U-turn with such loads. Do not attempt to position such loads using the articulated joint. Stop working if anyone is standing within the danger area around the machine. Start working only when all persons have moved out of the danger area. Always operate and use the machine in such a way that it remains stable. Ditches and trenches can collapse. Keep at a safe distance.

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Attachments and implements

PERSONNEL The assembly operations should be carried out only by operating or maintenance personnel who possess the required skills. If the personnel lack the necessary skills, they should be carefully guided by experienced personnel. They must have read and understood the operating instructions, particularly the "Basic safety information" section. During the assembly operations, only experienced personnel must be allowed to start the machine in order to make adjustments to the working tool. Operator errors with the machine or the working equipment can result in life-threatening situations.

PERSONAL PROTECTIVE EQUIPMENT AND WORK CLOTHES Wear close-fitting work clothes when working with the machine. Loose or wide items of clothing can become caught in machine parts, and thus cause injuries. Wear a hard hat, protective shoes and gloves.

TOOLS AND ACCESSORIES Tools, lifting gear, lifting accessories, support frames and other equipment must be in a reliable working condition. When driving in or removing fastening bolts, metal splinters may fly off and cause injury. Therefore, use a brass or copper drift for driving in or removing bolts, and wear safety glasses.

SECURING THE ATTACHNENT Lower the attachment to the ground, so that it will not move when mechanical or hydraulic connections are loosened. If the machine has to be jacked up, secure the front axle with wedges to prevent swinging. If working near the articulation, lock the joint. Remove all locking and securing devices when the work is complete. If work tools or tool parts are to be attached or removed, or adjusted while in position, they should be secured with suspension/propping equipment to prevent unintentional movements, slipping or falling

SECURING THE MACHINE Only carry out work on the attachment if the machine has been secured as described in the section "Securing the machine".

CHOOSING THE ATTACHMENT The machine can be equipped with a variety of working attachments. The components of the attachment are made up of hydraulic cylinders and connecting parts. Various component combinations are possible in order to adapt the working attachment optimally to the type of application Only operate the machine with the attachments and component combinations approved by the manufacturer. Equipment supplied by other manufacturers, to which EC machines guideline 89/392 EWG applies, should only be attached and operated if they carry

â&#x20AC;˘ â&#x20AC;˘

the manufacturer's statement of conformity the statement of compatibility.

Use only the steps, platforms and handles provided when getting in or out. Keep steps, platforms and handles in a condition where they provide a secure grip. Clean them immediately if they become soiled with oil, grease, soil, mud, snow, ice, or other matter.

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SECURING THE MACHINE

RISK OF INJURY The machine should not be started by unauthorized persons. It should therefore be secured

before any maintenance and repair work on the machine

before adding or changing attachments

. Secure the machine as described below:

Park the machine on level ground with sufficient load-carrying capacity.

• • •

Lock the articulated joint. Lower the working equipment to the ground. Apply the parking brake.

NOTE: Do not stop the engine when under full load, but let it run for about three to five minutes to allow temperatures to equalise.

• •

Switch off the engine.

• • •

Depressurize the hydraulic system.

Before working on the electrical system, disconnect the batteries.

Before carrying out welding operations on the machine, read the section "Repair - Welding work.

Turn the electrical system key switch to 0 and take out the key. Secure open engine hoods Secure the machine with chocks to prevent it rolling.

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4

INSPECTION AND MAINTENANCE

4.1

General information

Repair manual Before starting work, personnel appointed to carry out work on the machine must have read and understood the repair manual. Pay particular attention to: Basic Safety Information " and all the warning signs and instruction plates attached to the machine. The repair manual contains all the technical information necessary for carrying out maintenance and repair work on the machine. Work on the machine should only be carried out by personnel trained for this purpose!

INSPECTION AND MAINTENANCE PERSONNEL The inspecting and maintenance personnel must have experience in the inspection and maintenance of these or similar machines. The necessary know-how can be acquired through an instruction course that lasts a few days (possibly given by a technician), or by taking part in a driver training course.

If attachments or implements are to be mounted / removed, or adjusted while in position, they should be secured with suspension/propping equipment to prevent unintentional movement, slipping or dropping.

SECURING THE MACHINE Only carry out work on the working equipment if the machine has been secured as described in the section "Securing the machine".

GETTING IN AND OUT Use only the steps, platforms and handles provided when getting in or out. Keep steps, platforms and handles in a condition where they provide a secure grip. Clean them immediately if they become soiled with oil, grease, soil, mud, snow, ice, or other material. Face towards the machine when getting in or out.

CHECK THE CONDITION OF TOOLS Only work with fully functional and reliable tools. Choose only tools that are suitable for the task.

PERSONAL PROTECTIVE EQUIPMENT AND WORK CLOTHES Wear close-fitting work clothes when working with the machine. Loose or wide items of clothing can become caught in machine parts, and thus cause injuries. Wear a hard hat, protective shoes and gloves, and ear protection if there is loud noise. SECURING THE WORKING EQUIPMENT Lower the working equipment to the ground, so that it will not move when mechanical or hydraulic connections are loosened.

Ill-fitting wrenches, for example, may slip off and cause injury.

CLEANING OPERATIONS Before starting work, clean up any assemblies located in the work area. The choice of cleaning agent will depend on the type of material in the parts to be cleaned. For example: Do not use solvents or steam jets to clean electrical or rubber components.

