New Holland F156.6 / F156.6A GRADER. Workshop 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.

F156.6 / F156.6A

INTRODUCTION

IN - 1

FOR THE READER

- information for carrying out the performance tests

on the machine;

This Workshop Manual is written for the Repair-

- troubleshooting, information concerning the rec-

Technician. It provides important information on

ognition and correction of failures on the machine,

how to perform skilful repairs.

- technical information necessary for carrying out

We recommend to consult the Workshop Manual

the Service and Repair operations on the Machine,

and also the Motor-Grader Operation and Mainte-

the equipment necessary for the maintenance op-

nance Instruction Manual before initiating any repair-

erations, the information concerning the Stand-

work operation. Utilize the Workshop Manual as

ards to be applied in the Maintenance operations,

well as the Operation and Maintenance Instruc-

the Procedures for the Removal and Installation

tion Manual and the Parts Catalog as a prompt-

operations as well as for Disassembly and As-

book and adviser, even if the Motor-Grader tech-

sembly operations.

nique is become familiar.

By means of the Workshop Manual the expert tech-

By means of the index contents a desired information

nician will be able to carry out a skilful repair-work

can be easily achieved.

operation.

For a better understanding the illustration of the part

will be displayed.

Therefore differences in arrangement of the Grader

USE

are possible, whenever the latter involves the uni-

vocal capability of the information.

The Workshop Manual refers to the initial Machine

configuration. Structural changes or rebuilding oper-

ations are not described in this Handbook.

REPAIR OPERATIONS

In this Workshop Manual the following information

can be found:

Carry out the necessary repair works as soon as pos-

- Safety Instructions;

sible. This procedure will avoid the maintenance

- Technical Data and Special Tools;

costs while increasing the availability of your Motor-

Grader.

- Functional Description;

Pay always attention during all works to the Work-

- Performance Testing;

shop Manual warnings and cautions and to the Op-

- Troubleshooting and Failure Correction;

eration and Maintenance Instruction Manual.

- Repair Instructions.

The Service Assistance will gladly carry out for you

the works not described in the Workshop Manual.

In the Section Safety Instructions the recom-

Always utilize the Original Spare Parts only.

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

FURTHER INFORMATION MATERIAL

maintenance operations on the machine can be

avoided.

Please notice the supplementary information con-

sulting the following Handbooks:

In the Section Technical Data the Service Data, the

- Operation and Maintenance Instruction

change tables and lists of the needed Special Tools

Manual;

and Maintenance materials are indicated.

- Parts Catalog.

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;

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

SECTION 0

SAFETY INSTRUCTIONS

INDEX

SUBJECT

PAGE

FUNDAMENTAL SAFETY INSTRUCTIONS

0-1

Warnings and symbols

0-1

Designated use

0-1

Organizational measures

0-2

Selection and qualification of personnel

Basic responsibilities

0-3

Safety instructions governing specific operational phases

0-4

Special work in conjunction with use of the machine

Maintenance and repairs during operation

Disposal of parts and consumables

0-5

Warning of special dangers

0-6

Transporting and towing

Recommissioning

0-7

WARNING AND INSTRUCTION SIGNS

0-8

Left side

0-9

Right side

0-11

OPERATION

0-13

General instructions

0-13

Refuelling

0-15

Refuelling system (Option)

0-16

Driving

0-17

Machine recovery / towing

0-19

Tow rod coupling

0-19

Transport

0-19

Crane loading

0-19

Working operation

0-20

Grader deployment

0-20

Working equipment

0-21

Securing the machine

0-22

INSPECTION AND SERVICING

0-23

General instructions

0-23

Fuel system

0-27

Electrical system

0-28

Powershift transmission

0-29

Hydraulic system

0-29

Brakes

0-30

Tyres and wheels

0-31

Air conditioner (Option)

0-33

Repair work

0-34

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 1

FUNDAMENTAL SAFETY INSTRUCTIONS

WARNINGS AND SYMBOLS

The grader can also be used with other working

equipment for special purposes. The technical data

The following signs are used in the manual to desig-

offer clear instructions in this respect.

nate instructions of particular importance:

Designated use includes following the operating in-

structions and fullfilling the inspection and mainte-

Precautionary rules and measures

nance conditions.

designed to protect the machine op-

erator and other persons from life-

threatening danger or injuries and to

Using the machine for purposes

prevent extensive damage.

other than or extending beyond

those stated above, e.g.:

Information and precautionary

- for the transportation of persons;

measures designed to prevent

- as a working platform;

damage to the machine or other

- for pulling or transporting loads

property.

without the working equipment

being approved for such purposes

is considered contrary to the desig-

DESIGNATED USE

nated use.

Improper use may involve a lifeth-

The machine has been built with state of the art tech-

reatening risk for operators or other

nology and in accordance with the officially recog-

personnel or may cause injury or ex-

nised safety regulations. Nevertheless, its use may

tensive damage.

constitute a risk to life and limb for the operator or

third parties, or cause damage to the the machine

The manufacturer/supplier cannot be held liable for

and other property.

any damage arising out of improper use. The risk

involved in improper use lies entirely with the user.

The machine must be used only in technically perfect

condition in accordance with its designated use and

Noise emission specification in accordance with the

the instructions set out in the operating manual, and

3^rd Ordinance of the Machine Safety Act (18/01/

only by safety-conscious persons who are fully aware

1991) and EC Machine Directive, 89/392/EEC.

of the risks involved in operating the machine. Im-

portant notices are to be found at the beginning of

If the earth-moving mchine is operated in accordance

the chapters. Functional disorders should be rectified

with its designated use, the installation of driver’s

immediately, especially those which could affect

seats complying with ISO 7096 ensures that the con-

safety conditions.

sidered vibration accelerations azw (measured as

per ISO 2631, Part 1) fulfil the requirements of pro-

The grader is intended mainly for:

tecting the driver against wholebody vibration.

- 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.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 2

SAFETY INSTRUCTIONS

F156.6 / F156.6A

ORGANIZATIONAL MEASURES

The operating instructions must always be at hand

Observe all safety instructions and warnings at-

at the place of use of the machine, e.g. by stowing

tached to the machine.

them in the tool compartment or tool-box provided

for such purpose.

See to it that safety instructions and warnings at-

tached to the machine are always complete and per-

In addition to the operating instructions, observe and

fectly legible.

instruct the user in all other generally applicable legal

and other mandatory regulations relevant to accident

In the event of safety-relevant modifications or

prevention and environmental protection.

changes in the behaviour of the machine during op-

eration, stop the machine immediately and report the

These compulsory regulations may also deal with the

malfunction to the competent authority/person.

handling of hazardous substances, issuing and/or

wearing of personal protective equipment or traffic

Never make any modifications, additions or conver-

regulations.

sions which might affect safety without the supplier’s

approval. This also applies to the installation and ad-

The operating instructions must be supplemented by

justment of safety devices and valves as well as to

instructions covering the duties involved in super-

welding work on load-bearing elements.

vising and notifying special organizational features,

such as job organization, working sequences or the

Spare parts must comply with the technical require-

personnel entrusted with the work.

ments specified by the manufacturer. Spare parts

from original equipment manufacturers can be relied

Personnel entrusted with work on the machine must

upon to do so.

have read the operating instructions and in particular

the chapter on safety before beginning work.

