New Holland F106.6 / F106.6A / F156.6 / F156.6A. SERVICE MANUAL (2007)

TO THE READER

mechanical assembly:

This repair manual is intended for professional

• technical

description

and information

repair technicians. It contains important

regarding the operation of essential systems

information, needed for carrying out specialised

and equipment;

repair work.

• information about performance tests on the

Please read carefully through the repair manual,

machine;

and also the operating instructions, before

• troubleshooting and information for identifying

undertaking any repair work.

faults on the machine;

Use the repair manual, but also use the operating

• technical information necessary for repair

instructions and parts catalogue for reference

operations on the machine, the equipment

and guidance, even if you are already familiar with

necessary for carrying out repairs, information

the technology used in graders.

about maintenance standards, procedures for

The repair manual will allow the experienced

removal/installation and for disassembly/

construction machine mechanic to carry out the

assembly.

necessary repair work correctly.

You can use the list of contents to find the necessary

information easily.

The illustrations are partially simplified to make

USE

them more easily understood.

The repair manual describes the machine model in

Although it may result in apparent differences with

the form it was originally delivered. It does not

your particular grader model, this is intended to

describe any implements and modifications that

make the information clearer.

maybe added later.

The repair manual contains the following

information:

REPAIR

• Safety instructions

Carry out the required repair operations as soon as

possible. Doing so will reduce repair costs and

• Technical data and special tools

increase the availability of your grader.

• Function description

In all repair operations, always follow the

• Performance test

instructions in the workshop manual and the

• Troubleshooting and fault correction

operating instructions. Customer Service will be

pleased to carry out for you any extensive

• Repair instructions

operations not described in the workshop manual.

The Safety Instructions section describes the

Always use only original replacement parts.

recommended procedures for preventing the risk of

injuries to the operator and the personnel

responsible for maintaining and working on the

FURTHER REFERENCE MATERIAL

machine.

In addition to the present manual, please also refer

The Specifications section contains service data,

to the following documentation:

conversion tables and lists of special tools and

• Operating instructions

maintenance materials required. The other sections

contain the following information for each

• Parts catalogue

Edition 12/2007

87726937A

PARAGRAPH 0

LIST OF CONTENTS

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

WARNING AND INSTRUCTION PLATES

0-12

2.1

Left side of vehicle

0-12

2.2

Right side of vehicle

0-14

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

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

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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87726937A

0 - 1

BASIC SAFETY INFORMATION

1.1

Warning notes and symbols

The Grader can also be used in conjunction with

other operating equipment for special applications.

The following symbols are used in the operating

The Technical Data provide clear information on this

instructions to indicate particularly important

subject.

information:

CAUTION: Safety rules and procedures, designed

Proper use of the machine also means following the

to protect the driver and others from mortal dangers

operating instructions and applying the inspection

or injuries, and to prevent serious damage to

and maintenance conditions.

property.

Using the grader for any other purpose, for example:

NOTE: Notes and precautions to avoid damage to

• transporting personnel,

machinery and property.

• as a working platform,

• towing or carrying loads without attaching the

1.2

Correct use

proper working attachments, is considered

This machine is constructed according to the

improper use.

recognized mechanical safety regulations, and

Improper use of the machine can pose mortal

using state-of-the-art technology. Nevertheless,

danger to operating personnel or other persons, or

when in operation, situations can occur that present

may result in physical injuries, or may cause

serious or mortal dangers to the operator and third

damage to property.

parties, or which could cause damage to the

machine and other property.

The manufacturer, supplier will not be liable for any

The machine should be used only if it is in proper

damage resulting from improper use. In this case,

operating condition, and only by operators who are

the user alone will be responsible.

aware of the dangers, know the safety procedures,

and have read the operating instructions!

Noise emission data as stated in statutory order 3

The important notes are placed at the start of this

pursuant to the mechanical safety law of 18/01/1991

section. Immediately repair any faults (or have them

or EC machinery guideline 89/392/EWG.

repaired) if these could have a prejudicial effect on

safety.

Using the earth-moving equipment properly, with

ISO 7096 standard driver seats, will ensure that the

This Grader is principally designed for:

measured vibration frequencies

(measured as

• Creating a double course

described in ISO 2631 Part

1) meet the

• Clearing top soils

requirements regarding protection from whole-body

vibrations.

• Scarifying old road surfaces and hard ground

• Cutting embankments

• Clearing ice and snow

• Placing, spreading, mixing, and compressing

materials.

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0 - 3

1.3

Organizational procedures

Check that all safety information and warning

notices at or on the machine remain fully and clearly

Keep the operating instructions stored at the

legible.

location where the machine is used, and in a place

where they can be easily accessed, for example in

If there are any changes that affect safety or the

the holder provided!

operating behaviour of the machine, stop the

machine immediately and inform the person or

In addition to the operating instructions, follow and

department responsible.

draw attention to the general legal regulations and

other obligatory requirements regarding accident

Modifications, conversions or retrofits that might

prevention and environmental protection!

affect safety must not be made to the machine

without the approval of the supplier! This also

These requirements may, for example, concern the

applies to the installation or re-adjustment of safety

handling of dangerous goods, the making

devices and valves, or welding work on

available / wearing of personal protective

load-bearing parts.

equipment or highway code regulations.