If working near the articulation, lock the joint. Remove all locking and securing devices when the work is complete. If the machine has to be jacked up, secure the front axle with wedges to prevent swinging.

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Use only fibre-free cleaning cloths to clean the hydraulic system or the engine. Cleaning agents and solvents can give off highly inflammable or noxious vapours. Only use such products in areas that are well ventilated - do not inhale the vapour, and do not smoke. Do not allow cleaning agents and solvents to come into contact with the skin. Wear solvent-resistant gloves. Follow the instructions on the product packaging.

HANDLING COMBUSTIBLE FLUIDS When handling combustible fluids:

• •

Avoid contact with the skin. Wear gloves and closefitting work clothes. Old oils can be injurious to health if they come into contact with the skin. If this occurs, wash the skin thoroughly with warm soapy water and apply a protective cream. Do not use fuels or solvents to clean the skin. If you have accidentally swallowed oil, do not induce vomiting, but seek medial assistance immediately.

VISIBLE OIL LEAKS If there is a visible oil leak, repair the leak immediately.

do not smoke, no open lights or naked flames.

Fuel and other operating fluids often have low flashpoints and are easily ignited. Do not use water to extinguish burning fluids. Instead, use:

• • •

Stand out of the direction of the oil spray.

Leaking oil is a danger to the environment! Use an oil binding agent to absorb any spilled oil. Gather up the binding agent and dispose of separately from other waste.

powder extinguisher, carbon dioxide or foam extinguishing equipment.

When it comes into contact with burning fluids, water vaporises abruptly and can cause burning oil to spray over a large area. Water will cause short-circuiting in the electrical system, thus possibly creating additional dangers. Notify the fire department.

FASTENINGS AND FIXING ELEMENTS Examine any fastenings and fixing elements, e.g. bolts, nuts and washers, before re-use.

RELEASE ANY RESIDUAL PRESSURE IN THE HYDRAULIC SYSTEM Hydraulic systems should only be opened after they have been depressurized. Even when the machine is parked on a horizontal surface, with the working equipment lowered to the ground and the drive motor switched off, a considerable amount of residual pressure can remain in some parts of the hydraulic system, for example, primary pressure due to the final hydraulic movements before the machine was stopped. This residual pressure is only released gradually. If work on the hydraulic system is required immediately after switching off, release the residual pressure as described in the section "Hydraulic system".

Replace damaged parts.

HANDLING OILS AND LUBRICANTS Risk of burns due to the uncontrolled release of hot lubricants or hydraulic fluid. If burns occur, chill immediately with running water, then apply a dry bandage.

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SCREW CONNECTIONS, PIPES, HYDRAULIC HOSES Repair any leaks in the pipe system immediately. A fine spray of hydraulic fluid at high pressure can penetrate the skin. Do not try to locate leaks with the fingers, but use a piece of cardboard and wear protective goggles. If fluid has penetrated the skin, seek medical assistance immediately. Do not repair damaged pipes, but replace them with new ones. Replace hydraulic hoses immediately if there is visible damage or seepage.

ENGINE EXHAUST Exhaust gases are harmful to health - do not inhale. If working in enclosed spaces an exhaust gases are present, use an extractor to evacuate the gases and keep the room well ventilated.

HANDLING BATTERIES Batteries give off explosive gases. Do not bring open lights or naked flames near batteries, and do not smoke. Remove the batteries, if welding or grinding work is to be carried out nearby. Take the batteries to a safe distance. Battery acid is poisonous and corrosive.

Only re-tighten depressurizing.

leaking

screw

plugs

after Avoid contact with the skin, mouth, eyes and clothing. Do not spill battery acid, and do not inhale acid vapour.

Leaking oil is a danger to the environment!

DISPOSE OF ENVIRONMENTALLY Oil, grease, brake fluid, cleaning agents, solvents and oil-containing parts, e.g. filters, cleaning cloths, replaced parts and unusable machine parts should be disposed of separately from each other, with respect for the environment Do not include these materials with normal household waste.

When handling batteries, wear acid-resistant gloves, close-fitting clothes and protective goggles. If acid comes into contact with the skin, wash thoroughly with water and seek medical assistance. If acid spray gets into the eyes, rinse thoroughly with running water and call an eye specialist immediately, or go to a hospital A&E department.

Put them into the containers provided for this purpose.

Do not place tools on the battery. This can cause a short circuit, which would ruin the battery and could cause injury.

Even bio-degradable "environment-friendly" hydraulic fluid must be disposed of separately, like any other oil.

Do not wear metal necklaces, bracelets or watch straps when working on the battery. Metal parts can cause a short circuit and possible burn injuries.

Do not allow oils and oily waste to penetrate the soil or water courses, as this would endanger the environment!

Dispose of old batteries separately from other waste, and with respect for the environment.

SEALING SURFACES Clean the sealing surfaces before assembling.

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BEFORE WORKING ON THE ELECTRICAL SYSTEM Before carrying out work on the electrical system, during which tools, replacement parts etc. could come into contact with electrical lines or contacts, disconnect the battery:

â&#x20AC;˘

disconnect the negative terminal first, then the positive.

When work is complete:

â&#x20AC;˘

connect the positive terminal first, then the negative.