Replace hydraulic hoses within stipulated and appro-

Reading the instructions after work has begun is too

priate intervals, even if no safety-relevant defects

late. This applies especially to persons working only

have been detected.

occasionally on the machine, e.g. during setting up

or maintenance.

Adhere to prescribed intervals or those specified in

the operating instructions for routine checks and in-

Check - at least from time to time - whether the per-

spections.

sonnel is carrying out the work in compliance with

the operating instructions and paying attention to

For the execution of maintenance work, tools and

risks and safety factors.

workshop equipment adapted to the task on hand

are absolutely indispensable.

For reasons of security, long hair must be tied back

or otherwise secured, garments must be close-fitting

The personnel must be familiar with the location and

and no jewellery, such as rings, may be worn. Injury

operation of fire extinguishers.

may result from being caught up in the machinery or

from rings catching on moving parts.

Observe all fire-warning and fire-fighting procedures.

Use protective equipment wherever required by the

circumstances or by law.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 3

SELECTION AND QUALIFICATION OF

PERSONNEL

BASIC RESPONSIBILITIES

Any work on and with the machine must be executed

Work on the electrical system and equipment of the

by reliable personnel only. Statutory minimum age

machine must be carried out only by a skilled elec-

limits must be observed.

trician or by instructed persons under the supervision

and guidance of a skilled electrician and in accord-

Employ only trained or instructed staff and set out

ance with electrical engineering rules and regula-

clearly the individual responsibilities of the personnel

tions.

for operation, set-up, maintenance and repair.

Work on chassis, brake and steering systems must

Make sure that only authorized personnel works on

be performed by skilled personnel only, which has

or with the machine.

been specially trained for such work.

Define the machine operator’s responsibilities - also

Work on the hydraulic system must be carried out

with regard to observing traffic regulations - giving

only by personnel with special knowledge and expe-

the operator the authority to refuse instructions by

rience of hydraulic equipment.

third parties that are contrary to safety.

Do not allow persons to be trained or instructed or

persons taking part in a general training course to

work on or with the machine without being perma-

nently supervised by an experienced person.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 4

SAFETY INSTRUCTIONS

F156.6 / F156.6A

SAFETY INSTRUCTIONS GOVERNING

SPECIFIC OPERATIONAL PHASES

Standard operation

Avoid any operational mode that might be prejudicial

Before starting work or travelling with the machine,

to safety.

check that the braking, steering, signalling and

lighting systems are fully functional.

Before beginning work, familiarize yourself with the

surroundings and circumstances of the site, such as

Before setting the machine in motion always check

obstacles in the working and travelling area, the soil

that the accessories have been safely stowed away.

bearing capacity and any barriers separating the con-

struction site from public roads.

When travelling on public roads, ways and places

always observe the valid traffic regulations and, if

Take the necessary precautions to ensure that the

necessary, make sure beforehand that the machine

machine is used only when in a safe and reliable

is in a condition compatible with these regulations.

state.

In conditions of poor visibility and after dark always

switch on the lighting system.

Operate the machine only if all protective and safety-

oriented devices, such as removable safety devices,

Persons accompanying the driver must be seated on

emergency shut-off equipment, soundproofing ele-

the passenger seats provided for this purpose.

ments and exhausters, are in place and fully func-

tional.

When crossing underpasses, bridges and tunnels or

when passing under overhead lines always make

Check the machine at least once per working shift

sure that there is sufficient clearance.

for obvious damage and defects. Report any

changes (incl. changes in the machine’s working be-

Always keep at a distance from the edges of building

haviour) to the competent organization/person im-

pits and slopes.

mediately. If necessary, stop the machine

immediately and lock it.

Avoid any operation that might be a risk to machine

stability.

In the event of malfunctions, stop the machine im-

mediately and lock it. Have any defects rectified im-

Never travel across slopes; always keep the working

mediately.

equipment and the load close to the ground, espe-

cially when travelling downhill.

Start the machine from the driver’s seat only.

On sloping terrain always adapt your travelling speed

During start-up and shut-down procedures always

to the prevailing ground conditions. Never change to

watch the indicators in accordance with the operating

a lower gear on a slope but always before reaching it.

instructions.

Before leaving the driver’s seat always secure the

Before setting the machine in motion, make sure that

machine against inadvertent movement and unau-

nobody is at risk.

thorized use. Stop the engine.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 5

SPECIAL WORK IN CONJUNCTION

WITH USE OF THE MACHINE

MAINTENANCE AND REPAIRS

DURING OPERATION

DISPOSAL OF PARTS AND CONSUMABLES

Observe the adjusting, maintenance and inspection

Wear a safety harness when carrying out mainte-

activities and intervals set out in the operating in-

nance work at greater heights.

structions, including information on the replacement

of parts and equipment. These activities may be ex-

Keep all handles, steps, handrails, platforms, land-

ecuted by skilled personnel only.

ings and ladders free from dirt, snow and ice.

Brief operating personnel before beginning special

Clean the machine, especially connections and

operations and maintenance work, and appoint a

threaded unions, of any traces of oil, fuel or preserv-

person to supervise the activities.

atives before carrying out maintenance/repair. Never

use aggressive detergents. Use lintfree cleaning

In any work concerning the operation, conversion or

rags.

adjustment of the machine and its safety-oriented de-

vices or any work related to maintenance, inspection

Before cleaning the machine with water, steam jet

and repair, always observe the start-up and shut-

(high-pressure cleaning) or detergents, cover or tape

down procedures set out in the operating instructions

up all openings which - for safety and functional rea-

and the information on maintenance work.

sons - must be protected against water, steam or

detergent penetration. Special care must be taken

Ensure that the maintenance area is adequately se-

with electric motors and switchgear cabinets.

cured.

Ensure during cleaning of the machine that the tem-

If the machine is completely shut down for mainte-

perature sensors of the fire-warning and firefighting

nance and repair work, it must be secured against

systems do not come into contact with hot cleaning

inadvertent starting by:

agents as this might activate the fire-fighting system.

- removing the ignition key;

After cleaning, remove all covers and tapes applied

- attaching a warning sign.

for that purpose.

Carry out maintenance and repair work only if the

After cleaning, examine all fuel, lubricant, and hy-

machine is positioned on stable and level ground and

draulic fluid lines for leaks, loose connections, chafe

has been secured against inadvertent movement

marks and damage. Any defects found must be rec-

and buckling.

tified without delay.