Replacement parts must meet the technical

Supplement the operating instructions with

requirements stated by the manufacturer. This can

additional instructions, including supervisory and

be ensured by always using original replacement

reporting duties, in order to take account of specific

parts.

operating conditions, for example, Particular work

plans, working processes or personnel.

Replace hydraulic hoses at the proper times or at

the stated intervals, even if no defects affecting

Before starting work, personnel appointed to carry

safety are visible!

out work on the machine must have read the

operating instructions, and particularly the Safety

For the periodic checks / inspections, keep to the

Information section. It will be too late to do this when

specified intervals or the times specified in the

the actual work has begun. This especially applies

operating instructions.

to personnel employed occasionally, for example,

for setting up or maintaining the machine.

When maintenance work is being carried out, fire

extinguishers and their operating instructions must

You must at least check occasionally that personnel

be displayed at a suitable place!

can demonstrate safety and risk awareness when

working!

Pay attention to fire detection and firefighting

devices.

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!

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Edition 12/2007

1.4

Personnel selection and

Work on the machine’s electrical equipment should

only be carried out by a qualified electrician, or a

qualifications - basic

trained technician under the supervision and

responsibilities

guidance of a qualified electrician, in accordance

Only trained and reliable personnel should be

with the electrical regulations.

allowed to work on or with the machine. Apply the

minimum age required by law.

Work on the chassis, an the brake and steering

systems should only be carried out by personnel

Only use personnel who have been suitably trained

trained for this purpose!

or instructed, and clearly set out the responsibilities

assigned for operating, setting up, maintenance,

Only personnel with the necessary skills and

and repair!

experience should be allowed to work on the

hydraulic systems.

Ensure that only the personnel appointed for the

task concerned is allowed to work on or with the

machine!

Define the responsibilities of the driver

(also in

relation to highway code regulations) and authorize

him/her to reject third-party instructions that would

lead to a breach of safety regulations.

Personnel being trained, instructed or briefed, or

persons undergoing general training, must only be

allowed to work on or with the machine if they are

given constant supervision by an experienced

person!

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0 - 5

1.5

Safety information for specific

Before starting work / driving, check whether the

brake, steering, lighting and signalling systems are

phases of operation

operational.

Normal operation

Refrain from any working methods that might be

Before moving off, always check that attachments

prejudicial to safety!

are secured to prevent accidents!

Before starting work, familiarize yourself with the

If using public roads, streets, or other areas, follow

particular working environment at the location

the regulations in the highway code and, if

concerned. Working environment includes, for

necessary, make the machine road-worthy as

example, obstacles in the working/traffic area,

required by the highway code before doing so.

load-bearing capacity of the ground, and safety

barriers necessary at the worksite relative to public

In conditions of poor visibility or when dark, always

traffic areas.

switch on the vehicle lights!

Take steps to ensure that the machine is only

Passengers should only sit in the passenger seats

operated when in a safe and operative condition!

provided for this purpose.

Only operate the machine if all safety devices and

When passing through underpasses, bridges,

safety-related systems, for example, removable

tunnels, under overhead lines, etc., always check

safeguards, emergency shut-off devices, noise

that there is sufficient headroom!

insulation, extractor systems, are present and in

operative condition.

Always keep at a sufficient distance from the edges

of trenches and embankments.

The machine must be inspected at least once in

each shift for visible damage and defects!

Any changes that occur

(including changes in

Do not use any working methods that might

operational behaviour) must be reported

endanger the stability of the machine!

immediately to the department or person

responsible! If necessary, stop the machine

Do not drive with overhead attachments positioned

immediately and secure it.

in a transverse direction; always drive with

attachments and loads lowered and near the

If there is a malfunction, stop the machine

ground, especially when driving uphill/downhill!

immediately and secure it! Faults must be repaired

immediately!

When on a gradient, always adapt vehicle speed to

the particular conditions! Always change to the

Start the machine only from the driver’s position.

lowered position in advance of the gradient, never

while driving on it!

Follow the operating instructions, during

the

switch-on/switch-off procedures.

Before leaving the driver’s seat, always immobilise

the machine to prevent it moving off accidentally,

and to prevent access by unauthorized persons.

Before starting up the machine, ensure that no one

Switch off the engine!

will be put at risk by when the machine is started!

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87726937A

Edition 12/2007

REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

1.6

Special operations when using

For assembly work carried out above body height,

use the appropriate safety hoists and work platforms

the machine, servicing and fault

provided for this purpose.

repair work as part of working

Do not use machine parts as hoists!

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

repair

work,

the

switch-on/switch-off procedures described in the

operating instructions and the notes concerning

repair operations.

Whenever required, seal off the repair area, leaving

plenty of room!

