New Holland F156.6 Instruction manual

F156.6
F156.6A
GRADER
Workshop Manual
Print No. 604.13.572 English
III - 2005
THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.
Read and heed carefully the safety instructions listed and follow the precautions recommended to
avoid potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:
WARNING - Cautions directed to avoid improper repair interventions involving potential consequences
for the safety of the personnel performing the repairs.
DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other
persons directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the
Service Organisation of the Manufacturer, observing strictly the instructions explained using, whenever
necessary, the recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own,
for the damages that may result.
Neither the Factory nor any Organisations in its Distribution Network, including but not limited to national,
regional or local distributors, are responsible for any liability arising from any damage resulting from defects
caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing prod-
ucts manufactured or merchandised by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or
merchandised by the Factory, when failures are caused by the use of parts and/or components not approved
by the Factory.

AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the
farm, at home or on the road, are caused by the fail-
ure of some individuals to follow simple and funda-
mental safety rules and precautions. For this reason
MOST ACCIDENTS CAN BE PREVENTED by recog-
nising the real cause and doing something aboiut it
before the accident occurs.
Regardless of the care used in the design and con-
struction of any type of equipment, there are many
conditions that cannot be completely safeguarded
against without interfering in the reasonable accessi-
bility and efficient operation.
A carefull operator is the best insurance against an
accident. The complete observance of one simple
rule would prevent many serious accidents.
The rule is simple: never attempt to clean, lubricate or
maintain a machine while it is in motion.
WARNING
Prior to engaging in any maintenance, adjustment
or repair operation on machines having hydrauli-
cally, mechanically, and/or cable controlled equip-
ment (such as shovels, loaders, dozers, excavators
etc.) be certain the equipment is lowered to the
ground.
If it is necessary to have the equipment partially or
fully raised to gain access to certain items, be sure
the equipment is suitably supported by means
other than the devices used for controlling the
equipment.
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SUMMARY
SAFETY INSTRUCTIONS .................................................................................. SECTION 0
TECHNICAL DATA ............................................................................................. SECTION 1
ENGINE .............................................................................................................. SECTION 2
TRANSMISSION ................................................................................................. SECTION 3
REAR AXLE ........................................................................................................ SECTION 4
FRONT AXLE...................................................................................................... SECTION 5
ATTACHMENT.................................................................................................... SECTION 6
HYDRAULIC SYSTEM........................................................................................ SECTION 7
BRAKE SYSTEM ................................................................................................ SECTION 8
STEERING SYSTEM .......................................................................................... SECTION 9
ELECTRICAL SYSTEM .................................................................................... SECTION 10
OPERATOR’S CAB .......................................................................................... SECTION 11
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F156.6 / F156.6A INTRODUCTION IN - 1
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)
FOR THE READER
This Workshop Manual is written for the Repair-
Technician. It provides important information on
how to perform skilful repairs.
We recommend to consult the Workshop Manual
and also the Motor-Grader Operation and Mainte-
nance Instruction Manual before initiating any repair-
work operation. Utilize the Workshop Manual as
well as the Operation and Maintenance Instruc-
tion Manual and the Parts Catalog as a prompt-
book and adviser, even if the Motor-Grader tech-
nique is become familiar.
By means of the Workshop Manual the expert tech-
nician will be able to carry out a skilful repair-work
operation.
USE
The Workshop Manual refers to the initial Machine
configuration. Structural changes or rebuilding oper-
ations are not described in this Handbook.
In this Workshop Manual the following information
can be found:
- Safety Instructions;
- Technical Data and Special Tools;
- Functional Description;
- Performance Testing;
- Troubleshooting and Failure Correction;
- Repair Instructions.
In the Section Safety Instructions the recom-
mended procedures are described, so that through
the relevant compliance with, a risk of accident for
the User and for the personnel responsible of the
maintenance operations on the machine can be
avoided.
In the Section Technical Data the Service Data, the
change tables and lists of the needed Special Tools
and Maintenance materials are indicated.
