New Holland F106.8A User manual

SERVICE MANUAL
F106.8 / F106.8A / F156.8 / F156.8A
Motor Grader
Part number 47829043
English
January 2015
© 2015 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICE
MANUAL
1/2
Part number 47829043
F106.8
F106.8A
F156.8
F156.8A
Motor Grader

SERVICEMANUAL
F106.8A
F106.8
F156.8A
F156.8
4782904322/01/2015
EN
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LinkProduct/Engine
ProductMarketProductEngine
F106.8EuropeF4HFE613Y*B003
F106.8AEuropeF4HFE613Y*B003
F156.8EuropeF4HFE613Y*B003
F156.8AEuropeF4HFE613Y*B003
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.500]SelectiveCatalyticReduction(SCR)exhausttreatment...........................10.2
[10.501]ExhaustGasRecirculation(EGR)-DieselParticulateFilter(DPF)exhaust
treatment....................................................................................10.3
[10.400]Enginecoolingsystem.............................................................10.4
[10.304]Enginelubricationsystem..........................................................10.5
Transmission..............................................................................21
[21.113]Powershifttransmission............................................................21.1
[21.135]Powershifttransmissionexternalcontrols..........................................21.2
[21.105]Powershifttransmissionlubricationsystem........................................21.3
[21.155]Powershifttransmissioninternalcomponents......................................21.4
[21.700]Torqueconverter...................................................................21.5
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.2
Rearaxlesystem........................................................................27
[27.106]Rearbevelgearsetanddifferential................................................27.1
[27.120]Planetaryandnaldrives..........................................................27.2
[27.600]Tandemaxle........................................................................27.3
[27.650]Chaindrivesystem.................................................................27.4
Hydrostaticdrive.........................................................................29
[29.204]Reservoir,cooler,andlines........................................................29.1
[29.218]Pumpandmotorcomponents......................................................29.2
Brakesandcontrols....................................................................33
[33.202]Hydraulicservicebrakes...........................................................33.1
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[33.110]Parkingbrakeorparkinglock......................................................33.2
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.300]Reservoir,cooler,andlters........................................................35.2
[35.104]Fixeddisplacementpump..........................................................35.3
[35.102]Pumpcontrolvalves................................................................35.4
[35.105]Chargepump.......................................................................35.5
[35.204]Remotecontrolvalves.............................................................35.6
[35.354]Hydrauliccentraljoint..............................................................35.7
[35.739]Swingarmhydraulicsystem.......................................................35.8
[35.741]Dozerbladecylinders..............................................................35.9
[35.742]Ripperhydraulicsystem..........................................................35.10
[35.310]Distributorandlines..............................................................35.11
Framesandballasting.................................................................39
[39.100]Frame..............................................................................39.1
Steering.....................................................................................41
[41.200]Hydrauliccontrolcomponents......................................................41.1
[41.206]Pump...............................................................................41.2
[41.216]Cylinders...........................................................................41.3
Wheels......................................................................................44
[44.511]Frontwheels........................................................................44.1
[44.520]Rearwheels........................................................................44.2
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.100]Harnessesandconnectors.........................................................55.2
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[55.302]Battery..............................................................................55.3
[55.988]SelectiveCatalyticReduction(SCR)electricalsystem............................55.4
[55.989]ExhaustGasRecirculation(EGR)electricalsystem...............................55.5
[55.640]Electronicmodules.................................................................55.6
[55.512]Cabcontrols........................................................................55.7
[55.530]Camera.............................................................................55.8
[55.408]Warningindicators,alarms,andinstruments......................................55.9
Dozerbladeandarm...................................................................86
[86.110]Dozerblade........................................................................86.1
[86.112]Moldboardblade...................................................................86.2
Tools.........................................................................................89
[89.128]Ripperassembly...................................................................89.1
Platform,cab,bodywork,anddecals.............................................90
[90.150]Cab.................................................................................90.1
[90.120]Mechanically-adjustedoperatorseat...............................................90.2
[90.100]Enginehoodandpanels...........................................................90.3
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INTRODUCTION
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Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing(*)................................3
Safetyrules(*)..................................................................................4
Personalsafety(*)..............................................................................5
Torque–Minimumtighteningtorquesfornormalassembly(*)...............................14
Torque–Standardtorquedataforhydraulics(*).............................................16
Specialtools(*)...............................................................................23
Basicinstructions-Shopandassembly(*)...................................................28
Basicinstructions–Precautionfordisassemblyandassembly(*)...........................30
Basicinstructions–Electricalequipmentprecautions(*).....................................32
Basicinstructions–Hydrauliccontamination(*)..............................................33
Basicinstructions–Biodieselfuel(*).........................................................34
Capacities(*).................................................................................36
Consumables(*)..............................................................................37
Productidentication(*)......................................................................47
Productidentication–Machineorientation(*)...............................................53
(*)Seecontentforspecicmodels
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INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
F106.8AWE
F106.8WE
F156.8AWE
F156.8WE
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecicationsatanytimewithout
noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specications,descriptions,and
illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
Incaseofquestions,refertoyourNEWHOLLANDCONSTRUCTIONSalesandServiceNetworks.