AFTER MAINTENANCE To prevent corrosion damage, coat all bare metal machine parts with a film of grease. When the work is completed, re-attach all safety devices. Only start the drive motor when no one is working on the machine. Carry out a function test on the machine.

Read and pay attention to the "Electrical system" section

CHOOSING OILS / LUBRICANTS Only use the recommended grades, viscosities according to temperature level.

select

FILTERS Replace all filter elements and /or cartridges at the stated times. All filters are carefully selected to suit the equipment concerned. Trouble-free operation and long service life for the engine and hydraulic assemblies can only be ensured by using original replacement parts.

SEALS When removing components, pay attention to their seals. Before installing, check the seals and replace them even if only slightly damaged. Check that they are correctly seated when assembling.

CHECK OIL LEVEL / OIL CHANGE Place the machine horizontally. Change the oil when the machine is warm. Warm oil flows better and carries particles in suspension better (oil carbon and abrasion particles).

GREASE LUBRICATION Clean the lubricating nipples, then lubricate as indicated in the lubrication plan.

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F106.7 / F106.7A F156.7 / F156.7A

Fuel system

RISK OF EXPLOSION DUE TO FUEL VAPOUR Fuel vapour is highly inflammable and can burst into flame. Therefore, avoid causing sparks and do not use naked flames such as lighters or matches for illumination. If you have to work on the fuel system:

• • • •

switch off the engine and auxiliary heater, secure the machine,

FUELLING FROM CANS If the machine is mostly or regularly fuelled from cans or drums, there is a greater risk that dirt particles and water will penetrate into the fuel system. In this case:

always pour in the fuel through a fine-mesh strainer,

drain the fuel filter more often than indicated in the maintenance plan,

drain the water and sediment from the fuel tank more often,

replace all fuel filters at shorter intervals.

avoid using naked flames, do not eat, drink or smoke.

POSSIBLE RISKS TO HEALTH Diesel fuel and drained water / fuel mixtures can be injurious to health. These fluids are harmful if swallowed. Also, avoid prolonged contact with the skin. Do not inhale fuel vapour. Wear protective gloves or use a barrier cream.

AVOIDING DAMAGE TO THE ENVIRONMENT Collect overflowing fuel in a container and dispose of it without causing damage to the environment. Dispose of fuel filters and fuel-soaked cleaning cloths separately from other waste. NOTE: NEVER FILL WITH BIODIESEL! Biodiesel can damage the engine and injection system. Use only diesel fuel produced from mineral oil, which meets EN 590 standard. For more information, contact your dealer's service department.

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F106.7 / F106.7A F156.7 / F156.7A

Electrical system

4.3.2

Risk of injury from battery acid and gases. Wear protective goggles, work gloves and closefitting work clothes.

4.3.1

Switch off the engine.

Disconnect the control units and control console from the on-board electrical system.

Turn the electrical system key switch to 0 and take out the key.

Before carrying out work on the electrical system, during which tools, replacement parts etc. could come into contact with electrical lines or contacts, disconnect the batteris. disconnect the negative terminal first, then the positive.

When work is complete:

connect the positive terminal first, then the negative.

Read and follow the instructions in "Operating instructions- Alternator, control units and control console”. Read and pay attention to the section "Inspection and maintenance - General information. Use only measuring instruments for carrying out voltage tests and continuity checks. Do not use test lamps. Do not "short to ground". The resulting short circuit will cause damage to the alternator or to the electronics.

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Never disconnect the electrical connections at the alternator, regulator or battery while the engine is running. This will damage the alternator and regulator When connecting the batteries, do not mix up the cables (check the polarities).

Before working on the electrical system

• •

Alternator

Use only measuring instruments for carrying out voltage tests and continuity checks. Do not use test lamps. Do not "short to ground". The resulting short circuit will cause damage to the alternator or to the electronics. When the engine is started, the alternator is actuated (pre-excited) by an electronic circuit. This ensures that the alternator is able to deliver power. This circuit is part of the main electronic system in the control console. A LED (charge indicator)on the control console indicates whether the alternator is functioning correctly. This LED must light up when the key switch is turned to the On position; it should go off once the engine is running. If this is not the case, then there is a fault in the alternator electrical circuit or in the control console. To prevent further damage, the cause of the fault must be found and resolved as quickly as possible. Contact your dealer's service department.

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4.3.3

F106.7 / F106.7A F156.7 / F156.7A

Power relay (K10.1), start relay (K1.5) and grid heater power relay (K1.7)

ATTENTION: Mortal danger due to short-circuit! For safety reasons, disconnect the positive terminal of the battery before removing / replacing the relay cover (1).

4.4

Powershift Transmission

Read and pay attention to: "Inspection and maintenance - General information.â&#x20AC;? Since the torque converter of the power shift transmission can drain into the transmission when the engine is off, the oil must be checked with the engine running. It is therefore essential to apply the safety measures listed in the next sections.

4.5

Hydraulic system

RISK OF INJURY From hydraulic fluid at high pressure.

1

From hot hydraulic fluid or hot engine parts.

If the cover is removed and if for any reason the relay protective caps have slipped, there is a risk that the cover panel can touch the relay contact and ground at the same time.