In other Sections, for each mechanical group, when
available can be found:
- a functional description with information con-
cerning the operation of the essential devices and
equipments;
- information for carrying out the performance tests
on the machine;
- troubleshooting, information concerning the rec-
ognition and correction of failures on the machine,
- technical information necessary for carrying out
the Service and Repair operations on the Machine,
the equipment necessary for the maintenance op-
erations, the information concerning the Stand-
ards to be applied in the Maintenance operations,
the Procedures for the Removal and Installation
operations as well as for Disassembly and As-
sembly operations.
By means of the index contents a desired information
can be easily achieved.
For a better understanding the illustration of the part
will be displayed.
Therefore differences in arrangement of the Grader
are possible, whenever the latter involves the uni-
vocal capability of the information.
REPAIR OPERATIONS
Carry out the necessary repair works as soon as pos-
sible. This procedure will avoid the maintenance
costs while increasing the availability of your Motor-
Grader.
Pay always attention during all works to the Work-
shop Manual warnings and cautions and to the Op-
eration and Maintenance Instruction Manual.
The Service Assistance will gladly carry out for you
the works not described in the Workshop Manual.
Always utilize the Original Spare Parts only.
FURTHER INFORMATION MATERIAL
Please notice the supplementary information con-
sulting the following Handbooks:
-Operation and Maintenance Instruction
Manual;
-Parts Catalog.
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IN - 2 INTRODUCTION F156.6 / F156.6A
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)
NOTES:
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SECTION 0
SAFETY INSTRUCTIONS
INDEX
SUBJECT
FUNDAMENTAL SAFETY INSTRUCTIONS .....................................................................................
Warnings and symbols.......................................................................................................................
Designated use ..................................................................................................................................
Organizational measures ...................................................................................................................
Selection and qualification of personnel
Basic responsibilities..........................................................................................................................
Safety instructions governing specific operational phases ................................................................
Special work in conjunction with use of the machine
Maintenance and repairs during operation
Disposal of parts and consumables ...................................................................................................
Warning of special dangers ...............................................................................................................
Transporting and towing
Recommissioning...............................................................................................................................
WARNING AND INSTRUCTION SIGNS ...........................................................................................
Left side .............................................................................................................................................
Right side ...........................................................................................................................................
OPERATION......................................................................................................................................
General instructions ...........................................................................................................................
Refuelling ...........................................................................................................................................
Refuelling system (Option).................................................................................................................
Driving................................................................................................................................................
Machine recovery / towing .................................................................................................................
Tow rod coupling................................................................................................................................
Transport ...........................................................................................................................................
Crane loading.....................................................................................................................................
Working operation..............................................................................................................................
Grader deployment ............................................................................................................................
Working equipment ............................................................................................................................
Securing the machine ........................................................................................................................
INSPECTION AND SERVICING........................................................................................................
General instructions ...........................................................................................................................
Fuel system........................................................................................................................................
Electrical system ................................................................................................................................
Powershift transmission .....................................................................................................................
Hydraulic system................................................................................................................................
Brakes................................................................................................................................................
Tyres and wheels...............................................................................................................................
Air conditioner (Option) ......................................................................................................................
Repair work........................................................................................................................................
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SECTION 0
SAFETY INSTRUCTIONS
INDEX
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F156.6 / F156.6A SAFETY INSTRUCTIONS 0 - 1
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)
FUNDAMENTAL SAFETY INSTRUCTIONS
WARNINGS AND SYMBOLS
The following signs are used in the manual to desig-
nate instructions of particular importance:
DESIGNATED USE
The machine has been built with state of the art tech-
nology and in accordance with the officially recog-
nised safety regulations. Nevertheless, its use may
constitute a risk to life and limb for the operator or
third parties, or cause damage to the the machine
and other property.
The machine must be used only in technically perfect
condition in accordance with its designated use and
the instructions set out in the operating manual, and
only by safety-conscious persons who are fully aware
of the risks involved in operating the machine. Im-
portant notices are to be found at the beginning of
the chapters. Functional disorders should be rectified
immediately, especially those which could affect
safety conditions.