If the machine is switched off completely for

maintenance and repair work, it must be secured to

prevent it being switched on accidentally:

• Take out the key and

• attach a warning sign.

Only carry out maintenance and repair work when

the machine is parked on a level, sufficiently

load-bearing surface and secured to prevent it

moving off or collapsing!

When being replaced, individual components and

major assemblies should be carefully fastened and

secured to the lifting gear. Only use suitable and

correctly functioning lifting gear, and load-handling

equipment with sufficient carrying capacity. Do not

stand or work under suspended loads!

Only appoint experienced persons to attach loads

and instruct crane drivers! The instructor must stand

where they are visible to the operator, or be in

contact with him by voice communications.

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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!

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Edition 12/2007

REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

1.7

Notes on special types of

1.7.3

Hydraulic, pneumatic system

hazard

Regularly inspect all pipes, hoses, and screw

connections for leaks and visible damage. Repair

1.7.1

Electrical energy

any damage immediately! Spurting oil can cause

burns and other injuries.

Use only original fuses with the correct current

rating! Switch the machine off immediately if there

are faults in the electrical system.

Before starting repair work, any system blocks and

pressure lines (hydraulic, compressed air) that are

to be opened up must first be depressurized as

Keep the machine at a sufficient distance from

indicated in the descriptions of the assemblies.

overhead power lines. If working close to overhead

power lines, keep the equipment away from the

lines. Danger of death!

Hydraulic and compressed air lines must be

Find out the what the required safety clearances

correctly laid and assembled. Do not get the

are.

connections mixed up!

If contact is made with high-voltage lines:

Valves, and the length and quality of hoses must

meet the requirements.

• Do not leave the machine.

• Drive the machine out of the danger area.

1.7.4

Noise

• Warn persons on the ground not to come

Noise insulation devices must be in the protection

near, or to touch the machine.

position during operation.

• Have the voltage switched off.

• Only leave the machine when the

Wear the prescribed personal ear protection!

contacted/damaged power line has been

safely de-energized.

1.7.5

Oil, grease and other chemical

The machine’s electrical equipment should be

substances

regularly inspected. Faults such as loose

If handling oil, grease or other chemical substances,

connections or braised cables must be corrected

follow the safety instructions for the product

immediately.

concerned!

Be careful when handling operating fluids and

1.7.2

Gas, dust, vapour, smoke

auxiliary materials (risk of burns and scalds).

Only operate combustion engines and fuel-driven

heaters in well-ventilated areas!

If using the equipment in an enclosed space, ensure

there is sufficient ventilation before starting.

Follow the local regulations applying at the worksite.

Only carry out welding, firing, or grinding work on

the machine if this has been explicitly approved

- risk of fire and explosions!

Before carrying out welding, firing or grinding work,

clean away dust and combustible materials from the

machine and its surroundings, and provide

adequate ventilation (risk of explosion)!

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

CAUTION: Read the warning signs and instruction plates on the machine.

Keep these signs and plates clean and legible.

Replace these plates immediately if they are no longer legible.

New warning signs and instruction plates can be obtained from the spare parts department. When ordering,

part numbers can be found on the replacement parts lists for the machine.

Legend for left side

Do not start up the machine before you have read and understood the operating instructions.

At this point, the equipment can be secured against accidental start-up.

Inspect wheel nuts regularly - see the operating instructions.

Risk of injury from hot or rotating parts in the engine compartment. Only open the engine compartment

cover when the engine has stopped.

Risk of injury due to unauthorized starting of the machine. Before working on the machine, switch off the

engine and remove the key.

This plate indicates the maximum speed permitted on public roads.

10. Lashing ropes or chains must be attached here if the machine is to be transported.

11. Risk of injury due to hot or pressurized hydraulic fluid. Follow the operating instructions.

12. Risk of injury by crushing. Do not start up the machine if anyone is near the articulated joint.

Risk of injury by crushing. Do not start up the machine if anyone is standing between the machine and

an adjoining barrier.

14. The CE symbol certifies that this machine has been constructed according to the European regulations

on mechanical safety. L_WA indicates the level of noise emissions in dB_A, as stated in EC standard

2007/14/EG).

15. Driving on public roads. This plate indicates the steps to be taken before driving on public roads.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

CAUTION: Read the warning signs and instruction plates on the machine.

Keep these signs and plates clean and legible.

Replace them immediately if they are no longer legible.

New warning and instruction plates can be obtained from the spare parts department. When ordering, part

numbers can be found on the replacement parts lists for the machine.

Legend for left side

At this point, the equipment can be protected from accidental start-up.

Risk of injury from hot or rotating parts in the engine compartment. Only open the engine compartment

cover when the engine has stopped.

Risk of injury if engine hood falls shut. Close the engine hood by releasing the safety rod with the foot.

Read the operating instructions before carrying out repair / maintenance work.

Risk of injury from hot coolant. Only take off the radiator cap once the radiator has cooled down.

Coolant level marking.