Before working on the hydraulic system, ensure that the system is depressurized, and that residual pressure has also been released (see section "Hydraulic system"). Switch off the engine and allow the machine to cool down. Secure the machine as described in the section "Securing the machine". Do not allow the skin to come into contact with hydraulic fluid. Hydraulic fluid can be harmful if it comes into contact with the skin. Wear gloves and close-fitting work clothes. Read and pay attention to: "Inspection and maintenance - General information.

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Brakes

PERSONNEL Only carry out inspection and maintenance work on the brakes if you have been trained to work on brake systems. If in doubt, have this work carried out by our service department. Read and apply the section "Inspection and maintenance - General information. SECURING THE MACHINE Only carry out inspection and maintenance work on the brakes if the machine has been secured as described in the section "Securing the machine". HEALTH PROTECTION Do not inhale abrasion dust - wear a dust mask.

HYDRO - PNEUMATIC The hydraulic system contains pressure reservoirs. These pressure reservoirs contain nitrogen, which is maintained at high pilot pressure. Even when the pressure in the hydraulic system has been released, the nitrogen in the reservoir remains pressurized. When in operation, pressure reservoirs are quite safe. However, there is a risk of explosion if handled incorrectly! Therefore:

Do not perform any mechanical work on the pressure reservoir - no welding or soldering.

Inspection and maintenance work should be carried out only by skilled personnel.

The system must be depressurized before any inspection or maintenance operations are carried out.

Before disassembling the pressure reservoir, wear protective goggles and work gloves.

Fill the pressure reservoir with nitrogen only. Never use compressed air or oxygen.

Report any faults or damage immediately to the machine's licensee.

Before starting up again, the machine must be inspected by a skilled / experienced technician if the pressure reservoir has been damaged, or the permitted operating temperature or pressure have been exceeded.

Do not remove or paint over warning signs and instruction plates, or the model plate or stamped model badge. Replace illegible or damaged plates immediately.

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F106.7 / F106.7A F156.7 / F156.7A

Wheels and tyres

RISK OF INJURY Gas combustion due to heating of the tyres can cause explosions in air-filled tyres. This heating may be due to frequent braking, or due to welding work carried out on the machine. Explosions that occur in this way are much more violent than the normal bursting of a tyre. They can cause pieces of tyre and wheel rim to be flung to a distance of several hundred metres. Exploding or bursting tyres and flying parts of rims can cause very serious injuries, which can even be fatal in some cases.

TYRE PRESSURES Bursting tyres and flying rims or parts of rims can cause serious injuries. Therefore:

Before inflating, check tyres, rims and rim parts for damage. Check that they are firmly seated, and check for any foreign bodies that may have penetrated.

If damage is found, always have this repaired immediately at a specialised workshop.

Check tyre pressures only when the tyres are hot; tyre pressure increases as the tyres become heated.

Use a fill valve with long hose, self-holding nozzle and pressure gauge.

Pump up the tyres only with compressed ambient air. Never use combustible gases risk of explosion!

While pumping, keep away from the tyre and stand facing the tyre tread.

Watch the tyre and pressure gauge constantly while pumping is in progress, and never exceed the specified tyre pressures.

If a wheel is removed, place a safety cage around it.

While pumping, ensure that no one is standing near the tyre.

Therefore:

• •

If you suspect that a tyre has become too hot, secure the machine and wait at a safe distance until it has cooled down. Before inflating, check tyres, rims and rim parts for damage. Check that they are firmly seated, and check for any foreign bodies that have penetrated.

If damage is found, always have this repaired immediately at a specialised workshop.

If you feel that tyres, rims or parts of rim may be unsafe, have the entire wheel removed from the machine at a specialised workshop. When changing tyres, rims or rim pieces, special tools and procedures are required. Therefore, always have this type of work carried out at a workshop that has the appropriate specialised equipment.

Do not carry out any work on tyres and rims if you have not received the appropriate training.

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Always pump the tyre to the specified air pressure:

Excessively high pressures will cause poor handling on the land, and the danger of bursting tyres.

Pressures that are too low will lead to increased tyre wear, and will make the machine less stable.

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WHEEL NUTS Always tighten the wheel nuts with a torque wrench. After a few hours of operation, use the torque wrench to check that they are still firmly attached.

DRIVING ON ROADS When driving on roads, ensure that tyres have the required minimum tread depth and that they are at the correct pressures. Ensure that only tyres of the same size are fitted on the same axle and that they show the same degree of wear. Different tyre diameters can cause damage to the rear-axle differential. You can prevent excess tyre wear by: keeping tyres at the correct pressure; not braking or starting off abruptly; not driving too fast around bends. Before driving on public roads, clean the tyres and spaces between tyres. This will prevent hazards to other road-users caused by dirt tracks left on the road or stones and lumps of earth thrown off by the tyres.

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F106.7 / F106.7A F156.7 / F156.7A

Air conditioning system (optional)

This section describes the inspection and maintenance work to be carried out by the machine operator. In addition, work on the air conditioning system requires specialised knowledge and special tools, and should therefore only be carried out by qualified personnel. In this case, call a workshop that specialises in air conditioning systems. For your own safety, please pay attention to the following instructions: Do not reach inside the equipment and do not insert any objects. Switch off the engine and allow it to cool down before carrying out maintenance work. Disconnect the fan from the power supply, to prevent injuries caused by the fan being switched on accidentally. Some parts of the air conditioning system (for example, heat exchanger and heating resistor on the fan) may still be hot after switching off. Risk of burns. Allow these to cool before opening up the equipment.

