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SERVICE MANUAL

F106.6 / F106.6A F156.6 / F156.6A

SERVICE MANUAL F106.6 / F106.6A / F156.6 / F156.6A Grader

Grader

Print No. 87726937A

Print No. 87726937A


Copyright © New Holland


Copyright © New Holland REPAIR INSTRUCTIONS ENGINE

F106.6 / F106.6A F156.6 / F156.6A

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. Use the repair manual, but also use the operating instructions and parts catalogue for reference and guidance, even if you are already familiar with the technology used in graders. 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 The repair manual describes the machine model in the form it was originally delivered. It does not describe any implements and modifications that maybe added later. The repair manual contains the following information:

• • • • • •

Safety instructions 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 12/2007

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 operations, always follow the instructions in the workshop manual and the operating instructions. Customer Service will be pleased to carry out for you any extensive 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:

• •

87726937A

Operating instructions Parts catalogue

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Copyright © New Holland REPAIR INSTRUCTIONS ENGINE

F106.6 / F106.6A F156.6 / F156.6A

NOTES:

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87726937A

Edition 12/2007


Copyright © New Holland REPAIR INSTRUCTIONS FRONT AXLE

F106.6 / F106.6A F156.6 / F156.6A

SAFETY INSTRUCTIONS

0

SPECIFICATIONS

1

ENGINE

2

TRANSMISSION

3

REAR AXLE

4

FRONT AXLE

5

EQUIPMENT

6

HYDRAULIC SYSTEM

7

BRAKE SYSTEM

8

STEERING SYSTEM

9

ELECTRICAL SYSTEM

10

CAB AND OPERATING PLATFORM

11

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Copyright © New Holland REPAIR INSTRUCTIONS FRONT AXLE

2

F106.6 / F106.6A F156.6 / F156.6A

87726937A

Edition 12/2007


Section

0

Copyright © New Holland

0 SAFETY INSTRUCTIONS

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

87726937A

© 2007 CNH Baumaschinen GmbH December, 2007


Copyright © New Holland


Copyright © New Holland REPAIR INSTRUCTIONS SAFETY INSTRUCTIONS

F106.6 / F106.6A F156.6 / F156.6A

PARAGRAPH 0 LIST OF CONTENTS

1

BASIC SAFETY INFORMATION ........................................................................0-3

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

Warning notes and symbols .......................................................................................................... 0-3 Correct use .................................................................................................................................... 0-3 Organizational procedures ............................................................................................................. 0-4 Personnel selection and qualifications - basic responsibilities ...................................................... 0-5 Safety information for specific phases of operation ....................................................................... 0-6 Special operations when using the machine, servicing and fault repair work as part of working procedure, waste disposal ............................................................................................ 0-7 Notes on special types of hazard ................................................................................................... 0-9 Electrical energy ............................................................................................................................ 0-9 Gas, dust, vapour, smoke .............................................................................................................. 0-9 Hydraulic, pneumatic system ......................................................................................................... 0-9 Noise .............................................................................................................................................. 0-9 Oil, grease and other chemical substances ................................................................................... 0-9 Transport, towing and restarting .................................................................................................. 0-10

2

WARNING AND INSTRUCTION PLATES ........................................................0-12

2.1 2.2

Left side of vehicle ....................................................................................................................... 0-12 Right side of vehicle ..................................................................................................................... 0-14

3

OPERATION .....................................................................................................0-17

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 Remarks ......................................................................................................................... 0-17 Fuelling ........................................................................................................................................ 0-19 Fuelling system (optional) ............................................................................................................ 0-20 Driving .......................................................................................................................................... 0-21 Towing /recovery ......................................................................................................................... 0-23 Towing devices ............................................................................................................................ 0-23 Transport ..................................................................................................................................... 0-23 Crane loading .............................................................................................................................. 0-23 Everyday operation ...................................................................................................................... 0-24 Using the grader .......................................................................................................................... 0-24 Working equipment ...................................................................................................................... 0-25 SECURING THE MACHINE ........................................................................................................ 0-26