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INTRODUCTION
Safetyrules
F106.8AWE
F106.8WE
F156.8AWE
F156.8WE
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY.
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Personalsafety
F106.8AWE
F106.8WE
F156.8AWE
F156.8WE
CarefullyreadthisManualbeforeproceedingwithmain-
tenance,repairs,refuellingorothermachineoperations.
Repairshavetobecarriedoutonlybyauthorizedandin-
structedstaff;specicprecautionshavetobetakenwhen
grinding,weldingorwhenusingmalletsorheavyham-
mers.
Notauthorizedpersonsarenotallowedtorepairorcarry
outmaintenanceonthismachine.Donotcarryoutany
workontheequipmentwithoutpriorauthorization.
Askyouremployeraboutthesafetyinstructionsinforce
andsafetyequipment.
Nobodyshouldbeallowedinthecabduringmachine
maintenanceunlessheisaqualiedoperatorhelping
withthemaintenancework.
Ifitisnecessarytomovetheequipmenttocarryoutre-
pairsormaintenance,donotliftorlowertheequipment
fromanyotherpositionthantheoperator’sseat.
TULI12WEX2004AA1
Nevercarryoutanyoperationonthemachinewhenthe
engineisrunning,exceptwhenspecicallyindicated.
Stoptheengineandensurethatallpressureisrelieved
fromhydrauliccircuitsbeforeremovingcaps,covers,
valves,etc.
Allrepairandmaintenanceoperationsshouldbecarried
outwiththegreatestcareandattention.
Servicestairsandplatformsusedinaworkshoporinthe
eldshouldbebuiltincompliancewiththesafetyrulesin
force.
Anyfunctionaldisorders,especiallythoseaffectingthe
safetyofthemachine,shouldthereforeberectiedim-
mediately.
DANGER
Unexpectedmovement!
Makesureparkingbrakeisapplied.Secure
machinewithwheelchocks.
Failuretocomplywillresultindeathorserious
injury.D0013A
Beforeperforminganyworkonthemachine,attacha
maintenanceinprogresstag.Thistagcanbeappliedon
thedashboard,onthecabdoor,oratanyotherwellvisi-
bleplace.
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INTRODUCTION
Emergency
Bepreparedforemergencies.Alwayskeepareextin-
guisherandrstaidkitreadilyavailable.Ensurethatthe
reextinguisherisservicedinaccordancewiththeman-
ufacturer’sinstructions.
SMIL12WEX0174AA2
Equipment
Wearclosettingclothingandsafetyequipmentappropri-
ateforthejob:
•Safetyhelmet
•Safetyshoes
•Heavygloves
•Reectiveclothing
•Wetweatherclothing
Ifworkingconditionsrequire,thefollowingpersonalsafety
equipmentshouldbeonhand:
•Respirators(ordustproofmasks)
•Earplugsoracousticearsprotections
•Goggleswithlateralshieldormasksforeyesprotection
Donotwearrings,wristwatches,jewels,unbuttonedor
appingclothingsuchasties,tornclothes,scarves,open
jacketsorshirtswithopenzipswhichcouldgetcaughtinto
movingparts.
TULI12WEX2008AA3
Engine-Radiator
Neverleavetheenginerunninginenclosedspaceswith-
outproperventilationwhichisabletoevacuatetoxicex-
haustgases.Keeptheexhaustmanifoldandtubefree
fromcombustiblematerials.