To avoid the risk of accidents, individual parts and

Always tighten any screwed connections that have

large assemblies being moved for replacement pur-

been loosened during maintenance and repair.

poses should be carefully attached to lifting tackle

and secured. Use only suitable and technically per-

Any safety devices removed for set-up, maintenance

fect lifting gear and suspension systems with ade-

or repair purposes must be refitted and checked im-

quate lifting capacity. Never work or stand under

mediately upon completion of the maintenance and

suspended loads.

repair work.

The fastening of loads and the instructing of crane

Ensure that all consumables and replaced parts are

operators should be entrusted to experienced per-

disposed of safely and with minimum environmental

sons only. The marshaller giving the instructions

impact.

must be within sight or sound of the operator.

For carrying out overhead assembly work always use

specially designed or otherwise safety-oriented lad-

ders and working platforms. Never use machine

parts as a climbing aid.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 6

SAFETY INSTRUCTIONS

F156.6 / F156.6A

WARNING OF SPECIAL DANGERS

Electric energy

Hydraulic and pneumatic equipment

Use only original fuses with the specified current

Check all lines, hoses and screwed connections reg-

rating. Switch off the machine immediately if trouble

ularly for leaks and obvious damage. Repair damage

occurs in the electrical system.

immediately. Splashed oil may cause injury and fire.

When working with the machine, maintain a safe dis-

Depressurize all system sections and pressure pipes

tance from overhead electric lines. If work is to be

(hydraulic system, compressed-air system) to be re-

carried out close to overhead lines, the working

moved in accordance with the specific instructions

equipment must be kept well away from them. Cau-

for the unit concerned before carrying out any repair

tion, danger! Check out the prescribed safety dis-

work.

tances.

Hydraulic and compressed-air lines must be laid and

If your machine comes into contact with a live wire:

fitted properly. Ensure that no connections are inter-

- do not leave the machine;

changed. The fittings, lengths and quality of the

hoses must comply with the technical requirements.

- drive the machine out of the hazard zone;

- warn others against approaching and touching the

Noise

machine;

- have the live wire de-energized;

During operation, all sound baffles of the machine

- do not leave the machine until the damaged line

must be closed.

has been safely de-energized.

Always wear the prescribed ear protectors.

The electrical equipment of machines is to be in-

spected and checked at regular intervals.

Oil, grease and other chemical substances

Defects such as loose connections or scorched ca-

bles must be rectified immediately.

When handling oil, grease and other chemical sub-

stances, observe the product-related safety regula-

Gas, dust, steam and smoke

tions.

Operate internal combustion engines and fueloper-

Be careful when handling hot consumables (risk of

ated heating systems only on adequately ventilated

burning or scalding).

premises. Before starting the machine on enclosed

premises, make sure that there is sufficient ventila-

tion.

Observe the regulations in force at the respective

site.

Carry out welding, flame-cutting and grinding work

on the machine only if this has been expressly au-

thorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and

grinding operations, clean the machine and its sur-

roundings from dust and other inflammable sub-

stances and make sure that the premises are

adequately ventilated (risk of explosion).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 9

Always observe the warning and in-

struction signs attached to the ma-

chine.

Keep signs clean and legible.

Replace signs immediately if they

have become illegible.

New warning and instruction signs

can be ordered from the Spare-Parts

Service. The Part nos. required for

orders can be found in the Parts

Catalog of your machine.

LEFT SIDE

The machine must not be started up unless the Op-

This sign indicates the admissible maximum speed

eration and Maintenance Instructions Manual have

for driving on public roads

been read and understood

10.

Fixing points for fastening chains and ropes for ma-

The equipment can be secured at this point against

chine transport

inadvertent activation

12.

Risk of injury through crushing. Never start up the

Check wheel nuts at regular intervals; see Operation

machine without ensuring that nobody is standing

and Maintenance Instructions Manual

within the range of the center-pivot joint

Risk of injury through hot or rotating components

Risk of injury through crushing. Never start up the

in the engine compartment. Never open engine hood

machine without ensuring that nobody is standing in

until engine is stationary

the area between the machine and a nearby obstacle

Risk of injury through engine hood slamming

14.

The CE sign indicates that this machine has been

closed.

built in conformity with the European prescriptions

Open engine hood until the safety rod engages in

for the safety of machines. L_WA is the level of noise

the lock position.

emissions specified in dB_A (in acc. with standard

Read Operation and Maintenance Instructions

2001/14/EC)

Manual before carrying out any repair / servicing

15.

Driving on public roads. This sign specifies

work

measure to be taken before driving on public roads.

Risk of injury through hot coolant. Open cap on ra-

diator only after the radiator has cooled down -

Coolant level indicators

Risk of injury by unauthorized starting of the ma-

chine. Before undertaking any work on the machine

shut off the engine and withdraw the key

Fuel tank, fill in diesel only

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 11

Always observe the warning and in-

struction signs attached to the ma-

chine.

Keep signs clean and legible.

Replace signs immediately if they

have become illegible.

New warning and instruction signs

can be ordered from the Spare-Parts

Service. The Part nos. required for

orders can be found in the Parts

Catalog of your machine.

RIGHT SIDE

The equipment can be secured at this point against

12.

Risk of injury through crushing. Never start up th

inadvertent activation

machine without ensuring that nobody is standing

Risk of injury through hot or rotating components

within the range of the center-pivot joint

in the engine compartment. Never open engine hood

Risk of injury through crushing. Never start up the

until engine is stationary

machine without ensuring that nobody is standing in

Risk of injury through engine hood slamming

the area between the machine and a nearby obstacle

closed. Close engine hood by disengaging the safety

13.

Damage to the alternator, regulator and electronic

bar with your foot. Read Operation and Maintenance

modules may result from the battery being discon-

Instructions Manual before carrying out any repair /

nected while the engine is running. Always stop the

servicing work

engine before disconnecting and removing batteries

Risk of injury through hot coolant. Open cap on ra-

16.

Screen washer. Filler opening of screen-washer res-

diator only after the radiator has cooled down -

ervoir. Top up with water

Coolant level indicators

17.

Risk of injury through crushing. Never start up the

Risk of injury by unauthorized starting of the ma-

machine without ensuring that nobody is standing in

chine. Before undertaking any work on the machine

the area between the machine and a nearby ob-

shut off the engine and withdraw the key

stacle.

Fuel tank, fill in diesel only

18.

Fixing points for fastening chains and ropes for ma-

This sign indicates the admissible maximum speed

chine transport

for driving on public roads

10. Fixing points for fastening chains and ropes for ma-

chine transport

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 13

OPERATION

GENERAL INSTRUCTIONS

Never operate the machine before

SAFETY BELT

having read and understood the op-

For machines with a safety belt for

erating instructions.

operating personnel:

Pay special attention to:

Check safety belt attached to driver’s

seat. In the event of damage or after

"Fundamental Safety Instructions"

an accident, have it replaced imme-

and all warnings and safety instruc-

diately.

tions attached to the machine.

Apply safety belt before starting

Familiarize yourself with the layout,

work.

the functioning and the activating de-

vices of the control elements prior to

starting up the machine.

