New Holland F106.6 User manual

F106.6 / F106.6A / F156.6 / F156.6A
F106.6 / F106.6A
F156.6 / F156.6A
Print No. 87726937A
Print No. 87726937A
SERVICE MANUAL
SERVICE
MANUAL
Grader
Grader

CNH Baumaschinen GmbH
Product documentation
Staakener Str. 53 - 63
13581 Berlin
Tel.: [phone]
FAX: [phone]
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Edition 12/2007 87726937A 1
REPAIR INSTRUCTIONS F106.6/F106.6A
ENGINE F156.6 / F156.6A
TO THE READER
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.
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
mechanical assembly:
•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.
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:
•Operating instructions
•Parts catalogue
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2 87726937A Edition 12/2007
REPAIR INSTRUCTIONS F106.6/F106.6A
ENGINE F156.6 / F156.6A
NOTES:
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Edition 12/2007 87726937A 1
REPAIR INSTRUCTIONS F106.6/F106.6A
FRONT AXLE 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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2 87726937A Edition 12/2007
REPAIR INSTRUCTIONS F106.6/F106.6A
FRONT AXLE F156.6 / F156.6A
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Section
0
0
CNH Baumaschinen GmbH
Product documentation
13581 Berlin, Staakener Str. 53-63
87726937A © 2007 CNH Baumaschinen GmbH
December, 2007
SAFETY INSTRUCTIONS
Copyright © New Holland
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PARAGRAPH 0
LIST OF CONTENTS
Edition 12/2007 87726937A 0 - 1
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
1 BASIC SAFETY INFORMATION ........................................................................0-3
1.1 Warning notes and symbols ..........................................................................................................0-3
1.2 Correct use ....................................................................................................................................0-3
1.3 Organizational procedures .............................................................................................................0-4
1.4 Personnel selection and qualifications - basic responsibilities ......................................................0-5
1.5 Safety information for specific phases of operation .......................................................................0-6
1.6 Special operations when using the machine, servicing and fault repair work as part
of working procedure, waste disposal ............................................................................................0-7
1.7 Notes on special types of hazard ...................................................................................................0-9
1.7.1 Electrical energy ............................................................................................................................0-9
1.7.2 Gas, dust, vapour, smoke ..............................................................................................................0-9
1.7.3 Hydraulic, pneumatic system .........................................................................................................0-9
1.7.4 Noise ..............................................................................................................................................0-9
1.7.5 Oil, grease and other chemical substances ...................................................................................0-9
1.8 Transport, towing and restarting ..................................................................................................0-10
2 WARNING AND INSTRUCTION PLATES ........................................................0-12
2.1 Left side of vehicle .......................................................................................................................0-12
2.2 Right side of vehicle .....................................................................................................................0-14
3 OPERATION .....................................................................................................0-17
3.1 General Remarks .........................................................................................................................0-17
3.2 Fuelling ........................................................................................................................................0-19
3.3 Fuelling system (optional) ............................................................................................................0-20
3.4 Driving ..........................................................................................................................................0-21
3.5 Towing /recovery .........................................................................................................................0-23
3.5.1 Towing devices ............................................................................................................................0-23
3.5.2 Transport .....................................................................................................................................0-23
3.5.3 Crane loading ..............................................................................................................................0-23
3.6 Everyday operation ......................................................................................................................0-24
3.7 Using the grader ..........................................................................................................................0-24
3.8 Working equipment ......................................................................................................................0-25
3.9 SECURING THE MACHINE ........................................................................................................0-26
4 INSPECTION AND MAINTENANCE ................................................................0-27
4.1 General information .....................................................................................................................0-27
4.2 Fuel system .................................................................................................................................0-31
4.3 Electrical system ..........................................................................................................................0-32
4.4 Power shift transmission ..............................................................................................................0-33
4.5 Hydraulic system .........................................................................................................................0-33
4.6 Brakes ..........................................................................................................................................0-34
4.7 Wheels and tyres .........................................................................................................................0-35
4.8 Air conditioning system (optional) ................................................................................................0-37
4.9 Repair ..........................................................................................................................................0-38
5 PROTECTING ELECTRONIC UNITS WHEN WELDING .................................0-40
5.1 Disconnect the connectors of the electronic equipment ..............................................................0-40
5.1.1 Transmission control ‘EST37A’ (XA1) and front wheel drive control ‘FWD’ (XA8.1) ...................0-40
5.1.2 AIC connections ...........................................................................................................................0-41
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0 - 2 87726937A Edition 12/2007
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
5.1.3 Engine control ..............................................................................................................................0-41
5.1.4 Cab connectors ............................................................................................................................0-41
5.1.5 Alternator connector ....................................................................................................................0-42
6 VACUUM PUMP ................................................................................................0-43
6.1 General information .....................................................................................................................0-43
6.2 Package content ..........................................................................................................................0-43
6.3 Vacuum pump connection ...........................................................................................................0-43
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Edition 12/2007 87726937A 0 - 3
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
1 BASIC SAFETY INFORMATION
1.1 Warning notes and symbols
The following symbols are used in the operating
instructions to indicate particularly important
information:
CAUTION: Safety rules and procedures, designed
to protect the driver and others from mortal dangers
or injuries, and to prevent serious damage to
property.
NOTE: Notes and precautions to avoid damage to
machinery and property.
1.2 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
•Cutting embankments
•Clearing ice and snow
•Placing, spreading, mixing, and compressing
materials.
The Grader can also be used in conjunction with
other operating equipment for special applications.
The Technical Data provide clear information on this
subject.
Proper use of the machine also means following the
operating instructions and applying the inspection
and maintenance conditions.
Usingthe grader for any otherpurpose,forexample:
•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.