Donotrefuelwiththeenginerunning,especiallyifhot,as
thisincreasesrehazardincaseoffuelspillage.
Neverattempttocheckoradjustthebeltswhentheen-
gineisrunning.
Neverlubricatethemachinewiththeenginerunning.
TULI12WEX2009AA4
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INTRODUCTION
Payattentiontorotatingcomponentsanddonotallow
toanyonetoapproachtheseareastoavoidbecoming
entangled.
Hands,clothingortoolsgettingcaughtinthefanblades
ortransmissionbelts,cancauseamputations,violent
hemorragesandgenerateconditionsofgravedanger.
Forthisreasonavoidtouchingorapproachingallrotating
ormovingparts.
Asurgingsprayofthecoolantfromtheradiatorcancause
seriousburnsandscalds.
Beforecheckingthecoolantlevel,shut-offtheengine
andallowmachinetocooldowntheradiatorandhoses.
Slowlyunscrewthecaptoreleaseanyresidualpressure.
TULI12WEX2010AA5
Ifitisnecessarytoremovethecapwhileengineishot,
wearsafetyclothesandequipment,thenloosenthecap
slowlytorelievethepressuregradually.
Whencheckingthefuel,oilandcoolantlevels,uselights
andlampsexplicitlydesignatedasexplosionproof.If
thesetypesoflampsarenotuse,resorexplosionsmay
occur.
TULI12WEX2011AA6
Hydraulicsystems
Jetsofuidsunderpressurecanpenetratetheskincaus-
ingseriousinjuries.
Avoidthishazardbyrelievingpressurebeforedisconnect-
inghydraulicorotherlines.
Relievetheresidualpressurebymovingthehydraulic
controlleversseveraltimes.
Tightenallconnectionsbeforeapplyingpressure.
Toprotecttheeyeswearafacialshieldorsafetygoggles.
Protectyourhandsandbodyfrompossiblejetsofuids
underpressure.
Swallowinghydraulicoilisaseverehealthhazard.
TULI12WEX2012AA7
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INTRODUCTION
Whenhydraulicoilhasbeenswallowed,avoidvomiting,
butconsultadoctororgotoahospital.
Ifanaccidentoccurs,seeadoctorfamiliarwiththistype
ofinjuryimmediately.
Anyuidpenetratingtheskinmustberemovedwithinfew
hourstoavoidseriousinfections.
Flammablesplashesmayoriginatebecauseofheating
nearlineswithuidsunderpressure,resultinginserious
burns.Donotweldorusetorchesnearlinescontaining
uidsorotherammablematerials.
Linesunderpressurecanaccidentallybepiercedwhen
theheatexpandsbeyondtheareaimmediatelyheated.
Arrangefortemporaryreresistantshieldstoprotect
hosesorothercomponentsduringweldingortorchuse.
Haveanyvisibleleakagerepairedimmediately.
Dischargedoilpollutestheenvironment.Soakupany
oilthathasspilledwithaproperbindingagent.Sweep
upbindingagentanddisposeofitseparatelyfromother
waste.
Neversearchforleakageswithngers;instead,usea
pieceofcardboardandalwaysweargoggles.
Neverrepairadamagedline;alwaysreplaceit.Replace
hydraulichosesimmediatelyondetectinganydamaged
ormoistareas.
Alwaysstorehydraulicoilintheoriginalcontainers.
TULI12WEX2013AA8
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INTRODUCTION
Hosesandtubes
Alwaysreplacehosesandtubesiftheconeendorthe
endconnectionsonthehosearedamaged.
Wheninstallinganewhose,looselyconnecteachend
andmakesurethehosetakesupthecorrectpositionbe-
foretighteningtheconnections.Clampsshouldbetight-
enedsufcientlytoholdthehosewithoutcrushingandto
preventchang.
Afterhosereplacementtoamovingcomponent,check
thatthehosedoesnotfoulbymovingthecomponent
throughthecompleterangeoftravel.Besureanyhose
whichhasbeeninstalledisnotkinkedortwisted.