STATE OF THE MACHINE

Activate the control elements from

Operate the machine only in a safe

the driver’s seat only.

state and only in accordance with its

designated use. Always observe the

Keep the operating instructions with

safety instructions.

the machine at all times.

Always have inspection and mainte-

nance work carried out on schedule.

OPERATING PERSONNEL

The operating personnel must be

Operate the machine only with the

fully informed of the operation and

equipment and component combina-

application of this or comparable ma-

tions approved by the Manufacturer.

chines.

Clearcut data are given in the tech-

nical specifications.

The necessary know-how can be ac-

quired in several days’ instruction,

Never install and commission other

e.g. by a CNH mechanic or by at-

equipment and component combina-

tending a CNH operators’ training

tions without the Manufacturer

course.

having first inspected and approved

the project.

PERSONAL PROTECTIVE WEAR

Before starting work or travelling

AND WORKING CLOTHING

with the machine, check that the

Wear a safety helmet and working

braking, steering, signalling and

footwear with non-slip soles.

lighting systems are fully functional.

Smooth soles may slip from steps

and pedals, resulting in injury or in-

Poor visibility may result in acci-

correct operation.

dents. Always clean the windows

and the glass covers of all lights be-

Wear closely fitting working clothing

fore starting up the machine.

when operating the machine.

Loose, wide garments may result in

Check that all warnings and safety in-

the control lever being inadvertently

structions attached to the machine

activated.

are present and legible.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 14

SAFETY INSTRUCTIONS

F156.6 / F156.6A

ENTERING AND LEAVING

MARSHALLERS

THE MACHINE

The marshall must keep outside the

Use only the steps, platforms and

hazard zone.

handrails provided when entering

and leaving the machine.

Have a marshall to assist you:

- when you have no clear overview

Always keep steps, platforms, han-

over the hazard zone of the ma-

dles and handrails in a non-slip, safe

chine;

state and remove any oil, grease,

- when reversing;

soil, clay, snow, ice and other foreign

- when shunting.

matter immediately.

Use only those communication sig-

Always face the machine when en-

nals which you and the marshall un-

tering and leaving.

derstand, or use aids for

communication (e.g. walkie-talkie /

camera).

HAZARD RANGE

Calls cannot be understood by the

The hazard range is that zone around

marshaller because of the noise

the machine in which persons are

made by the machine during opera-

within reach of falling loads or falling

tion.

attachments due to operational

movements by the machine, to its

Keep in constant contact with the

equipment and attachments or to

marshaller.

swinging loads.

Stop the machine immediately if you

lose contact with the marshaller.

PERSONS WITHIN THE HAZARD

ZONE

Always use the horn to warn persons

SECURING THE MACHINE

in the immediate vicinity of the ma-

Secure the machine as described in

chine before starting up the machine.

the chapter "Securing the Machine"

before:

Ensure that no one sets foot in the

- mounting or dismantling the at-

hazard zone of the machine. Interrupt

tachment;

work until such persons have left the

- parking the machine after daily op-

hazard zone.

eration;

- carrying out any servicing or repair

work.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 15

REFUELLING

EXPLOSION HAZARD

FILLING IN FUEL

Fuels and fuel vapours are highly

Read and observe "Refuelling -

flammable and likely to explode.

safety instructions" before filling in

Therefore, avoid the formation of

fuel.

sparks and do not use open flames

such as lighters or matches for illu-

mination purposes.

REFUELLING FROM CANS

If the machine is filled up frequently

or regularly with fuel from cans or

POSSIBLE HEALTH HAZARD

drums, there is an increased risk of

Diesel fuel and the fuel vapours are

dirt particles and water getting into

a health hazard.

the fuel system.

Fuels must not be swallowed.

Avoid prolonged contact with the

In this case:

skin.

- always fill in fuel through a

Do not inhale the fumes.

finemeshed strainer;

Wear protective gloves or use a bar-

- use only microfilter-equipped suc-

rier cream.

tion hoses;

Do not eat, drink or smoke during re-

- dewater the fuel filter more often

fuelling.

than specified in the servicing plan;

- drain water and deposits from the

tank bottom at shorter intervals;

AVOID ENVIRONMENT POLLUTION

- replace all fuel filters at shorter in-

Avoid spilling fuel. Do not let fuel get

tervals.

into the ground, it pollutes the envi-

ronment.

Soak up any overflowing fuel imme-

NEVER FILL IN "BIO-DIESEL"

diately with cleaning rags or binding

The injection system and the engine

agents and discard without polluting

are at risk of being damaged if "Bio-

the environment.

diesel" is used.

Report fuel accidents immediately to

Fill up the machine only with diesel

the owner of the machine or to his

fuel made from mineral oils acc. to

representative.

the EN 590 standard.

For more information please contact

your dealer service.

SECURING THE MACHINE

Secure the machine against unau-

thorized starting during refuelling:

- park the machine on level and firm

ground;

- lower the working equipment to the

ground;

- switch off any fuel-operated auxil-

iary heaters and air conditioners;

- shut off the engine;

- apply the parking brake;

- withdraw the key from the keys-

witch of the electrical system.

Refuelling must always be per-

formed from the ground.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 16

SAFETY INSTRUCTIONS

F156.6 / F156.6A

REFUELLING SYSTEM (Option)

RISK OF EXPLOSION

Do not smoke and do not use naked

flames. Fuels and fuel vapours are

flammable. Risk of fire.

Switch off fuel-operated auxiliary

heating systems and air condi-

tioners.

HEALTH AND ENVIRONMENT

PROTECTION

Fuel may damage the skin. Wear pro-

tective gloves or use a barrier cream.

Do not spill fuel. Do not let fuel seep

into the ground. Fuel pollutes the en-

vironment.

Soak up any overflowing fuel imme-

diately with cloths or binding agents.

Then discard without polluting the

environment.

Report any accidents involving fuels

immediately to the owner of the ma-

chine or his authorized representa-

tive.

SECURING THE MACHINE

Secure the machine against unau-

thorized starting during refuelling:

- Lower the working equipment to

the ground

- Shut off the engine

- Withdraw the key from the elec-

trical system key-switch.

INCREASED RISK

OF CONTAMINATION

If the machine is refilled frequently

or regularly with fuel from cans or

barrels, there is an increased risk of

contamination for the fuel system.

In this case, the fuel prefilter must be

drained and cleaned more often than

specified in the servicing plans.

The fuel filter must be replaced at

shorter intervals.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 17

DRIVING

BEFORE SETTING OFF

PARKING THE MACHINE

Clean off any earth, mud, snow, ice,

Machines parked on sloping terrain

grease and oil adhering to your

may start moving inadvertently.

working footwear before operating

Park the machine therefore on a level

the machine. There is otherwise a

surface and lower the working equip-

risk of slipping off the pedals and in-

ment to the ground.

itiating inadvertent movements.

DRIVING LONG DISTANCES

Adjust the driver’s seat, steering

The blade must not interfere with the

column and mirrors and fasten the

steering range of the front wheels or

safety belt before setting off.

with the steering linkage.