4

INSPECTION AND MAINTENANCE ................................................................0-27

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9

General information ..................................................................................................................... 0-27 Fuel system ................................................................................................................................. 0-31 Electrical system .......................................................................................................................... 0-32 Power shift transmission .............................................................................................................. 0-33 Hydraulic system ......................................................................................................................... 0-33 Brakes .......................................................................................................................................... 0-34 Wheels and tyres ......................................................................................................................... 0-35 Air conditioning system (optional) ................................................................................................ 0-37 Repair .......................................................................................................................................... 0-38

5

PROTECTING ELECTRONIC UNITS WHEN WELDING .................................0-40

5.1 5.1.1 5.1.2

Disconnect the connectors of the electronic equipment .............................................................. 0-40 Transmission control ‘EST37A’ (XA1) and front wheel drive control ‘FWD’ (XA8.1) ................... 0-40 AIC connections ........................................................................................................................... 0-41

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F106.6 / F106.6A F156.6 / F156.6A

5.1.3 5.1.4 5.1.5

Engine control .............................................................................................................................. 0-41 Cab connectors ............................................................................................................................ 0-41 Alternator connector .................................................................................................................... 0-42

6

VACUUM PUMP ................................................................................................0-43

6.1 6.2 6.3

General information ..................................................................................................................... 0-43 Package content .......................................................................................................................... 0-43 Vacuum pump connection ........................................................................................................... 0-43

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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:

The Grader can also be used in conjunction with other operating equipment for special applications. The Technical Data provide clear information on this subject.

CAUTION: Safety rules and procedures, designed to protect the driver and others from mortal dangers or injuries, and to prevent serious damage to property.

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:

NOTE: Notes and precautions to avoid damage to machinery and property.

• • •

1.2

Correct 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 third parties, or which could cause 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. This Grader is principally designed for:

• • • • • •

Creating a double course Clearing top soils Scarifying old road surfaces and hard ground

transporting personnel, as a working platform, towing or carrying loads without attaching the proper working attachments, is considered improper use.

Improper use of the machine can pose mortal danger to operating personnel or other persons, or may result in physical injuries, or may cause 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 the mechanical safety law of 18/01/1991 or EC machinery guideline 89/392/EWG. Using the earth-moving equipment properly, with ISO 7096 standard driver seats, will ensure that the measured vibration frequencies (measured as described in ISO 2631 Part 1) meet the requirements regarding protection from whole-body vibrations.

Cutting embankments Clearing ice and snow Placing, spreading, mixing, and compressing materials.

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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 requirements may, for example, concern the handling of dangerous goods, the making available / wearing of personal protective equipment or highway code regulations. Supplement the operating instructions with additional instructions, including supervisory and reporting duties, in order to take account of specific operating conditions, for example, Particular work plans, working processes or personnel. 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 when the actual work has begun. This especially applies to personnel employed occasionally, for example, for setting up or maintaining the machine. You must at least check occasionally that personnel can demonstrate safety and risk awareness when working! Loose or long hair must be tied up, and personnel must not wear loose clothing or jewellery, including rings. These are a potential risk, for example, if they are caught up or pulled in by machinery.

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. Modifications, conversions or retrofits that might affect safety must not 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 proper times or at the stated intervals, even if no defects affecting safety are visible! For the periodic checks / inspections, keep to the specified intervals or the times specified 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.

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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1.4

F106.6 / F106.6A F156.6 / F156.6A

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, an 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 hydraulic systems.

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 highway code 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 given constant supervision by an experienced person!

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Safety information for specific phases of operation

Normal operation 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. Working environment includes, for example, obstacles in the working/traffic area, load-bearing capacity of the ground, and safety barriers necessary at the worksite relative to public traffic areas. Take steps to ensure that the machine is only operated when in a safe and operative condition! Only operate the machine if all safety devices and safety-related systems, for example, removable safeguards, emergency shut-off devices, noise insulation, extractor systems, are present and in operative condition. The machine must be inspected at least once in each shift for visible damage and defects! Any changes that occur (including changes in operational behaviour) must be reported immediately to the department or person responsible! If necessary, stop the machine immediately and secure it. If there is a malfunction, stop the machine immediately and secure it! Faults must be repaired immediately! Start the machine only from the driver’s position. Follow the operating instructions, during the switch-on/switch-off procedures. Before starting up the machine, ensure that no one will be put at risk by when the machine is started!