Hoseconnectionswhicharedamaged,dented,crushed
orleaking,restrictoilowandtheproductivityofthecom-
ponentsbeingserved.Connectorswhichshowsignsof
movementfromtheoriginalpositionhavefailedandwill
ultimatelyseparatecompletely.
Ahosewithafrayedoutersheathwillallowwaterpenetra-
tion.Concealedcorrosionofthewirereinforcementcould
subsequentlyoccuralongthehoselengthwithresultant
hosefailure.
Ballooningofthehoseindicatesaninternalleakagedueto
structuralfailure.Thisconditionrapidlydeterioratesand
totalhosefailuresoonoccurs.
Kinked,crushed,stretchedordeformedhosesgenerally
sufferinternalstructuraldamagewhichcanresultinoil
restriction,areductioninthespeedofoperationandulti-
matehosefailure.
Free-moving,unsupportedhosesmustneverbeallowed
totoucheachotherorrelatedworkingsurfaces.This
causeschangwhichreduceshoselife.
TULI12WEX2014AA9
O-rings
ReplaceO-rings,sealringsandgasketswheneverthey
aredisassembled.
NevermixnewandoldsealsorO-rings,regardlessof
condition.AlwayslubricatenewsealringsandO-rings
withhydraulicoilbeforeinstallationtorelevantseats.
ThiswillpreventtheO-ringsfromrollingoverandtwisting
duringmountingwhichwilljeopardizesealing.
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INTRODUCTION
Battery
Batteriesgiveoffexplosivegases.
Neverhandlenakedamesandunshieldedlightsources
nearbatteries.(Nosmokingisaddressedinnextinstruc-
tion).
Topreventanyriskofexplosion,observethefollowing
instructions:
•Whendisconnectingthebatterycables,alwaysdiscon-
nectthenegative(-)cablerst.
•Toreconnectthebatterycables,alwaysconnectthe
negative(-)cablelast.
•Nevershort-circuitthebatteryterminalswithmetalob-
jects.
•Donotweld,grindorsmokenearabattery.
Batteryelectrolytecausessevereburns.Thebatterycon-
tainssulphuricacid.Avoidanycontactwiththeskin,eyes
orclothing.
TULI12WEX2015AA10
Antidote:
•EXTERNAL:Rinsewellwithwater,removinganysoiled
clothing.
•INTERNAL:Avoidvomiting.Drinkwatertorinseyour
mouth.Consultadoctor.
•EYES:Rinseabundantlywithwaterfor15minandcon-
sultadoctor.
•Whentheelectrolyteofabatteryisfrozen,itcanex-
plodeifyouattempttochargethebatteryorifyoutryto
starttheengineusingaboosterbattery.Alwayskeep
thebatterychargedtopreventtheelectrolytefreezing.
Providegoodventilationwhenchangingabatteryorusing
abatteryinanenclosedspace.Alwaysprotectyoureyes
whenworkingnearabattery.
TULI12WEX2016AA11
Neversettoolsdownonthebattery.Theymayinduce
ashortcircuit,causingirreparabledamagetothebattery
andinjuringpersons.
Neverwearmetalnecklaces,braceletsorwatchstraps
whenworkingonthebattery.Themetalpartsmayinduce
ashortcircuitresultinginburns.
Disposeofusedbatteriesseparatelyfromotherwastein
theinterestsofenvironmentalprotection.
TULI12WEX2017AA12
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INTRODUCTION
Flammableliquids
Whenhandlingammableliquids:
•Donotsmoke.
•Keepawayfromunshieldedlightsourcesandnaked
ames.
Fuelsoftenhavealowashpointandarereadilyignited.
Neverattempttoextinguishburningliquidswithwater.
Use:
•Drypowder
•Carbondioxide
•Foam
Waterusedforextinguishingpurposeswouldvaporizein-
stantaneouslyoncontactwithburningsubstancesand
spreadburningoil,forexample,overawidearea.Water
generatesshortcircuitsintheelectricalsystem,possibly
producingnewhazards.
TULI12WEX2016AA13
Stayawayfromopenamesduringrellingofhydraulic
oilorfuel.
Fueloroilspillscancauseslippinghazards;thoroughly
containandcleanaffectedareas.
Alwaystightenthesafetyplugsoffueltankandhydraulic
oiltankrmly.