Risk of injury due to unauthorized starting of the machine. Before working on the machine, switch off the

engine and remove the key.

Fuel tank, fill with diesel fuel here.

This plate indicates the maximum speed permitted on public roads.

10. Lashing ropes or chains must be attached here if the machine is to be transported.

12. Risk of injury by crushing. Do not start up the machine if anyone is near the articulated joint.

Risk of injury by crushing. Do not start up the machine if anyone is standing between the machine and

an adjoining barrier.

13. Alternator, regulator and electronic assemblies may be damaged if the battery is disconnected while the

engine is running. Therefore, switch off the engine before disconnecting and removing the battery.

16. Windscreen washer system. Water can be added here for the windscreen washer system.

17. Risk of injury by crushing. Do not start up the machine if anyone is standing between the machine and

an adjoining barrier.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

OPERATION

3.1

General Remarks

OPERATING CONDITION OF THE MACHINE

Only operate the machine if in a reliable operating

Do not operate the machine until you have read and

condition, and only as required by the regulations.

understood the operating instructions.

Always follow the safety instructions.

Pay particular attention to:

Always carry out inspections and maintenance work

punctually (or have them carried out).

the ‘Basic Safety Information’ and all the warning

signs and instruction plates attached to

the

Only operate the machine with the attachments and

machine.

component combinations approved by the

manufacturer. See the Technical Data for clear

Before starting the machine, familiarize yourself with

information on this subject.

the locations, functions and operating directions of

the controls. Operate the controls only from the

Only attach and work with different equipment or

driver’s seat.

component combinations if the manufacturer has

checked and approved the planned type of

Keep the operating instructions stored permanently

assembly.

at the machine.

Before starting work / driving, check whether the

brake, steering, lighting and signalling systems are

OPERATING PERSONNEL

operational.

Operating personnel must be experienced in

working with and operating this or similar machines.

Poor visibility can lead to accidents. Clean the

windows, and the lenses on lamps, before operating

The required skills can be acquired through a

the machine.

course of instruction lasting a few days, which could

be provided by a service technician, or by attending

Check whether all warning signs and instruction

a driver training course.

plates on the machine are present, and that they are

clearly legible.

PERSONAL PROTECTIVE EQUIPMENT AND

GETTING IN AND OUT

WORK CLOTHES

Face towards the machine when getting in or out.

Wear a hard hat and protective shoes with non-slip

soles. Smooth soles can slip on steps and pedals,

Use only the steps, platforms and handles provided

thus causing injuries or operator errors.

when getting in or out.

Wear close-fitting work clothes when operating the

Keep steps, platforms and handles in a condition

machine. Loose or wide items of clothing can cause

where they provide a secure grip. Clean them

the control lever to be operated accidentally.

immediately if they become soiled with oil, grease,

soil, mud, snow, ice, or other matter.

SEAT BELT

On machines with seat belts for operating

DANGER AREA

personnel:

The danger area is that area around the machine

Check the seat belt attached to the driver’s seat.

where anyone might come within the range of

Replace immediately if damaged, or after an

movement of the machine, its working equipment

accident. Put the seat belt on before starting work.

and attachments, swinging loads, falling loads, or

downward moving tools.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

PERSONS IN THE DANGER AREA

Warn bystanders with a horn signal before starting

the machine.

Check that no one is standing within the danger

area around the machine. Stop working until all

persons have moved out of the danger area.

MARSHALLER

The marshaller must stand outside the danger area.

You should have the marshaller assist you:

• if you are unable to see the entire danger area

around the machine,

• when reversing,

• when manoeuvring.

Use only signs that will be understood both by you and

the marshaller, or use a communication device (for

example radio telephone / camera). The marshaller

will not be able to understand unaided speech

because of the operating noise from the machine.

Remain in constant contact with the marshaller.

Stop the machine immediately, if your lose contact

with the marshaller.

SECURING THE MACHINE

Secure the machine as described in the section

‘Securing the machine’, before:

• attaching/removing working equipment,

• switching the machine off after everyday

operations,

• carrying out maintenance or repair work.

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87726937A

Edition 12/2007

REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

3.2

Fuelling

FUELLING FROM CANS

If the machine is mostly or regularly fuelled from

RISK OF EXPLOSION

cans or drums, there is a greater risk that dirt

Fuel and fuel vapour are easily ignited and can

particles and water will penetrate into the fuel

explode into flame. Therefore, avoid causing sparks

system.

and do not use naked flames such as lighters or

matches for illumination.

In this case:

• always pour in the fuel through a fine-mesh

strainer

POSSIBLE RISKS TO HEALTH

• only use siphon pipes along with a fine filter

Diesel fuel and fuel vapour can be injurious to

health. Fuel should not be swallowed. Also, avoid

• drain the fuel filter more often than indicated

prolonged contact with the skin. Do not inhale fuel

in the maintenance plan

vapour. Wear protective gloves or use a barrier

• drain the water and sediment from the fuel

cream. Do not eat, drink or smoke while fuelling.

tank more often

• replace all fuel filters at shorter intervals.