0 - 4 87726937A Edition 12/2007
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
1.3 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.
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!
Check that all safety information and warning
notices at or on the machine remainfully 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.

Edition 12/2007 87726937A 0 - 5
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
1.4 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!
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!
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.

0 - 6 87726937A Edition 12/2007
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
1.5 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!
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!

Edition 12/2007 87726937A 0 - 7
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
1.6 Special operations when using
the machine, servicing and fault
repair work as part of working
procedure, waste disposal
Apply the intervals specified in the operating
instructions for adjustment, maintenance, and
inspection tasks, and pay attention to the
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.
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!

0 - 8 87726937A Edition 12/2007
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS 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!

Edition 12/2007 87726937A 0 - 9
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
1.7 Notes on special types of
hazard
1.7.1 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.
If contact is made with high-voltage lines:
•Do not leave the machine.
•Drive the machine out of the danger area.
•Warn persons on the ground not to come
near, or to touch the machine.
•Have the voltage switched off.
•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
Only operate combustion engines and fuel-driven
heaters in well-ventilated areas!
If using the equipment inan enclosed space, ensure
there is sufficient ventilation before starting.
Followthelocalregulations 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)!
1.7.3 Hydraulic, pneumatic system
Regularly inspect all pipes, hoses, and screw
connections for leaks and visible damage. Repair
any damage immediately! Spurting oil can cause
burns and other injuries.
Before starting repair work, any system blocks and
pressure lines (hydraulic, compressed air) that are
to be opened 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.
1.7.4 Noise
Noise insulation devices must be in the protection
position during operation.
Wear the prescribed personal ear protection!
1.7.5 Oil, grease and other chemical
substances
If handling oil, greaseor 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).

0 - 10 87726937A Edition 12/2007
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
1.8 Transport, towing and
restarting
Towing, loading and transporting should be carried
out only as described in the operating instructions!
If towing, use the specified transport position, and
keep to the permitted speed and distance!
Only use suitable means of transport and lifting
gear, with sufficient load-carrying capacity.
When restarting, follow only the procedure
described in the operating instructions.

Edition 12/2007 87726937A 0 - 11
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
NOTES:

0 - 12 87726937A Edition 12/2007
REPAIR INSTRUCTIONS F106.6/F106.6A
SAFETY INSTRUCTIONS F156.6 / F156.6A
2 WARNING AND INSTRUCTION PLATES
2.1 Left side of vehicle
GT3_00_001