Neverusefueltocleanmachinepartsthatwillbeexposed
todirtordebris.
Useanon-inammableproductforcleaningparts.
Alwaysperformfueloroilrellinginwellairedandventi-
latedareas.
TULI12WEX2018AA14
Duringrefuellingholdthepistolrmlyandalwayskeepit
incontactwiththellerneckuntiltheendoftherefuelling,
toavoidarcingduetostaticelectricity.
Donotoverllthetankbutleaveaspaceforfuelexpan-
sion.
Neverrefuelwhentheengineisrunning.
Takeallthenecessarysafetymeasureswhenwelding,
grindingorwhenworkingnearanakedame.
TULI12WEX2019AA15
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INTRODUCTION
Tires
Beforeinatingthetires,alwayschecktheconditionof
rimsandtheouterconditionoftirestondoutthepres-
enceofdents,cuts,tearsofreinforcementpliesorother
faults.Beforeinatingatire,makesurethatthereareno
nearbypersons,thenpositionyourselfattreadside.
Wheninatingtires,ensuretirepressuredoesnotexceed
thatprescribedbythetiremanufacturer.Ensurethatthe
pressureoftherighttirecorrespondstothepressureof
thelefttire.
NOTE:Thefrontandreartirepressuresmaybedifferent.
Neverusereconditionedrimsbecausepossiblewelds,
heattreatmentsorbrazingsnotperformedcorrectlycan
weakenthewheelsandcausefollowingdamagesorfail-
ures.Deatethetiresbeforetheirdisassembly.
Beforetakingoutpossiblejammedobjectsfromtherims,
itisnecessarytodeatethetires.Inatetiresbymeans
ofaninationpistolcompletewithextensionandpressure
controlvalve.
TULI12WEX2020AA16
Cleaning
Cleantheexteriorofallcomponentsbeforecarryingout
anyformofrepair.Dirtanddustcanreducetheefcient
workinglifeofacomponentandleadtocostlyreplace-
ment.
Solventsshouldbecheckedthattheyaresuitableforthe
cleaningofcomponentsandalsothattheydonotriskthe
personalsafetyoftheuser.
Dirt,oil,greaseandscatteredtoolsaredangerousforpeo-
ple,becausetheycancreateslippingortrippinghazards.
Formachinecleaning,useajetofwarmwaterorsteam
underpressureandcommercialdetergents.Neveruse
fuel,petroleumorsolvents,becausetheycanleavean
oilyresiduethatattractsdust,andsolvents(evenifweak)
damagethepaintandcanleadtotheinformationofrust.
Neverusewaterjetsorsteamonsensors,connectorsor
otherelectriccomponents.
Avoiddirectsprayofsealsandseamstopreventwater
penetrationinsidethecab.
TULI12WEX2021AA17
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INTRODUCTION
Wastedisposal
Improperlydisposingofwastecanthreatentheenviron-
ment.
Eachcountryhasitsownregulationsonthissubject.It
isthereforeadvisabletopreparesuitablecontainersto
collectandstoremomentarilyallsolidanduidmaterials
thatmustnotbescatteredintheenvironmenttoavoid
pollution.
Atpresetintervalstheseproductswillbedeliveredtodis-
posalstationslegallyrecognizedandpresentinthiscoun-
try.
Hereunderarelistedsomeproductsofthemachinere-
quiringdisposal:
•Lubricatingoil
•Brakesystemoil
•Coolantmixture,condensationrestsandpurean-
tifreeze
•Fuel
•Filterelements,oilandfuellters
•Filterelements,airlters
•Battery
Alsopollutingrags,paper,sawdustandglovesmustbe
disposedincompliancewiththesameprocedures.
Donotusefoodorbeveragecontainersthatmaymislead
someoneintodrinkingfromthem.Donotpourwasteonto
theground,downadrain,orintoanywatersource.Air
conditioningrefrigerantsescapingintotheaircandamage
theEarth’satmosphere.Governmentregulationsmayre-
quireacertiedairconditioningservicecentretorecover
andrecycleusedairconditioningrefrigerants.Obtainin-
formationontheproperwaytorecycleordisposeofwaste
fromyourlocalenvironmentalorrecyclingcentre,orfrom
yourDealer.
TULI12WEX2022AA18
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