The grader is intended mainly for:
- Creating fine-graded surfaces;
- Clearing away top soil;
- Tearing up old road surfaces and hard ground;
- Cutting slopes;
- Clearing away ice and snow;
- Gathering, spreading, mixing and compacting ma-
terials.
Precautionary rules and measures
designed to protect the machine op-
erator and other persons from life-
threatening danger or injuries and to
prevent extensive damage.
Information and precautionary
measures designed to prevent
damage to the machine or other
property.
The grader can also be used with other working
equipment for special purposes. The technical data
offer clear instructions in this respect.
Designated use includes following the operating in-
structions and fullfilling the inspection and mainte-
nance conditions.
The manufacturer/supplier cannot be held liable for
any damage arising out of improper use. The risk
involved in improper use lies entirely with the user.
Noise emission specification in accordance with the
3rd Ordinance of the Machine Safety Act (18/01/
1991) and EC Machine Directive, 89/392/EEC.
If the earth-moving mchine is operated in accordance
with its designated use, the installation of driver’s
seats complying with ISO 7096 ensures that the con-
sidered vibration accelerations azw (measured as
per ISO 2631, Part 1) fulfil the requirements of pro-
tecting the driver against wholebody vibration.
Using the machine for purposes
other than or extending beyond
those stated above, e.g.:
- for the transportation of persons;
- as a working platform;
- for pulling or transporting loads
without the working equipment
being approved for such purposes
is considered contrary to the desig-
nated use.
Improper use may involve a lifeth-
reatening risk for operators or other
personnel or may cause injury or ex-
tensive damage.
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0 - 2 SAFETY INSTRUCTIONS F156.6 / F156.6A
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)
ORGANIZATIONAL MEASURES
The operating instructions must always be at hand
at the place of use of the machine, e.g. by stowing
them in the tool compartment or tool-box provided
for such purpose.
In addition to the operating instructions, observe and
instruct the user in all other generally applicable legal
and other mandatory regulations relevant to accident
prevention and environmental protection.
These compulsory regulations may also deal with the
handling of hazardous substances, issuing and/or
wearing of personal protective equipment or traffic
regulations.
The operating instructions must be supplemented by
instructions covering the duties involved in super-
vising and notifying special organizational features,
such as job organization, working sequences or the
personnel entrusted with the work.
Personnel entrusted with work on the machine must
have read the operating instructions and in particular
the chapter on safety before beginning work.
Reading the instructions after work has begun is too
late. This applies especially to persons working only
occasionally on the machine, e.g. during setting up
or maintenance.
Check - at least from time to time - whether the per-
sonnel is carrying out the work in compliance with
the operating instructions and paying attention to
risks and safety factors.
For reasons of security, long hair must be tied back
or otherwise secured, garments must be close-fitting
and no jewellery, such as rings, may be worn. Injury
may result from being caught up in the machinery or
from rings catching on moving parts.
Use protective equipment wherever required by the
circumstances or by law.
Observe all safety instructions and warnings at-
tached to the machine.
See to it that safety instructions and warnings at-
tached to the machine are always complete and per-
fectly legible.
In the event of safety-relevant modifications or
changes in the behaviour of the machine during op-
eration, stop the machine immediately and report the
malfunction to the competent authority/person.
Never make any modifications, additions or conver-
sions which might affect safety without the supplier’s
approval. This also applies to the installation and ad-
justment of safety devices and valves as well as to
welding work on load-bearing elements.
Spare parts must comply with the technical require-
ments specified by the manufacturer. Spare parts
from original equipment manufacturers can be relied
upon to do so.
Replace hydraulic hoses within stipulated and appro-
priate intervals, even if no safety-relevant defects
have been detected.
Adhere to prescribed intervals or those specified in
the operating instructions for routine checks and in-
spections.
For the execution of maintenance work, tools and
workshop equipment adapted to the task on hand
are absolutely indispensable.
The personnel must be familiar with the location and
operation of fire extinguishers.
Observe all fire-warning and fire-fighting procedures.
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