WHEN WORKING ON THE REFRIGERANT CIRCUIT (FOR QUALIFIED PERSONNEL): The refrigerant used (R 134a) is known as a safety refrigerant. This means that it is non-combustible, nonexplosive, non-toxic, non-irritant, odourless and tasteless. Nevertheless, please note the following points: Avoid contact with flowing refrigerant. Chill blains may be occur on skin that has come into contact with refrigerant. Tragen Sie zum Schutz der Augen eine Schutzbrille. If refrigerant still gets into the eyes, seek medical assistance immediately. Before carrying out repairs to the air conditioning system, drain the system. Do not allow refrigerant to leak out into the environment. Use only approved siphoning equipment. Welding work should not, in any circumstances, be carried out on parts of the sealed system, or in the area immediately surrounding it. Whether the system is full of refrigerant or not, heating it will cause a very high overpressure, which may cause damage to the system or even cause it to explode. Refrigerant containers should not be thrown and, when full, should not be left exposed for long periods to direct sunlight or other heat sources. The temperature of a filled refrigerant container should not be allowed to go above 45°C. It is very important to keep chlorine, chlorinecontaining materials, oil or grease away from the refrigerating system. The draining/filling equipment should be used only for R134a.

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REPAIR INSTRUCTIONS SAFETY INFORMATION

4.9

F106.7 / F106.7A F156.7 / F156.7A

Repair

Repair manual Do not carry out repair work until you have read and understood the repair manual. Pay particular attention to

• •

Lower the machine and remove the wedges when the work is complete.

“Basic safety information”, "Inspection and information”

maintenance

-

General

and

BLOCKING THE AXLES If the machine has to be jacked up, secure the front axle / rear axle with wedges to prevent swinging.

all warning signs and instruction plates attached to the machine.

The descriptions of work procedures contain information intended only for experienced personnel. Keep the operating instructions stored permanently at the machine.

REPAIR PERSONNEL The repair personnel must have specialised knowledge and experience in repairing this or similar machines. If the personnel lack the necessary skills, they should be carefully guided by experienced personnel. This kind of service can be provided by the service department.

PRE-TENSIONED ASSEMBLIES Do not open pre-tensioned assemblies if damaged replace them completely. In exceptional cases, they should only be opened if the personnel know the exact working procedure and the special tools required are available. The operating instructions do not provide any information on this subject.

DISASSEMBLING COMPONENTS Do not disassemble when the machine is warm. Oil, grease, brake fluid or coolant can reach high temperatures and can therefore cause burns and scalds. Allow the machine to cool down. Before starting work, depressurize pipes and hoses, cylinders, radiator, hydraulic tank, compressed air reservoir and other systems and assemblies. Replace damaged components promptly - this will prevent more serious damage later.

WORKING AT HEIGHTS For maintenance work at greater heights, wear fallprotection.

Clean faulty disassembling.

Attach a tested safety harness - this must be fitted with a fall arrester and safety ropes.

Mark disassembled parts in the order they were removed - this will make re-assembly easier.

LOCKING THE ARTICULATED JOINT If carrying out repairs near the articulation, lock the articulated joint. Remove the locking device when the work is complete.

1 - 36

components

carefully

before

When removing components, carefully seal off any exposed hose and pipe connections, and open bore holes and casings, to prevent dirt from entering.

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REPAIR INSTRUCTIONS SAFETY INFORMATION

F106.7 / F106.7A F156.7 / F156.7A

DO NOT REMOVE LEAD SEALS Do not change the nominal pressure of pressure limiting valves without express approval from the manufacturer. Do not remove the lead seals from pressure limiting valves and pressure reservoirs.

AFTER REPAIR To prevent corrosion damage, coat all bare metal machine parts with a film of grease.

If you have any problems or questions, please contact your dealer's service department. If parts of the machine have to be removed, read and follow the instructions in paragraph "Attachments and implements", and in sections "Inspection and maintenance - General information" and "Repair. Before carrying out welding work on the machine:

Disconnect the battery. Disconnect the negative terminal first, then the positive terminal.

Disconnect alternator.

Only start the drive motor when no one is working on the machine.

Pull out the connectors of the control units of the electronically controlled front wheel drive and power shift transmission.

Pull out the control console connector.

Test the functions of repaired components and all the machine functions in a trial operation.

Protect disconnected terminals and connectors from short circuits and dirt. Cover them with adhesive tape or film.

Only release the machine to be started up again if it performs all functions correctly.

Attach the welding current terminals directly to the weld.

When the work is completed, re-attach all safety devices, covers, noise insulation and vibration dampers.

WELDING WORK Only carry out welding work if you are trained for this kind of work. Follow the accident prevention regulations On containers that contain, or which contained, materials that:

• • •

have

the

positive

terminal

at

the

The welding current should not flow through the rotary joint, bolts, hinge joints or hydraulic cylinders. When the welding work is completed, restore all electrical connections. When re-connecting the battery, connect the positive terminal first, then the negative terminal.

are combustible or assist combustion, are potentially explosive, may give off harmful gases, vapours, mist, or dust during welding work,

all work should be carried out only with a competent supervisor present and only by persons specially trained for this kind of work.