0-6

Before starting work / driving, check whether the brake, steering, lighting and signalling systems are operational. Before moving off, always check that attachments are secured to prevent accidents! If using public roads, streets, or other areas, follow the regulations in the highway code and, if necessary, make the machine road-worthy as required by the highway code before doing so. 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, bridges, tunnels, under overhead lines, etc., always check 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 positioned in a transverse direction; always drive with attachments and loads lowered and near the ground, especially when driving uphill/downhill! When on a gradient, always adapt vehicle speed to the particular conditions! Always change to the lowered position in advance of the gradient, never while driving on it! Before leaving the driver’s seat, always immobilise the machine to prevent it moving off accidentally, and to prevent access by unauthorized persons. Switch off the engine!

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Copyright Š New Holland REPAIR INSTRUCTIONS SAFETY INSTRUCTIONS

1.6

F106.6 / F106.6A F156.6 / F156.6A

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

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 hoists!

Apply the intervals specified in the operating instructions for adjustment, maintenance, and inspection tasks, and pay attention to the replacement data for parts and 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:

• •

Take out the key and attach a warning sign.

Only carry out maintenance and repair work when the machine is parked on a level, sufficiently load-bearing surface and secured to prevent it moving off or collapsing! 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 carrying capacity. Do not stand or work under suspended loads! Only appoint experienced persons to attach loads and instruct crane drivers! The instructor must stand where they are visible to the operator, or be in contact with him by voice communications.

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F106.6 / F106.6A F156.6 / F156.6A

For maintenance work at greater heights, wear fall-protection! 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 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! 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 replaced 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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1.7 1.7.1

F106.6 / F106.6A F156.6 / F156.6A

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 what the required safety clearances are.

Do not leave the machine.

• •

Have the voltage switched off.

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 up must first be depressurized as indicated in the descriptions of the assemblies. Hydraulic and compressed air lines must be correctly laid and assembled. Do not get the connections mixed up! Valves, and the length and quality of hoses must meet the requirements.

If contact is made with high-voltage lines:

• • •

Hydraulic, pneumatic system

Drive the machine out of the danger area.

1.7.4

Warn persons on the ground not to come near, or to touch the machine.

Noise insulation devices must be in the protection position during operation.

Only leave the machine when the contacted/damaged power line has been safely de-energized.

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

Gas, dust, vapour, smoke

Noise

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 operating fluids and auxiliary materials (risk of burns and scalds).

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. 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 - risk of fire and explosions! 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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1.8

F106.6 / F106.6A F156.6 / F156.6A

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 AND INSTRUCTION PLATES

2.1

Left side of vehicle

GT3_00_001

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F106.6 / F106.6A F156.6 / F156.6A

CAUTION: 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 1. 2. 3. 4. 7. 9. 10. 11. 12.

14.

15.

Do not start up the machine before you have read and understood the operating instructions. At this point, the equipment can be secured against accidental start-up. Inspect wheel nuts regularly - see the operating instructions. 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 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. Lashing ropes or chains must be attached here if the machine is to be transported. 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. The CE symbol certifies that this machine has been constructed according to the European regulations on mechanical safety. LWA indicates the level of noise emissions in dBA, as stated in EC standard 2000/14/EG). Driving on public roads. This plate indicates the steps to be taken before driving on public roads.

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2.2

F106.6 / F106.6A F156.6 / F156.6A

Right side of vehicle

GT3_00_002

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CAUTION: Read the warning signs and instruction plates on the machine. Keep these signs and plates clean and legible. Replace them immediately if they are no longer legible. New warning 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 2. 4. 5. 6. 7. 8. 9. 10. 12.

13. 16. 17.