Do not let other persons accompany

Do not start the machine when the

you on the machine.

central warning lamp is flashing; lo-

cate the cause of the fault before-

Warn anyone in the vicinity with the

hand and rectify.

horn before setting off.

When driving on public roads:

- Observe the requirements of the

machine’s general operating

DO NOT TOW TRAILERS

permit.

The machine is not suited for towing

- Close the cab door.

trailers or other vehicles. Risk of

- The first-aid kit, the warning tri-

damage to gearboxes and axles.

angle and the warning lamp must

The tow-bar coupling is provided

be on board.

only for towing or recovering the ma-

chine out of hazard areas or for fas-

- Check that the contents of the first-

tening of the machine on transport

aid kit is complete, replacing

vehicles; see also "Machine re-

missing or old parts.

covery / towing".

Check when the engine is running:

- When making short left / right turns

the steering wheel must move

DRIVING ON SLOPES

easily and the steering must react.

Make sure the wheels have sufficient

- After driving a short distance, the

grip; only then are the machine’s full

braking effect of the service brake

steering and braking capabilities

must be tested.

available.

Do not drive across slopes.

Never idle the machine with the gear

Never turn on slopes.

lever in neutral position, e.g. when

Never steer with the pivot steering on

driving downhill.

slopes.

When driving with the door open, it

must be locked in its limit position.

REVERSING

During reversing operations, your

Bring the machine to operating tem-

view of the hazard zone is restricted.

perature as described in the "Opera-

Therefore, seek the assistance of ex-

tion and Maintenance Istruction

perienced marshallers. Instruct the

Manual - Warming up the machine"

marshaller in order to ensure that

before setting off.

you understand his signals cor-

rectly.

Never demand full performance from

the engine unless the machine is at

operating temperature.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 18

SAFETY INSTRUCTIONS

F156.6 / F156.6A

SEAT BELT

Always belt up before driving.

Never run belt over rigid or fragile ob-

jects such as bunches of keys or

spectacles. This may result in injury.

The belt must always be flat and firm

against the body and must not be

jammed.

The buckle opening must not be

locked, e. g. with paper, as the buckle

can then not engage.

Damaged seat belts and those

stretched in an accident must be re-

placed.

ADJUSTING THE STEERING

COLUMN

Do not adjust the steering column

while driving. Concentrate on the

road to avoid accidents.

Before adjusting the steering

column:

- Stop the machine;

- Set the gearshift lever to neutral po-

sition;

- Apply the parking brake.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 19

MACHINE RECOVERY / TOWING

TRANSPORT

Tow the machine with a tow-rod or

The machine may be loaded and

towing cable only.

transported only if all safety regula-

tions are complied with.

The tow rod or cable must be undam-

aged.

Entrust loading and transporting of

They must be dimensioned in such a

the machine to a company experi-

way that the calculated breaking load

enced in the transport of heavy

is equal to three times the tractive

equipment.

power of the towing machine.

The responsibility for loading and

The towing vehicle must have ade-

transporting lies with the transport

quate tractive power. Drive slowly

company or their representative.

and carefully.

Remove oil, grease, soil, mud, snow,

All persons must keep clear of the

ice and other materials from the ma-

tow rod or cable.

chine’s wheels and from ramps and

Tow only if the brakes and steering

loading platforms of the transport ve-

of the machine are functioning prop-

hicle to minimize slipping.

erly and if the machine cannot be

transported in another way.

Use only tying equipment of suffi-

cient strength (the weights of the ma-

Tow defective machines only as far

chine are set out in the Section

as is needed to recover the machine

“Technical Data”).

from hazard zones.

After being recovered, the machine

CRANE LOADING

must be secured against inadvertent

movement and unauthorized

starting.

Block the pivot joint if the machine is

to be lifted by a crane for loading.

Repair the machine before trans-

porting it over longer distances, or

load it onto a transport vehicle.

The towing speed must not exceed

10 km/h. Tow the machine only out

of the hazard zone or transport it on

a low loader.

Excessive trailing may damage the

transmission.

TOW ROD COUPLING

The tow rod couplings must not be

used to tow trailers.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 20

SAFETY INSTRUCTIONS

F156.6 / F156.6A

WORKING OPERATION

GRADER DEPLOYMENT

The versatility of the graders and the wide range of

Read the chapters "Fundamental

materials handled allow many different applications

safety instructions" and "Operation

and working methods.

- General instructions" carefully and

observe the instructions given in

We therefore recommend initial operator instruction

these sections.

by the Manufacturer.

Inspect the site for underground gas,

power and water lines before starting

Read and observe: "Operation and

work. Any damage to such lines is a

Maintenance Instruction Manual -

life-threatening risk.

Warming up the machine".

Clean off any earth, mud, snow, ice,

Never exceed the admissible trans-

grease and oil adhering to your

verse and longitudinal inclination of

working footwear before operating

the machine. This affects or inter-

the machine. There is otherwise a

rupts the engine lubrication.

risk of slipping off the pedals and in-

itiating inadvertent movements.

The admissible engine inclinations

are:

When driving with the door open, it

must be locked in its limit position.

Transverse: left

right

35°

Sound the hooter to warn persons in

the immediate vicinity of the machine

Longitudinal: deep

high

before starting work.

35°

Never drive across slopes.

Lower the working equipment imme-

diately and shut off the engine if the

Never turn on slopes.

warning lights for engine tempera-

ture, engine oil pressure or alternator

Never steer with the pivot steering on

light up.

slopes.

Stop work if anyone is in the hazard

range of the machine. Continue

working only after such persons

have left the hazard range.

Always use and operate the machine

in such a way as to guarantee its sta-

bility.

Trenches and building pits may cave

in. Keep well clear of them.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 21

WORKING EQUIPMENT

PERSONNEL

TOOLS AND AUXILIARIES

Assembly work may be performed

Tools, lifting equipment, slings,

only by operating or repair personnel

chocks and other equipment must be

possessing the necessary know-

in safe operating and working condi-

how.

tion.

In the case of insufficient knowhow,

Metal splinters can cause injury

meticulous instruction must be

when accessory bolts are being

given by experienced personnel, e.g.

driven in and out. Therefore, a brass

by the Manufacturer.

or copper mandrel should be used

and protective goggles must be

The personnel must have read and

worn.

understood the operating instruc-

tions, especially the chapter "Funda-

When entering and leaving the cab,

mental safety instructions".

use only the intended steps, plat-

forms and handrails.

These people only may operate the

machine during installation, in order

Keep steps, platforms and handles in

to make corrections to the working

safe condition for footholds and

equipment.

handholds. Remove any oil, grease,

Misuse or improper operation of the

earth, clay, snow, ice other sub-

machine or its working equipment

stances immediately.

can be highly dangerous.

SECURING WORKING EQUIPMENT

PERSONAL PROTECTIVE

Set all working equipment down on

EQUIPMENT AND WORKING

the ground, so that no movements

CLOTHES

can occur if mechanical or hydraulic

Wear closely fitting working clothes

connections become detached.

when working on the machine.