AVOIDING DAMAGE TO THE ENVIRONMENT

Avoid allowing fuel to overflow. Do not allow fuel to

CAUTION: NEVER FILL WITH BIODIESEL

penetrate into the soil, as this is dangerous for the

environment.

Biodiesel can damage the engine and injection

system.

Spilled fuel should be soaked up immediately with a

cleaning cloth or binding agent, then disposed of in

Use only diesel fuel produced from mineral oil,

an environmentally responsible way.

which meets EN 590 standard. For more

information, contact your dealer’s service

Fuel accidents should be reported immediately to

department.

the licensee or his agent.

SECURING THE MACHINE

When fuelling, secure the machine to prevent

unauthorized start-up:

Park the machine on level ground with sufficient

load-carrying capacity, lower the working equipment

to the ground, switch off fuel-driven auxiliary heaters

and air conditioning systems, switch off the engine,

apply the hand brake, take the key out of the key

switch for the electrical system.

Fuelling always takes place on the ground, with the

operator in standing position.

FUELLING

Read and apply the ‘Fuelling safety instructions’

before filling up with fuel.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

3.3

Fuelling system (optional)

RISK OF EXPLOSION!

Do not smoke, and keep away from naked flames.

Fuel and fuel vapour are inflammable; Danger of

fire.

Switch off fuel-driven auxiliary heaters and air

conditioning systems.

PROTECTING HEALTH AND THE ENVIRONMENT

Fuel can be harmful to the skin, so wear protective

gloves or use a barrier cream.

Do not spill fuel or allow it to penetrate the soil - this

would endanger the environment. Spilled fuel

should be soaked up immediately with a cleaning

cloth or binding agent, then disposed of in an

environmentally responsible way.

Report accidents with fuel immediately to the

machine licensee, or his agent.

SECURING THE MACHINE

When fuelling, secure the machine to prevent

unauthorized start-up:

• Lower working equipment to the ground

• Switch off the engine

• Take the key out of the electrical system key

switch.

INCREASED RISK OF CONTAMINATION

If the machine is mostly or regularly fuelled from

tanks or drums, there is an increased risk of

contamination of the fuel system.

In this case, the fuel prefilter must be drained and

cleaned more often than indicated in

the

maintenance plan.

The fuel filter must also be replaced at shorter

intervals.

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Edition 12/2007

REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

3.4

Driving

DRIVING OVER LONGER DISTANCES

The share should not extend into the steering area

BEFORE MOVING OFF

of the front wheels, or of the steering linkage.

Before operating the machine, clean your work

shoes to remove clinging soil, mud, snow, ice,

The central warning lamp should not flash when the

grease and oil. These could cause the shoes to slip

driver enters, otherwise determine the cause and

on the steps or pedals, thus causing unwanted

switch off.

movements.

If driving on public roads:

Before moving off, adjust the driver’s seat, steering

• Keep to the conditions of the general

column and mirror, and fasten your seat belt.

operating licence.

Do not carry passengers on the machine.

• Close the driver cab doors.

• Take along a first-aid box, hazard warning

Before moving off, warn any bystanders with the

triangle and warning lamp.

signal horn.

• Check the content of the first-aid box. Replace

items that have been used, or which have

become unusable.

NO TOWING

With the engine running, check:

This machine is not suitable for towing trailers or

• that the steering wheel moves easily, by

other vehicles; Doing so would cause damage to

turning it briefly to the left and right, and that

axles and gears. The tow coupling is intended only

the steering gear responds.

for towing or recovering the machine from hazard

areas, or for lashing onto transport vehicles; see

• Drive a short distance and operate the brake

‘Towing/recovery’.

to check that the service brake is working

effectively.

Never allow the machine to roll with the gear lever in

DRIVING WITH HANGING LOADS

the ‘N’ position, for example when driving downhill.

Ensure that the wheels provide sufficient ground

If driving with the door open, this should be engaged

adhesion; only this will ensure braking/steering

in the end position.

effectiveness. Do not drive with hanging loads

Before moving off, bring the machine up to

positioned cross-wise; Do not attempt a U-turn with

operating temperature as described in the

such loads. Do not attempt to position such loads

‘Operating instructions - warming up’.

using the articulated joint.

Only then should the engine be placed under full

load.

REVERSING

When reversing, the view of the danger area is

reduced. Therefore, obtain assistance from an

experienced marshaller. Agree on the meaning of

signals with the marshaller, to ensure that the

signals from the marshaller are correctly

understood.

PARKING THE MACHINE

Machines parked on slopes can move off by

themselves.

Therefore, always park the machine on an even,

horizontal surface, lower the working equipment

and its support to the ground.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

SEAT BELT

Fasten your seat belt before every trip.

Do not pass the seat belt over rigid or breakable

objects, for example a bunch of keys or spectacles.

This could result in bodily injuries.

The seat belt must always lie firmly against the body

and should not catch on anything.