At this point, the equipment can be protected from 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 from 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, fill with diesel fuel here. This plate indicates the maximum speed permitted on public roads. Lashing ropes or chains must be attached here if the machine is to be transported. 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. Alternator, regulator and electronic assemblies may be damaged if the battery is disconnected while the engine is running. Therefore, switch off the engine before disconnecting and removing the battery. Windscreen washer system. Water can be added here for the windscreen washer system. Risk of injury by crushing. Do not start up the machine if anyone is standing between the machine and an adjoining barrier.

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3

OPERATION

3.1

General Remarks

F106.6 / F106.6A F156.6 / F156.6A

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 locations, functions and operating directions of the controls. Operate the controls only from the driver’s seat. Keep the operating instructions stored permanently at the machine.

OPERATING PERSONNEL Operating personnel must be experienced in working with and operating this or similar machines. The required skills can be acquired through a course of instruction lasting a few days, which could be provided by a service technician, or by attending 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 12/2007

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 Technical Data 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 matter. DANGER AREA The danger area is that area around the machine where anyone might come within the range of movement of the machine, its working equipment and attachments, swinging loads, falling loads, or downward moving tools.

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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 a communication device (for example radio telephone / 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 your lose contact with the marshaller.

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

• •

attaching/removing working equipment,

carrying out maintenance or repair work.

switching the machine off after everyday operations,

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3.2

F106.6 / F106.6A F156.6 / F156.6A

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

CAUTION: 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 ground with sufficient load-carrying capacity, lower the working equipment to the ground, switch off fuel-driven auxiliary heaters and air conditioning systems, switch off the engine, apply the hand brake, take the key out of the key switch for the electrical system. Fuelling always takes place on the ground, with the operator in standing position.

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 spill fuel or allow it to penetrate the soil - this would endanger the environment. Spilled fuel should be soaked up immediately with a cleaning cloth or binding agent, then disposed of in an environmentally responsible way. Report accidents with fuel immediately to the machine licensee, or his agent.

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

• • •

Lower working equipment to the ground Switch off the engine Take the key out of the electrical system key switch.

INCREASED RISK OF CONTAMINATION If the machine is mostly or regularly fuelled from tanks or drums, there is an increased risk of contamination of 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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3.4

F106.6 / F106.6A F156.6 / F156.6A

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 share 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.

Before moving off, warn any bystanders with the signal horn.

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.

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 roll 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.

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.

PARKING THE MACHINE Machines parked on slopes can move off by themselves. Therefore, always park the machine on an even, horizontal surface, lower the working equipment 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 hand brake

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Towing /recovery

3.5.2

Transport

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 authorised representative. To reduce the risk of slipping, clean the drive-on ramps and loading area on the transport vehicle, and the wheels of the machine, to remove oil, grease, soil, mud, snow, ice and other matter. Use anchoring equipment with sufficient load-holding capacity (for the weight specifications of the machine, see the ‘Technical Data’ 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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F106.6 / F106.6A F156.6 / F156.6A

Everyday operation

3.7

Read carefully through the sections ‘Basic safety instructions’ 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 life-threatening 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. If driving with the door open, engage the door in the end position. Warn bystanders with a horn signal before starting work. Do not drive with hanging loads positioned cross-wise.

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°

Longitudinal tilt: Downward / upward 35° 35°

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

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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F106.6 / F106.6A F156.6 / F156.6A

Working equipment

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 WORKING EQUIPMENT Lower the working equipment 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 movement, slipping or falling.

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’.

CHOOSING THE WORKING EQUIPMENT The machine can be equipped with a variety of working equipment. The components of the working equipment are made up of hydraulic cylinders and connecting parts. Various component combinations are possible in order to adapt the working equipment optimally to the type of application. Only use equipment and component combinations with the machine, if these have been expressly approved by the manufacturer for this machine. Equipment supplied by other manufacturers, to which EC machines guideline 89/392 EWG applies, should only be attached and operated if they carry:

• •

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 protected. Secure the machine as described below:

Before any maintenance or repair work on the machine.

Whenever attaching or changing the working equipment.

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

• •

Lower the working equipment to the ground. Apply the hand brake.

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

• •

Switch off the engine.