Loose, wide working clothes can

When working in jointed areas lock

catch in machine parts and cause in-

the pivot joints. Remove the locks

jury.

when work is finished.

Wear a safety helmet, protective

Secure any equipment or compo-

working boots and gloves.

nents which are to be attached or de-

tached or whose position is to be

altered, with hoists or suitable

slinging/supporting devices to pre-

vent them from moving, slipping or

falling.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 22

SAFETY INSTRUCTIONS

F156.6 / F156.6A

SECURING THE MACHINE

Work on the working equipment

RISK OF INJURY

should only be carried out if the ma-

The machine must not be started by

chine has been secured as described

unauthorised persons.

in the chapter "Securing the ma-

Therefore, secure the machine.

chine".

Secure the machine as described below:

SELECTING THE WORKING

•

Before carrying out any servicing or repair work

EQUIPMENT

on the machine.

The machine can be fitted with a va-

•

Before fitting or changing the working equipment.

riety of working equipment. The

•

Park the machine on level, firm ground.

working equipment components are

•

Set working equipment down on the ground.

assembled with hydraulic cylinders

•

Apply parking brake.

and connectors. The components

can be combined in a variety of ways

so that the working equipment can

Never shut off the engine out of full

be best adapted to the specific task.

load, but continue running for ca.

three minutes at idling speed to cool

Operate the machine only with equip-

down.

ment and component combinations

approved by the Manufacturer for

•

Turn off engine.

this machine.

•

Remove key from the key switch in the electrical

Install and commission equipment

system.

and component combinations only

•

Depressurize the hydraulic system.

after the Manufacturer has checked

•

Lock the pivot joint.

the proposal and given its approval

•

Secure open hood.

in writing.

•

Secure the machine from rolling away by placing

chocks under the wheels.

Attachments from other manufac-

•

Switch off battery main switch and remove

turers subject to the EC Machine Di-

switching lever.

rective 89/392 EEC may be mounted

and put into operation only if:

•

Disconnect batteries before work on the electrical

system or before welding work.

- the manufacturer’s declaration of

conformity,

•

When doing welding jobs on the machine, observe

"Repair work - Welding operations”.

- the declaration of compatibility

from CNH are at hand.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 23

INSPECTION AND SERVICING

GENERAL INSTRUCTIONS

WORKSHOP MANUAL

SECURING WORKING EQUIPMENT

No inspection and servicing work

Stand working equipment on the

must be carried out until the Service

ground in such a way that no move-

Manual has been read and under-

ments can be made if mechanical or

stood.

hydraulic connections become de-

tached.

Pay special attention to the:

When working in jointed areas, block

off the joints. Remove the blocks on

"Fundamental Safety Instructions"

finishing work.

and all warnings and safety instruc-

tions attached to the machine.

If the machine has to be jacked up,

the front axle must first be wedged

The Workshop Manual contains the

in place to prevent it from moving.

necessary information in order to

Secure any equipment or component

perform all repair and maintenance

which is to be mounted or disman-

jobs.

tled, or whose position is to be

However working on the machine

changed, with hoists or appropriate

must be carried out only by special-

slinging/supporting devices to pre-

ised personnel specially trained for

vent them from moving, slipping or

this activity.

falling inadvertently.

INSPECTION AND SERVICING

SECURING THE MACHINE

PERSONNEL

Carry out servicing work only if the

Inspection and servicing personnel

machine is secured as described in

must have the necessary knowhow

the chapter "Securing the Machine".

on the inspection and servicing of

this or comparable machines.

CLIMBING ONTO AND OFF

The necessary know-how can be ac-

THE MACHINE

quired in several days’ instruction,

Use only the steps, platforms and

e.g. by a CNH mechanic or by at-

handrails provided when climbing

tending a CNH training course.

onto or off the machine.

Always keep steps, platforms, han-

dles and handrails in a non-slip, safe

PERSONAL PROTECTIVE

state and remove any oil, grease,

EQUIPMENT

soil, clay, snow, ice and other foreign

AND WORKING CLOTHING

matter immediately.

Wear closely fitting working clothing

when working on the machine.

Always face the machine when

Loose, wide garments may catch on

climbing on and off.

machine parts and result in injury.

Wear a safety helmet, safety foot-

wear, gloves and, in the event of high

CHECK STATE OF TOOLS

noise levels, ear protectors.

Use only fully functional, reliable

tools.

Select the right tool for the job.

Wrenches of the wrong size, for ex-

ample, may slip and cause injury.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 24

SAFETY INSTRUCTIONS

F156.6 / F156.6A

CLEANING JOBS

FASTENING AND SECURING

Clean the units within the working

ELEMENTS

range before starting work.

Check fastening and securing ele-

Select the cleaning agent according

ments, e.g. bolts, nuts, washers, be-

to the material constituting the parts

fore using them again.

to be cleaned.

Replace any damaged parts.

Example: Never clean rubber or elec-

trical parts with solvents or steam

jets.

HANDLING OILS AND GREASES

Use lint-free cleaning rags when

Hot lubricant or hydraulic oil

working on the hydraulic system or

emerging uncontrolled from the

the engine.

system may result in severe burns.

Cleaning agents and solvents may

give off harmful, readily flammable

Cool any burns immediately with

vapours.

running water and apply a dry

Never work with such agents except

dressing.

on well ventilated premises; never in-

hale the vapours and never smoke.

Never set foot within reach of the

Prevent solvents and cleaning

emerging oil jet.

agents from coming into contact with

the skin.

Avoid contact with the skin. Wear

Wear solvent-resistant gloves.

gloves and firm protective clothing.

Observe the instructions on the

packaging.

Used oil may be harmful to the skin.

Clean soiled skin thoroughly with

HANDLING FLAMMABLE LIQUIDS

warm soapy water and apply a barrier

When handling flammable liquids:

cream. Never use fuels or solvents

- never smoke;

for cleaning the skin.

- keep away from unshielded light

If you have swallowed any oil, avoid

sources and naked flames.

vomiting but consult a doctor or a

Fuel and other consumables often

hospital immediately.

have low flash points and are readily

ignited.

Never attempt to extinguish burning

VISIBLE LOSS OF OIL

liquids with water. Use:

Have any visible leakage repaired im-

- dry powder,

mediately.

- carbon dioxide or

- foam extinguishers.

Escaping oil is an environmental

hazard.

Water used for extinguishing

purposes would vapourize

Soak up any oil that has escaped with

instantaneously on contact with

a binding agent. Sweep up binding

burning substances and spread

agent and dispose of it separately

burning oil, for example, over a wide

from other waste.

area. Water generates short circuits

in the electrical system, possibly

producing new hazards.