The belt buckle guide should not be obstructed (for

example, with papers), otherwise the buckle tongue

will not engage.

Seat belts that are damaged, or which were

stressed during an accident and have therefore

been stretched, must be replaced.

ADJUSTING THE STEERING COLUMN

Do not adjust the steering column while driving.

Your attention will be distracted

- RISK OF

ACCIDENT!

Before adjusting the steering column:

• Stop the machine

• Gear lever in neutral position

• Apply the hand brake

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Edition 12/2007

REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

3.5

Towing /recovery

3.5.2

Transport

Only load up and transport the machine if all the

Tow the machine with the tow bar or tow rope only.

requirements of the safety regulations are met.

The tow bar / tow rope should not be damaged.

Arrange the loading and transport with a company

It must be designed so that the calculated load at

that is experienced in the transport of abnormal

rupture is three times the tractive force of the towing

loads.

machine.

Responsibility for the loading and transport is borne

The towing vehicle must have sufficient tractive

by the transport company or their authorised

force. Drive slowly and carefully.

representative.

To reduce the risk of slipping, clean the drive-on

No one should be standing near the tow bar/rope.

ramps and loading area on the transport vehicle,

Only tow the machine if the brakes and steering are

and the wheels of the machine, to remove oil,

functional and the machine cannot be transported

grease, soil, mud, snow, ice and other matter.

any other way.

Use anchoring equipment with sufficient

If these are not functional, only tow the machine as

load-holding capacity (for the weight specifications

far as is necessary to recover the machine from

of the machine, see the ‘Technical Data’ section).

danger areas.

After recovery, the machine must be secured to

3.5.3

Crane loading

prevent it rolling, and prevent unauthorized start-up.

If loading with a crane, lock the articulated joint.

Before transporting over long distances, either

repair the machine or load it onto a transport

vehicle.

Towing speed should not go above 10 km/h.

Tow the machine out of the danger area only,

otherwise tow it on a low-bed trailer.

Towing any further can cause damage to the

transmission.

3.5.1

Towing devices

The towing devices should not be used for towing

trailers.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

3.6

Everyday operation

3.7

Using the grader

Read carefully through the sections ‘Basic safety

Due to the versatility of the grader and the diversity

instructions’ and ‘Operation - General information’

of the materials, there are many possible

and follow the instructions given.

applications and working methods. We therefore

recommend having the driver instructed by the

Before starting work, examine the worksite for

manufacturer.

embedded gas and water pipes, and electrical

Read and pay attention to: ‘Operating instructions -

power lines. Damaging these lines can cause a

Warming up’.

life-threatening situation!

Do not exceed the machine’s permitted

Before operating the machine, clean your work

transverse/longitudinal tilt angle. Doing so will

shoes to remove clinging soil, mud, snow, ice,

reduce or interrupt the engine lubrication.

grease and oil.

These could cause the shoes to slip on the steps or

The permitted tilt angles of the machine are:

pedals, thus causing unwanted movements.

• Transverse tilt:

Left / right 35° 35°

If driving with the door open, engage the door in the

end position.

• Longitudinal tilt:

Downward / upward 35° 35°

Warn bystanders with a horn signal before starting

work.

If the engine temperature, oil pressure or alternator

warning lamps come on, lower the working

Do not drive with hanging loads positioned

equipment immediately and switch the engine off.

cross-wise.

Do not attempt a U-turn with such loads. Do not

attempt to position such loads using the articulated

joint.

Stop working if anyone is standing within the danger

area around the machine. Start working only when

all persons have moved out of the danger area.

Always operate and use the machine in such a way

that it remains stable.

Ditches and trenches can collapse. Keep at a safe

distance.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

3.8

Working equipment

SECURING THE WORKING EQUIPMENT

Lower the working equipment to the ground, so that

PERSONNEL

it will not move when mechanical or hydraulic

The assembly operations should be carried out only

connections are loosened.

by operating or maintenance personnel who

possess the required skills.

If the machine has to be jacked up, secure the front

axle with wedges to prevent swinging.

If the personnel lack the necessary skills, they

should be carefully guided by experienced

If working near the articulation, lock the joint.

personnel.

Remove all locking and securing devices when the

work is complete.

They must have read and understood the operating

instructions,

particularly

the

‘Basic safety

If work tools or tool parts are to be attached or

information’ section.

removed, or adjusted while in position, they should

be secured with suspension/propping equipment to

During the assembly operations, only experienced

prevent unintentional movement, slipping or falling.

personnel must be allowed to start the machine in

order to make adjustments to the working tool.

SECURING THE MACHINE

Operator errors with the machine or the working

Only carry out work on the working equipment if the

equipment can result in life-threatening situations.

machine has been secured as described in the

section ‘Securing the machine’.