• • • •

Depressurize the hydraulic system.

Switch off the battery main switch and remove the control lever.

Before working on the electrical system, disconnect the batteries.

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

Take the key out of the electrical system key switch. Lock the articulated joint. 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.

If working equipment 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 movement, slipping or falling.

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 matter. Face towards the machine when getting in or out.

The required skills can be acquired through a course of instruction lasting a few days, which could be provided by a service technician, or by attending a driver training course.

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.

CHECK THE CONDITION OF TOOLS Only work with fully functional and reliable tools. Choose only tools that are suitable for the task. Ill-fitting wrenches, for example, may slip off and cause injury.

Wear a hard hat, protective shoes and gloves, and ear protection if there is loud noise.

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.

SECURING THE WORKING EQUIPMENT Lower the working equipment to the ground, so that it will not move when mechanical or hydraulic connections are loosened.

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 close-fitting 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. Use the following:

• • •

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 will vaporise abruptly and 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 Check fastenings and fixing elements, for example, bolts, nuts, washers, before re-using.

RELEASE 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, 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 stops. 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 parts containing oil, for example, 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 working on the electrical system, when there is a possibility of tools, spare parts, etc. touching electric wires and contacts, disconnect the battery:

disconnect the negative terminal first, then the positive.

When work is complete:

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 cartridges at the specified intervals. 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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4.2

F106.6 / F106.6A F156.6 / F156.6A

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 at shorter intervals,

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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F106.6 / F106.6A F156.6 / F156.6A

Electrical system

ALTERNATOR Never disconnect the electrical connections at the alternator, regulator or battery while the engine is running.

Risk of injury from battery acid and gases. Wear protective goggles, close-fitting work clothes.

work

gloves

and This will damage the alternator and regulator.

BEFORE WORKING ON THE ELECTRICAL SYSTEM Switch off the engine. Turn the electrical system key switch to the 0 and take out the key. Turn the battery main switch to the OFF position and remove the control lever. Disconnect the control units and control console from the on-board electrical system. Before working on the electrical system, when there is a possibility of tools, spare parts, etc. touching electric wires and contacts, disconnect the batteries.

Disconnect the negative terminal first, then the positive.

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 and regulator. 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.

When work is complete:

When connecting the batteries, do not mix up the cables (check the polarities).

connect the positive terminal first, then the negative.

Read and apply the ‘Operating instructionsAlternator, 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’.

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.

The resulting short circuit will cause damage to the alternator or to the electronics.

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4.4

F106.6 / F106.6A F156.6 / F156.6A

Power shift transmission

4.5

Hydraulic system

Read and pay attention to: ‘Inspection and maintenance - General information’.

RISK OF INJURY From hydraulic fluid at high pressure.

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.

From hot hydraulic fluid or hot engine parts.

It is therefore essential to apply the safety measures listed in the next sections.

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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F106.6 / F106.6A F156.6 / F156.6A

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 work 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.

PRESSURE RESERVOIRS The hydraulic system contains pressure reservoirs. These pressure reservoirs contain nitrogen, which is maintained at high pilot pressure. Eve 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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4.7

F106.6 / F106.6A F156.6 / F156.6A

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 rim pieces can cause very serious injuries, which can even be fatal in some cases.

TYRE PRESSURES Bursting tyres and flying rims or rim pieces 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 have penetrated.

If damage is found, have this repaired 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 in the direction of 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 rim pieces 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.

Edition 12/2007

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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F106.6 / F106.6A F156.6 / F156.6A

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 around bends too fast. 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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4.8

F106.6 / F106.6A F156.6 / F156.6A

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 (R134a) is known as a safety refrigerant. This means that it is non-combustible, non-explosive, 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. Wear safety goggles to protect the eyes. 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 essential to keep chlorine, chlorine-containing materials, oils and grease out of the refrigerant system. The draining/filling equipment should be used only for R134a.

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4.9

F106.6 / F106.6A F156.6 / F156.6A

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.

WORKING AT HEIGHTS Wear fall-protections if working at a height.

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. Clean faulty disassembling.