Notify the fire brigade.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 25

RELIEVING RESIDUAL PRESSURE

ENVIRONMENTALLY COMPATIBLE

IN THE HYDRAULIC SYSTEM

DISPOSAL

Only unpressurized hydraulic sys-

Oils, greases, brake fluids, cleaning

tems may be opened. Even when a

agents, solvents and oily compo-

machine is parked on a horizontal

nents, e.g. filters, cleaning rags, re-

surface with its attachments sup-

placed wear parts and unserviceable

ported on the ground and its driving

machine parts, must be disposed of

motor switched off, there may still be

separately in the interests of environ-

substantial residual pressure in

mental protection.

parts of the hydraulic system, e.g.

primary pressure from the last hy-

Never dispose of such substances

draulic movements prior to stopping

with standard household refuse.

the machine.

Empty substances into the con-

Residual pressure is reduced only

tainers provided for this purpose.

gradually. If an intervention into the

hydraulic system is to be undertaken

Even biodegradable, "environmen-

immediately after stopping, depres-

tally friendly" hydraulic oil has to be

surize the system as described in the

disposed of separately like any other

Section “Hydraulic System".

oil.

Never allow oils and oily waste to get

SCREWED CONNECTIONS, PIPING,

into the soil or into water: environ-

HYDRAULIC HOSES

mental hazard!

Repair any leakages in the piping and

hose system immediately.

SEALING FACES

A fine, highly pressurized jet of hy-

Clean sealing faces prior to as-

draulic oil can penetrate the skin.

sembly.

Never search for leakages with the

fingers, but use a piece of cardboard

EXHAUST GASES

and always wear goggles.

Exhaust gases are a health hazard:

never inhale them.

If oil has penetrated into the skin,

consult a doctor immediately.

When working on enclosed

premises, draw off exhaust gases

Never repair damaged piping; always

with a suction plant and ventilate the

replace it.

premises well.

Replace hydraulic hoses immedi-

ately on detecting any damage or

moist areas.

Tighten leaking screw plugs only

when the system is depressurized.

Escaping oil is an environmental

hazard.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 26

SAFETY INSTRUCTIONS

F156.6 / F156.6A

HANDLING BATTERIES

SELECTING OILS AND GREASES

Batteries give off explosive gases.

Use the recommended qualities only,

matching viscosities with the tem-

Never handle batteries close to

perature level.

naked flames and unshielded light

sources, never smoke.

Remove batteries if welding or

FILTERS

grinding is to be done at close quar-

Replace all filter elements or filter

ters and store them in a safe place.

cartridges within the specified pe-

Battery acid is toxic and corrosive.

riods.

Avoid any contact with the skin,

All filters are coordinated carefully

mouth, eyes and clothing. Avoid

with the equipment. Original Parts

spilling battery acid or inhaling the

must be used to ensure smooth run-

vapours.

ning and a long service life of the en-

gine and the hydraulic units.

Wear solvent-resistant gloves, firm

protective clothing and goggles

when handling batteries.

SEALING ELEMENTS

If acid splashes onto the skin, rinse

When dismantling parts, pay atten-

off thoroughly with water, then seek

tion to sealing elements.

medical advice at a medical practice

Check sealing elements prior to in-

or hospital.

stallation and replace any that are

If the eyes are splashed with acid,

even slightly damaged.

rinse thoroughly with running water,

then seek medical advice immedi-

When assembling, ensure a perfect

ately at an opthalmological practice

fit.

or a hospital.

Never wear metal necklaces, brace-

OIL-LEVEL CHECK

lets or watch-straps when working

AND OIL CHANGE

on the battery. The metal parts may

Position the machine horizontally.

induce a short circuit, resulting in

burns.

Change the oil when the machine is

at operating temperature.

Dispose of used batteries separately

Warm oil flows better and carries

from other waste in the interests of

suspended particles (carbon or

environmental protection.

abraded matter) better.

PRIOR TO WORK

LUBRICATING

ON THE ELECTRICAL SYSTEM

Clean the lubricating nipple, then lu-

Prior to any work on the electrical

bricate as scheduled.

system involving tools, spares etc.

coming into contact with electric ca-

bles or contacts, disconnect the bat-

tery.

AFTER SERVICING

To prevent corrosion, coat all bright

Disconnect first the negative pole,

metal parts with a grease film.

then the positive pole.

On completing work, reinstall all pro-

After work:

tective devices.

Connect first the positive pole, then

the negative pole.

Never start up the drive motor while

Read and observe the chapter "Elec-

work is being done on the machine.

trical system".

Carry out a performance test with the

machine.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 27

FUEL SYSTEM

EXPLOSION HAZARD DUE

NEVER FILL IN "BIO-DIESEL"

TO VAPOURS

The injection system and the engine

Fuel vapours are easily flammable

are at risk of being damaged if "Bio-

and likely to explode. Therefore,

diesel" is used.

avoid the formation of sparks and do

not use open flames such as lighters

Fill up the machine only with diesel

or matches for illumination pur-

fuel made from mineral oils acc. to

poses.

the EN 590 standard.

When you have to work on the fuel

For more information please contact

system:

your Dealer service.

- shut off the engine and the auxiliary

heating;

REFUELLING FROM CANS

- secure the machine;

If the machine is filled up frequently

- avoid open flames;

or regularly with fuel from cans or

- do not eat, drink or smoke.

drums, there is an increased risk of

dirt particles and water getting into

the fuel system.

POSSIBLE HEALTH HAZARD

Diesel fuel and the water / fuel mix-

In this case:

ture drained off are a health hazard.

- always fill in fuel through a

These liquids must not be swal-

finemeshed strainer;

lowed.

- dewater the fuel filter more often

Avoid prolonged contact with the

than specified in the servicing plan;

skin.

- drain water and deposits from the

Do not inhale the fumes.

tank bottom at shorter intervals;

Wear protective gloves or use a bar-

- replace all fuel filters at shorter in-

rier cream.

tervals.

AVOID ENVIRONMENT POLLUTION

Collect escaping fuel and discard

without polluting.

Fuel filter cartridges and fuelstained

cleaning rags must be disposed of

separately from other waste.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 28

SAFETY INSTRUCTIONS

F156.6 / F156.6A

ELECTRICAL SYSTEM

Risk of injury from battery acid and

ALTERNATOR

gases.

Never disconnect electrical connec-

tions on the alternator, regulator and

Wear goggles, protective gloves and

battery when the engine is running.

strong working clothes.

This would damage the alternator

and regulator.

PRIOR TO WORKING ON THE ELEC-

TRICAL SYSTEM

When connecting the batteries,

Shut off the engine.

never interchange the cables (pay at-

Set ’Electrical System’ key switch to

tention to polarity).

0 and withdraw key.

Voltage and continuity tests must be

Set battery main switch to OFF and

done with a meter only.

withdraw switching lever.

Disconnect control elements and

Never use a test lamp.

control console from machine cir-

cuit.

Never check by touching ground

with a bare wire.

Prior to working on the electrical

system where tools, spare parts, etc.