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REPAIR INSTRUCTIONS SAFETY INFORMATION

5

F106.7 / F106.7A F156.7 / F156.7A

PROTECTING ELECTRONIC UNITS WHEN WELDING

ATTENTION: To prevent damage to electronic equipment when welding (e.g. AIC display, keypad, engine, etc.), follow the steps below.

• •

Switch off the engine.

Disconnect the control units and control console from the on-board electrical system, as follows.

Turn the electrical system key switch to 0 and take out the key.

5.1

Press locking lever (1) away from the connector and pull connector (2) upward and away from the FWD control (A). There is an extension (lug) on the front of the connector that has to be detached.

Loosen and pull off the connector transmission control EST37A (B), described above.

for as

2

Disconnect the connectors of the electronic equipment

B

A

The connectors of electronic components have to be disconnected at various places.

5.1.1

• •

1

Transmission control “EST37A” (XA1) and front wheel drive control “FWD” (XA8.1)

Remove the right side storage compartment.

2

Remove panels. Loosen the 3 screws with an Allen wrench and keep them in a safe place.

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5.1.2

F106.7 / F106.7A F156.7 / F156.7A

5.1.3

AIC connections

Engine control

A

1

B 1

1 1

C

The AIC is located under the panel behind the steering wheel. This panel is fastened to the steering column by 4 screws.

The engine control connectors (A, B, C) are located under the engine bonnet on the left of the engine.

• •

Raise the hood. Cut through cable tie (1), press locking lever (2) away from the connector, and pull off the engine control connectors (A, B). There is an extension (lug) on the front of the connector (C) that has to be detached.

Pull off connectors (1 + 2) from the AIC.

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REPAIR INSTRUCTIONS SAFETY INFORMATION

5.1.4

F106.7 / F106.7A F156.7 / F156.7A

5.1.5

Cab connectors

Alternator connector

2 B

A

1

Release the catch (1) and pull off connector (2) from the alternator. After completing all the above steps, welding work can be carried out on the machine (see and follow the instructions in paragraphs: “Welding work, safety instructions" and "Welding information). When the welding work is completed, restore the connections for all electronic components. To do this, follow the above steps in the reverse order.

C

ATTENTION: Failure to follow the above procedure will void the warranty and the manufacturer will not be liable for any resulting damage. The connectors (A, B are located on the right under the cab floor. Connector (C) is located at the rear left of the cab floor.

• •

Place the bonnet in service position II. Release connectors (A, B) and (C) and pull off.

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6

F106.7 / F106.7A F156.7 / F156.7A

VACUUM PUMP

NOTE: The images below are intended only to illustrate the above steps, and may not show your particular model.

6.1

General Remarks

When disassembling hydraulic pipes and pumps, fluid will flow from the hydraulic tank. In this case, a vacuum pump can be supplied for the machine as special equipment; when correctly installed, this pump will prevent the hydraulic tank from draining out. For longer repair operations, a case with a complete assortment of environmental protection plugs and stoppers can be ordered. These can be used, for example, to seal off disconnected pipes.

6.2

6.3

The vacuum pump is connected to the vehicle batteries. Therefore, the pump should be operated only briefly, for example while changing hoses or when inserting plugs and stoppers.

Depressurise the hydraulic tank. To do this, give the vent valve (1) about a 1/2 turn to open. After the air has been released (hydraulic tank is now depressurized), remove the vent valve completely.

Place vacuum pump (3) on the hydraulic tank. The vacuum pump must be at a higher level than the fluid in the hydraulic tank.

Press hose fitting (4) (4) carefully into opening (2).

Run the cable (5) to the batteries. First, connect the positive clamp (6) lead (6) to the positive terminal, then the negative clamp (7) to the negative terminal.

Switch on vacuum pump (3) using switch (8). The hydraulic system fluid is first pumped up into the hydraulic tank. Air is then drawn continuously into the hydraulic tank by the fluid, causing bubbling at the surface. The resulting vacuum prevents fluid from flowing out of the tank. The pressure on the pressure gauge must be 0.2 bar. If this is not the case, use the rotary switch (10) to adjust to the correct pressure.

Package content

GT3_00_003

1 2 3 4 5 6 7 8 9 10 11 12

Vacuum pump connection

Vacuum pump complete Positive terminal Cable lug Negative terminal Hose clip Hose, length 1.1 m Hose clip Filter Hose, length 0.13 m Tube Buffer Tube

To carry out the work required, for example changing hydraulic pipes, seal off all openings immediately with environmental stop plugs. When doing this, do not stop the vacuum pump. NOTE: When the work is completed, switch off the pump again. Disconnect cable (5) from the battery. First the negative terminal, then the positive terminal. Perform the above steps in the reverse order.