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

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

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PRE-TENSIONED ASSEMBLIES Do not open pre-tensioned assemblies if damaged replace them completely.

components

carefully

before

Mark disassembled parts in the order they were removed - this will make re-assembly easier. 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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Edition 12/2007


Copyright © New Holland REPAIR INSTRUCTIONS SAFETY INSTRUCTIONS

F106.6 / F106.6A F156.6 / F156.6A

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.

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 the paragraph ‘Working equipment’, the section ‘Inspection and maintenance - General information’ and the section ‘Repair’.

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

Before carrying out welding work on the machine:

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

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

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.

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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F106.6 / F106.6A F156.6 / F156.6A

PROTECTING ELECTRONIC UNITS WHEN WELDING

CAUTION: To protect electronic equipment from damage (for example, AIC display, keypad, engine, etc.) when welding, follow the steps below.

Loosen and pull out the connector (B) as described above.

Pull out the connector (arrowed).

Set the battery main switch to ‘OFF’ position. Disconnect the minus and positive terminals of batteries.

5.1

Disconnect the connectors of the electronic equipment

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

5.1.1

Transmission control ‘EST37A’ (XA1) and front wheel drive control ‘FWD’ (XA8.1)

Remove panels. Loosen the 6 screws with an Allen wrench and keep them in a safe place.

Press locking lever (1) away from the connector and pull connector (2) upwards and out of EST unit (A). On the front of the connector is an extension (lug) that has to be unhooked.

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5.1.2

F106.6 / F106.6A F156.6 / F156.6A

AIC connections

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

• •

Open the bonnet. Press locking lever (1) away from the connector and pull connector (2) upwards and out of the engine control (A, B). On the front of the connector is an extension (lug) that has to be unhooked.

5.1.4

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

Pull the connectors (1 + 2) out of the ACI.

5.1.3

Cab connectors

Engine control

These connectors are located under the cab floor panel.

• •

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Place the bonnet in service position II. Pull out connectors (A, B) and (C).

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5.1.5

F106.6 / F106.6A F156.6 / F156.6A

Alternator connector

After completing all the above steps, welding work can be carried out on the machine (see and follow the instructions in the 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. CAUTION: Failure to follow the above procedure will void the warranty and the manufacturer will not be liable for any resulting damage.

Release clamp (1) and pull out connector (2) from the alternator.

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6

F106.6 / F106.6A F156.6 / F156.6A

VACUUM PUMP

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

6.1

when inserting plugs and stoppers.

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

Place the 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) carefully into opening (2).

Run the cable (5) to the battery. Connect the positive lead (6) to the positive terminal first, then the negative lead (7) to the negative terminal.

Switch on vacuum pump (3) at 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.

General information

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

Package content

GT3_00_003

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

6.3

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

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.

Vacuum pump connection

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

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NOTES:

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Edition 12/2007


Section

1

Copyright © New Holland

1 SPECIFICATIONS

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

87726937A

© 2007 CNH Baumaschinen GmbH December, 2007


Copyright © New Holland


Copyright © New Holland REPAIR INSTRUCTIONS SPECIFICATIONS

F106.6 / F106.6A F156.6 / F156.6A

PARAGRAPH 1 LIST OF CONTENTS

1

Dimensions ........................................................................................................1-3

1.1 1.2

Main dimensions F106.6 and F106.6 A ......................................................................................... 1-3 Main dimensions F156.6 and F156.6 A ......................................................................................... 1-4

2 3 4

Engine .................................................................................................................1-5 Torque converter ...............................................................................................1-5 Transmission .....................................................................................................1-5

4.1

Ratios ............................................................................................................................................. 1-6

5

Tyre .....................................................................................................................1-7

5.1 5.1.1 5.1.2 5.1.3

Tyre types and pressures .............................................................................................................. 1-7 F106.6 / F106.6A ........................................................................................................................... 1-7 F156.6 / F156.6A ........................................................................................................................... 1-7 Wheel nut torques .......................................................................................................................... 1-7