The resulting short circuit damages

may come into contact with electrical

the alternator and the regulator.

cables or contacts, turn off the bat-

tery main switch or disconnect the

When starting up the engine, the al-

battery.

ternator is controlled (pre-excited)

Disconnect the negative pole first,

by an electronic circuit. This ensures

then the positive pole.

that the alternator can discharge

power.

After work:

Reconnect the positive pole first,

The circuit is an integral part of the

then the negative pole.

central electronic system in the con-

sole.

Read and observe "Operating In-

structions - Alternator, control ele-

A LED in the console (load control)

ments and control console".

shows that the alternator is func-

Read and observe "Inspection and

tioning correctly. This LED must light

servicing - General instructions".

up when the key-switch is switched

on and go out when the engine is run-

Always use a meter for voltage and

ning.

continuity testing.

If this is not the case, there is a fault

Do not use any test lamp.

in the alternator circuit or in the con-

sole.

Do not "tap against ground".

This will cause a short circuit with

To prevent further damage, the

consequent damage to the generator

cause of the fault must be located

or to the PCS electronic system.

and rectified as quickly as possible.

Consult your local Dealer.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 29

POWERSHIFT TRANSMISSION

HYDRAULIC SYSTEM

Read and observe: "Inspection and

RISK OF INJURY

servicing - General instructions".

from hydraulic oil under high pres-

sure.

As the torque converter of the pow-

ershift transmission may be emptied

from hydraulic fluid or hot parts of

into the transmission while the en-

the engine.

gine is stationary, the oil level must

be checked while the engine is run-

Before working on the hydraulic

ning.

system, make sure the system has

been depressurized and that any re-

It is vital therefore to respect the

sidual pressure has also been re-

safety instructions set out in the fol-

leased (see the section "Hydraulic

lowing sections.

system").

Shut off the engine and let the ma-

chine cool down.

Secure the machine as described in

the chapter "Securing the machine".

Avoid skin contact with hydraulic

oils. Skin contact with hydraulic oils

is a health hazard.

Wear gloves and firm working

clothing.

Read and observe: "Inspection and

servicing - General instructions".

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 30

SAFETY INSTRUCTIONS

F156.6 / F156.6A

BRAKES

PERSONAL

ACCUMULATORS

Do not carry out inspection and

Accumulators are installed in the hy-

maintenance work on brakes unless

draulic system. These accumulators

you are qualified for working on

contain nitrogen under high initial

brake systems.

pressure.

If in doubt, have the work performed

Even when the hydraulic pressure in

by our after-sales service.

the system is reduced, the nitrogen

remains in the accumulator.

Read and observe the instructions in

the section: "Inspection and serv-

The accumulators are completely

icing - General instructions".

safe in operation. If incorrectly han-

dled, however, there is a risk of ex-

plosion.

SECURING THE MACHINE

So:

Inspection and maintenance work on

- Never handle accumulator me-

brakes should only be carried out if

chanically, never weld or solder it.

the machine has been secured as de-

- Testing and servicing work must be

scribed in the section "Securing the

carried out by experts only.

machine".

- Prior to any testing and servicing

work, depressurize the hydraulic

part of the system.

HEALTH PRECAUTIONS

- To dismantle the accumulator, al-

Do not inhale abraded particles from

ways wear goggles and working

brake linings. Wear a breathing

gloves.

mask.

- Fill accumulator with nitrogen only,

never with compressed air or ox-

ygen.

- Report any defects or damage to

the machine owner without delay.

- Prior to recommissioning, an in-

spection by a specialist or expert is

essential if the accumulator was

damaged or if the admissible oper-

ating temperature or operating

pressure was exceeded.

Never remove or paint over warning

and information plates, rating plates

or type identification markings. Re-

place illegible or damaged plates im-

mediately.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

F156.6 / F156.6A

SAFETY INSTRUCTIONS

0 - 31

TYRES AND WHEELS

RISK OF INJURY

TYRE PRESSURE

Heat-induced combustion of gas in-

Bursting tyres and parts splintering

side the tyre may lead to explosions

away from the rims or from the tyre

in air-inflated tyres.

itself may cause severe injury.

This heat may be due, for instance,

The following instructions must

to frequent use of the brakes or to

therefore be strictly observed:

welding work carried out on the ma-

Before inflating the tyre, check the

chine. A heat-induced tyre explosion

tyres, rims and rim parts for

is more violent than that occuring

damage, penetrated foreign ob-

during normal bursting of tyres.

jects and proper fitting.

Such an explosion can eject parts of

Have all damage detected repaired

the tyre and the rim over several hun-

by a qualified workshop.

dreds of meters. Exploding and/or

Check the tyre inflation pressure

bursting tyres and ejected parts of

only when the tyres are cold. After

tyres and rims may cause severe or

warming up, the pressures indi-

sometimes even fatal injuries.

cated are higher than ususal.

Use a tyre inflator with a long filling

Therefore:

hose, snap-on valve and pressure

If a tyre is suspected to be too hot,

gauge.

secure the machine and wait some

Use only compressed ambient air

distance away until the tyre has

for inflating the tyres. Never use

cooled down.

flammable gases: risk of explosion.

Before inflating the tyre, check the

tyre itself, the rims and rim compo-

Keep away from the tyre during in-

nents for damage, penetrated for-

flation and always stand besides

eign objects and perfect fit.

the tyre tread.

Have detected faults always recti-

Watch the tyre and the gauge of the

fied immediately by specialized

filling gear permanently during in-

workshops.

flation and never exceed the spec-

If you are in doubt about the safe

ified tyre pressures.

condition of the tyre, the rims or rim

Place a safety cage around disman-

components, do nothing yourself

tled wheels.

but have the complete wheel re-

When pumping up, make sure all

moved by a special workshop.

persons are well clear of the tyre.

Changing of tyres, rims or rim com-

ponents requires special tools and

Always inflate the tyres to the pre-

procedures and must therefore al-

scribed pressure:

ways be carried out by a workshop

- Excessive pressures result in poor

with special equipment for this kind

off-road handling properties and

of work.

tyres may burst;

Never carry out works on rims and

tyres unless you are qualified to do

- Insufficient tyre pressures lead to

so.

increased tyre wear and to inade-

quate stability of the machine.

WHEEL-NUTS

Always tighten the wheel-nuts with a

torque wrench. Recheck with a

torque wrench for tightness after

several hours of operation.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 32

SAFETY INSTRUCTIONS

F156.6 / F156.6A

DRIVING ON ROADS

When driving on the road check that

the tyres have the prescribed min-

imum tread and the correct air pres-

sure.

Always make sure that both axles are

equipped with tyres of the same size

and same degree of wear.

Tyres with different diameters may

cause damage to the differentials.

To avoid excessive tyre wear:

- inflate to the correct air pressure;

- do not start or brake abruptly;

- take corners slowly.

Clean the tyres and the gaps between

the tyres before driving on public

roads. This helps to avoid putting

other road users at risk from soiled

traffic lanes or from lumps of soil or

stones ejected from the wheels.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)