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2

Chapter 2 SPECIFICATIONS

CNH Baumaschinen GmbH Product documentation 13581 Berlin, Staakener Str. 53-63

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© 2010 CNH Baumaschinen GmbH July 2010


REPAIR INSTRUCTIONS TECHNICAL DATA

F106.7 / F106.7A F156.7 / F156.7A

CHAPTER 2 TABLE OF CONTENTS

1

Dimensions ........................................................................................................2-3

1.1 1.2

Main dimension F106.7 / F106.7 A ................................................................................................ 2-3 Main dimension F156.7 / F156.7 A ................................................................................................ 2-4

2 3 4

Engine .................................................................................................................2-5 Torque converter ...............................................................................................2-5 Transmission .....................................................................................................2-5

4.1

Gear ratios ..................................................................................................................................... 2-6

5

Tyres ...................................................................................................................2-7

5.1 5.1.1 5.1.2 5.1.3

Tyre types and air pressures ......................................................................................................... 2-7 F106.7 / F106.7A ........................................................................................................................... 2-7 F156.7 / F156.7A ........................................................................................................................... 2-7 Wheel nut torques .......................................................................................................................... 2-7

6 7 8 9

Rear axle .............................................................................................................2-7 Front axle ............................................................................................................2-7 All-wheel drive ...................................................................................................2-8 Hydraulic system ...............................................................................................2-8

9.1 9.2 9.3 9.4 9.5 9.6

Working equipment pump .............................................................................................................. 2-8 Pump for front wheel drive (for F106.7A / F156.7A only) .............................................................. 2-8 Radial piston motor (F106.7A / F156.7A) ...................................................................................... 2-8 Motor for blade turning gear .......................................................................................................... 2-8 Cylinder on F106.7 / F106.7A ........................................................................................................ 2-9 Cylinder on F156.7 / F156.7A ...................................................................................................... 2-10

10

Brake .................................................................................................................2-11

10.1 10.2

Service brake ............................................................................................................................... 2-11 Hand brake .................................................................................................................................. 2-11

11

Steering ............................................................................................................2-12

11.1 11.2

Specifications for F106.7 / F106.7A ............................................................................................. 2-12 Specifications for F156.7 / F156.7A ............................................................................................. 2-13

12

Equipment ........................................................................................................2-14

12.1 12.2 12.3

Centre equipment ........................................................................................................................ 2-14 Front equipment (optional) ........................................................................................................... 2-15 Rear (optional) ............................................................................................................................. 2-15

13 14 15

Cab ....................................................................................................................2-16 Electrical system .............................................................................................2-16 Operating fluids and lubricants ......................................................................2-17

15.1 15.2

Filling quantities and specifications for F106.7 / F106.7A ........................................................... 2-17 Filling quantities and specifications for F156.7 / F156.7A ........................................................... 2-18

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REPAIR INSTRUCTIONS TECHNICAL DATA

F106.7 / F106.7A F156.7 / F156.7A

1

DIMENSIONS

1.1

Main dimensions F106.7 / F106.7 A Front plate + rear scarifier

8961

8372 Front plate + rear weight

Rear edge Rear weight

2174 Front weight front edge

1585

657 102

310

487

1424

1241

1981

136

10

5351 8996

3240

3586

Rear scarifier scraping width (from centre tooth to centre tooth) 2000 mm

F106.7A 1923 F106.7 1900 F106.7A 2375 F106.7 2352 3355

R-SM1004-002

NOTE: The figure shows Grader F106.7A with standard tyres 405/70 R20 SPT9. If other tyres are used, the dimensions that involve tyres also change. Tyre dimensions Standard tyres 405/70R20 SPT9 Dunlop 420/75R20 XMCL Michelin 455/70R20 SPT9 Dunlop

Edition 07-2010

Height

Tread

Width across tyres

0

0

0

+ 29 -9

+60 0

+ 110 +4

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REPAIR INSTRUCTIONS TECHNICAL DATA

1.2

F106.7 / F106.7A F156.7 / F156.7A

Main dimensions F156.7 / F156.7 A 10044 Front plate + rear scarifier 9371 Front plate + rear weight

2449 Rear edge Rear weight 1785

Front weight front edge

1525

183

371

584

38

697

3674

110

2504

1573 6023 10032

3330

Rear scarifier scraping width (from centre tooth to centre tooth) 2220 mm

F156.7A - 2100 F156.7 - 2094 2450 F156.7A - 2555 F156.7 - 2549 3660 R-SM1004-001

NOTE: The figure shows Grader F156.7A with standard tyres 17.5-25EM SGL D/2-A GY.. If other tyres are used, the dimensions that involve tyres also change. Tyre dimensions Standard tyres 17.5-25 EM SGL D/2 Good Year 17.5-R25 XHA Michelin 17.5-R25 XTLY Michelin 17.5-R25 RM94 Pirelli

2-4

Height

Tread

Width across tyres

0

0

0

+2 -9 + 31

0 0 0

-7 +4 - 23

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REPAIR INSTRUCTIONS TECHNICAL DATA

2

F106.7 / F106.7A F156.7 / F156.7A

ENGINE

The following engines are used in the graders: F4HE9684T J100 in grader F106.7 and F106.7A F4HE9684C J102 in Grader F156.7 and F156.7A. NOTE: For technical data, see repair manual for engine 87704088A.

3

TORQUE CONVERTER

Single-stage torque converter integrated in manual transmission. Automatic torque adjustment to variations in air drag and rolling resistance.