PERSONAL PROTECTIVE EQUIPMENT AND

WORK CLOTHES

CHOOSING THE WORKING EQUIPMENT

Wear close-fitting work clothes when working with

The machine can be equipped with a variety of

the machine. Loose or wide items of clothing can

working equipment. The components of the working

become caught in machine parts, and thus cause

equipment are made up of hydraulic cylinders and

injuries.

connecting parts. Various component combinations

are possible in order to adapt the working

Wear a hard hat, protective shoes and gloves.

equipment optimally to the type of application.

Only use equipment and component combinations

TOOLS AND ACCESSORIES

with the machine, if these have been expressly

Tools, lifting gear, lifting accessories, support frames

approved by the manufacturer for this machine.

and other equipment must be in a reliable working

condition.

Equipment supplied by other manufacturers, to

which EC machines guideline 89/392 EWG applies,

When driving in or removing fastening bolts, metal

should only be attached and operated if they carry:

splinters may fly off and cause injury. Therefore, use

a brass or copper drift for driving in or removing

• the manufacturer’s statement of conformity,

bolts, and wear safety glasses.

• the statement of compatibility.

Use only the steps, platforms and handles provided

when getting in or out.

Keep steps, platforms and handles in a condition

where they provide a secure grip. Clean them

immediately if they become soiled with oil, grease,

soil, mud, snow, ice, or other matter.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

3.9

SECURING THE MACHINE

RISK OF INJURY

The machine should not be started by unauthorized

persons.

It should therefore be protected.

Secure the machine as described below:

• Before any maintenance or repair work on the

machine.

• Whenever attaching or changing the working

equipment.

• Park the machine on level ground with

sufficient load-carrying capacity.

• Lower the working equipment to the ground.

• Apply the hand brake.

NOTE: Do not stop the engine when under full

load, but let it run for about three to five minutes to

allow temperature balancing.

• Switch off the engine.

• Take the key out of the electrical system key

switch.

• Depressurize the hydraulic system.

• Lock the articulated joint.

• Secure open engine hoods.

• Secure the machine with chocks to prevent it

rolling.

• Switch off the battery main switch and remove

the control lever.

• Before working on the electrical system,

disconnect the batteries.

• Before carrying out welding operations on the

machine, read the section ‘Repair - Welding

work’.

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F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

INSPECTION AND MAINTENANCE

4.1

General information

If working equipment or tool parts are to be attached

or removed, or adjusted while in position, they

Repair manual

should be secured with suspension/propping

Before starting work, personnel appointed to carry

equipment to prevent unintentional movement,

out work on the machine must have read and

slipping or falling.

understood the repair manual.

Pay particular attention to:

SECURING THE MACHINE

‘Basic Safety Information’ and all the warning signs

Only carry out work on the working equipment if the

and instruction plates attached to the machine.

machine has been secured as described in the

section ‘Securing the machine’.

The repair manual contains all the technical

information necessary for carrying out maintenance

GETTING IN AND OUT

and repair work on the machine. Work on the

machine should only be carried out by personnel

Use only the steps, platforms and handles provided

trained for this purpose!

when getting in or out.

Keep steps, platforms and handles in a condition

INSPECTION AND MAINTENANCE PERSONNEL

where they provide a secure grip. Clean them

The inspecting and maintenance personnel must

immediately if they become soiled with oil, grease,

have experience in the inspection and maintenance

soil, mud, snow, ice, or other matter.

of these or similar machines.

Face towards the machine when getting in or out.

The required skills can be acquired through a

course of instruction lasting a few days, which could

be provided by a service technician, or by attending

CHECK THE CONDITION OF TOOLS

a driver training course.

Only work with fully functional and reliable tools.

Choose only tools that are suitable for the task.

PERSONAL PROTECTIVE EQUIPMENT AND

WORK CLOTHES

Ill-fitting wrenches, for example, may slip off and

Wear close-fitting work clothes when working with

cause injury.

the machine. Loose or wide items of clothing can

become caught in machine parts, and thus cause

injuries.

CLEANING OPERATIONS

Before starting work, clean up any assemblies

Wear a hard hat, protective shoes and gloves, and

located in the work area.

ear protection if there is loud noise.

The choice of cleaning agent will depend on the type

of material in the parts to be cleaned.

SECURING THE WORKING EQUIPMENT

Lower the working equipment to the ground, so that

Example: Do not use solvents or steam jets to clean

it will not move when mechanical or hydraulic

electrical or rubber components.

connections are loosened.

If working near the articulation, lock the joint.

Remove all locking and securing devices when the

work is complete. If the machine has to be jacked

up, secure the front axle with wedges to prevent

swinging.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

Use only fibre-free cleaning cloths to clean the

Stand out of the direction of the oil spray.

hydraulic system or the engine.

Avoid contact with the skin. Wear gloves and

Cleaning agents and solvents can give off highly

close-fitting work clothes.

inflammable or noxious vapours.

Only use such products in areas that are well

Old oils can be injurious to health if they come into

ventilated - do not inhale the vapour, and do not

contact with the skin. If this occurs, wash the skin

smoke.

thoroughly with warm soapy water and apply a

Do not allow cleaning agents and solvents to come

protective cream. Do not use fuels or solvents to

into contact with the skin. Wear solvent-resistant

clean the skin.

gloves.