6 7 8 9

Rear axle .............................................................................................................1-7 Front axle ............................................................................................................1-7 All-wheel drive ...................................................................................................1-8 Hydraulic system ...............................................................................................1-8

9.1 9.2 9.3 9.4 9.5 9.6

Working equipment pump .............................................................................................................. 1-8 Pump for front wheel drive (for F106.6A / F156.6A only) .............................................................. 1-8 Radial piston motor (F106.6A / F156.6A) ...................................................................................... 1-8 Motor for blade turntable ................................................................................................................ 1-8 Cylinder on F106.6 / F106.6A ........................................................................................................ 1-9 Cylinder on F156.6 / F156.6A ...................................................................................................... 1-10

10

Brake .................................................................................................................1-11

10.1 10.2

Service brake .............................................................................................................................. 1-11 Parking brake ............................................................................................................................... 1-11

11

Steering ............................................................................................................1-12

11.1 11.2

Specifications for F106.6 / F106.6A ............................................................................................. 1-12 Specifications for F156.6 and F156.6A ........................................................................................ 1-13

12

Equipment ........................................................................................................1-14

12.1 12.2 12.3

Centre equipment ........................................................................................................................ 1-14 Front equipment (optional) ........................................................................................................... 1-15 Rear equipment (optional) ........................................................................................................... 1-15

13 14 15

Cab ....................................................................................................................1-16 Electrical system .............................................................................................1-16 Operating fluids and lubricants ......................................................................1-17

15.1 15.2

Fill quantities and specifications for F106.6 and F106.6A ........................................................... 1-17 Fill quantities and specifications for F156.6 and F156.6A ........................................................... 1-18

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1-1


Copyright © New Holland REPAIR INSTRUCTIONS SPECIFICATIONS

1-2

F106.6 / F106.6A F156.6 / F156.6A

87726937A

Edition 12/2007


Copyright © New Holland REPAIR INSTRUCTIONS SPECIFICATIONS

F106.6 / F106.6A F156.6 / F156.6A

1

DIMENSIONS

1.1

Main dimensions F106.6 and F106.6 A

FRONT PLATE + REAR SCARIFIER FRONT PLATE + REAR WEIGHT

*)

FRONT WEIGHT FRONT EDGE

*) *)

*) *)

REAR SCARIFIER SCRAPING WIDTH (FROM CENTRE TOOTH TO CENTRE TOOTH) = 2,220 MM

*) These dimensions vary according to tyre type

GT3_01_001

Edition 12/2007

87726937A

1-3


Copyright © New Holland REPAIR INSTRUCTIONS SPECIFICATIONS

1.2

F106.6 / F106.6A F156.6 / F156.6A

Main dimensions F156.6 and F156.6 A

FRONT PLATE + REAR SCARIFIER FRONT PLATE + REAR WEIGHT

*)

FRONT WEIGHT FRONT EDGE

*)

*) *) REAR SCARIFIER SCRAPING WIDTH (FROM CENTRE TOOTH TO CENTRE TOOTH) = 2,220 MM

*) These dimensions vary according to tyre type

GT3_01_002

1-4

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2

F106.6 / F106.6A F156.6 / F156.6A

ENGINE

The following engines are used in the graders: F4HE9684T J100 in grader F106.6 and F106.6. F4HE9684C J102 in grader F156.6 and F156.6A. 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

F106.6/F106.6A 1.87 : 1 Heat exchanger

F156.6/F156.6A 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 F106.6 / F106.6A Manufacturer Model Type Control Driving switch Engine power Turbine torque Engine rpm Stall torque ratio Mass (without oil) Torque Rotational speed

Edition 12/2007

ZF Ergo Power 6WG115 EST 37 A VTS-3 max. 99 kW max. 750 Nm max. 2,300 rpm 1.7 to 3.0 About 360 kg Live power take-off 500 Nm 1 x n engine

87726937A

F156.6 / F156.6A ZF Ergo Power 6WG160 EST 37 A VTS-3 max. 129 kW max. 750 Nm max. 2,300 rpm 1.7 to 3.0 About 360 kg 680 Nm 1 x n engine

1-5


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