Converter ratio Cooling

4

F106.7/F106.7A 1.87 : 1 Heat exchanger

F156.7/F157.6A 1.91 : 1 Heat exchanger

TRANSMISSION

Full power-shift transmission with 6 forward and 3 reverse gears selectable under load. One-lever electric gearshift with reverse lock in gears 3-6. Transmission F106.7 / F106.7A Manufacturer Model Type Control Driving switch Engine Power Turbine torque Engine rpm Stall torque ratio Mass (without oil) Torque speed

Edition 07-2010

ZF Ergo Power 6WG115 EST 37 A VTS-3 max. 99 kW max. 750 Nm max. 2300 min-1 1.7 to 3.0 approx. 360 kg Live power take-off 500 Nm 1 x n engine

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F156.7 / F156.7A ZF Ergo Power 6WG160 EST 37 A VTS-3 max. 129 kW max. 750 Nm max. 2300 min -1 1.7 to 3.0 approx. 360 kg 680 Nm 1 x n engine

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REPAIR INSTRUCTIONS TECHNICAL DATA

4.1

Ratios Driving direction

Forwards

Reverse

Driving direction Forwards

Reverse

2-6

F106.7 / F106.7A F156.7 / F156.7A

F106.7 / F106.7A ratios Transmission Gear

Ratio

1. 2. 3. 4. 5. 6. 1. 2. 3.

5.636 3.728 2.374 1.570 1.023 0.676 5.344 2.251 0.970

Tandem axle Total

Ring gear and pinion

Planetary gear drive

Chain drive

Total

3.111

3.421

1.421

15.123

3.111

3.421

1.421

15.123

F156.7 / F156.7A ratios Transmission

85.235 56.380 35.903 23.744 15.471 10.223 80.819 34.043 14.670

Tandem axle Planetary gear drive

Chain drive

Total

Total

Gear

Ratio

Ring gear and pinion

1. 2. 3. 4. 5. 6. 1. 2. 3.

5.202 3.367 2.191 1.418 0.944 0.611 4.939 2.078 0.895

2.818

6.00

1.167

19.731

2.818

6.00

1.167

19.731

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102.641 66.434 43.231 27.979 18.626 12.056 97.451 40.001 17.659

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REPAIR INSTRUCTIONS TECHNICAL DATA

F106.7 / F106.7A F156.7 / F156.7A

5

TYRE

5.1

Tyre types and pressures

5.1.1

F106.7 / F106.7A Tyres

405/70R20 EM 420/75R20 455/70R20 EM 5.1.2

Tread SPT9 XMCL SPT9

Dunlop Michelin Dunlop

Tread

Brand

EM 17.5 R25 EM 17.5 R25 EM 17.5 R25

SGL XHA XTLA RM94

Rear 3.50 2.00 2.50

Good Year Michelin Michelin Pirelli

Pressure Front 2.00 2.00 2.00 2.20

Rear 2.25 2.10 2.10 2.20

Wheel nut torques

with lock washer with pressure plate

6

Pressure Front 3.00 2.00 2.50

F156.7 / F156.7A Tyre

5.1.3

Brand

F106.7 / F106.7A 450 Nm 500 Nm

F156.7 / F156.7A 550 600

REAR AXLE

Grader rear axle with automatic no-spin differential. Tandem axles in swing arrangement with power transmission through high-performance roller chains. Differential Tandem axle

7

F106.7 / F106.7A 31 l 2 x 60 l

F156.7 / F156.7A 36 l 2 x 64 l

FRONT AXLE

Swing axle with double-pivot steering and hydraulic wheel camber adjustment. Axle swing Camber adjustment left / right Ground clearance

Edition 07-2010

F106.7 / F106.7A ± 15° ± 14°24′ 485 / 504 mm

84329014A

F156.7 / F156.7A ± 14° / ± 15° ± 12° 614 / 646mm

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REPAIR INSTRUCTIONS TECHNICAL DATA

8

F106.7 / F106.7A F156.7 / F156.7A

ALL-WHEEL DRIVE

For hydrodynamic rear wheel drive, engageable hydrostatic front wheel drive with EDCV Electronic Drive Control Each of the wheel hub motors in the front wheels is driven hydrostatically in a sealed circuit by one helical gear pump with 2 pumping directions (forward / backward). A hydraulic differential lock prevents the front wheels spinning on one side. A microprocessor monitors and controls the adjustment of front wheel drive to rear wheel drive. A step switch allows the driver to adjust the force of the front wheel drive to the operating conditions.

9

HYDRAULIC SYSTEM

9.1

Implement pump

Pump Flow volume Vg max.

9.2

F106.7 / F106.7A A 10 VO 45 DFR 45 cm³

Pump for front wheel drive (for F106.7A / F156.7A only) F106.7A A4VG 56EP2 0 to 56 cm³/ U 115 L / min

Type Displacement Volume flow

9.3

F106.7A MS8 428 cm³ 857 cm³

F156.7A MS11 629 cm³ 1229 cm³

F106.7 / F106.7A OMR 80 80.3 cm³ 6.9 kg 750 rpm 155 Nm 60 L/min 140 bar 130 Nm

F156.7 / F156.7A OMR 100 99.8 cm3 7.0 kg 600 rpm 200 Nm 60 l/min 140 bar 170 Nm

Motor for blade turning gear

Type Displacement Weight Max. rpm Max. torque Max. oil flow Max. entry pressure Min. starting torque

2-8

F156.7A AV4VG 71 EP2 0 to 71 cm³/ U 160 L / min

Radial piston motor (F106.7A / F156.7A)

Type Min. displacement Max. displacement

9.4

F156.7 / F156.7A A 10 VO 60 DFR1 60 cm³

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