Follow the instructions on the product packaging.

If you have accidentally swallowed oil, do not induce

vomiting, but seek medial assistance immediately.

HANDLING COMBUSTIBLE FLUIDS

When handling combustible fluids:

VISIBLE OIL LEAKS

If there is a visible oil leak, repair the leak

• do not smoke,

immediately.

• no open lights or naked flames.

Leaking oil is a danger to the environment!

Fuel and other operating fluids often have low

flashpoints and are easily ignited.

Use an oil binding agent to absorb any spilled oil.

Gather up the binding agent and dispose of

Do not use water to extinguish burning fluids. Use

separately from other waste.

the following:

• powder extinguisher,

RELEASE RESIDUAL PRESSURE IN THE

• carbon dioxide or

HYDRAULIC SYSTEM

• foam extinguishing equipment.

Hydraulic systems should only be opened after they

have been depressurized. Even when the machine

When it comes into contact with burning fluids,

is parked on a horizontal surface, the working

water will vaporise abruptly and cause burning oil to

equipment lowered to the ground, and the drive

spray over a large area.

motor switched off, a considerable amount of

residual pressure can remain in some parts of the

hydraulic system, for example, primary pressure

Water will cause short-circuiting in the electrical

due to the final hydraulic movements before the

system, thus possibly creating additional dangers.

machine stops.

Notify the fire department.

Residual pressure is only released gradually. If work

on the hydraulic system is required immediately

FASTENINGS AND FIXING ELEMENTS

after switching off, release the residual pressure as

Check fastenings and fixing elements, for example,

described in the section ‘Hydraulic system’.

bolts, nuts, washers, before re-using.

Replace damaged parts.

HANDLING OILS AND LUBRICANTS

Risk of burns due to the uncontrolled release of hot

lubricants or hydraulic fluid.

If burns occur, chill immediately with running water,

then apply a dry bandage.

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Edition 12/2007

REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

SCREW CONNECTIONS, PIPES, HYDRAULIC

ENGINE EXHAUST

HOSES

Exhaust gases are harmful to health - do not inhale.

Repair any leaks in the pipe system immediately.

If working in enclosed spaces an exhaust gases are

A fine spray of hydraulic fluid at high pressure can

present, use an extractor to evacuate the gases and

penetrate the skin.

keep the room well ventilated.

Do not try to locate leaks with the fingers, but use a

piece of cardboard and wear protective goggles.

HANDLING BATTERIES

Batteries give off explosive gases.

If fluid has penetrated the skin, seek medical

assistance immediately.

Do not bring open lights or naked flames near

batteries, and do not smoke.

Do not repair damaged pipes, but replace them with

new ones.

Remove the batteries, if welding or grinding work is

to be carried out nearby. Take the batteries to a safe

distance.

Replace hydraulic hoses immediately if there is

visible damage or seepage.

Battery acid is poisonous and corrosive.

Only re-tighten leaking screw plugs after

depressurizing.

Avoid contact with the skin, mouth, eyes and

clothing. Do not spill battery acid, and do not inhale

acid vapour.

Leaking oil is a danger to the environment!

When handling batteries, wear acid-resistant

DISPOSE OF ENVIRONMENTALLY

gloves, close-fitting clothes and protective goggles.

Oil, grease, brake fluid, cleaning agents, solvents

and parts containing oil, for example, filters,

If acid comes into contact with the skin, wash

cleaning cloths, replaced parts and unusable

thoroughly with water and seek medical assistance.

machine parts should be disposed of separately

from each other, with respect for the environment.

If acid spray gets into the eyes, rinse thoroughly with

running water and call an eye specialist

Do not include these materials with normal

immediately, or go to a hospital A&E department.

household waste.

Do not place tools on the battery. This can cause a

Put them into the containers provided for this

short circuit, which would ruin the battery and could

purpose.

cause injury.

Even

bio-degradable

‘environment-friendly’

Do not wear metal necklaces, bracelets or watch

hydraulic fluid must be disposed of separately, like

straps when working on the battery. Metal parts can

any other oil.

cause a short circuit and possible burn injuries.

Do not allow oils and oily waste to penetrate the soil

Dispose of old batteries separately from other

or water courses, as this would endanger the

waste, and with respect for the environment.

environment!

SEALING SURFACES

Clean the sealing surfaces before assembling.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

BEFORE WORKING ON THE ELECTRICAL

AFTER MAINTENANCE

SYSTEM

To prevent corrosion damage, coat all bare metal

Before working on the electrical system, when there

machine parts with a film of grease.

is a possibility of tools, spare parts, etc. touching

electric wires and contacts, disconnect the battery:

When the work is completed, re-attach all safety

• disconnect the negative terminal first, then the

devices.

positive.

When work is complete:

Only start the drive motor when no one is working on

the machine.

• connect the positive terminal first, then the

negative.

Carry out a function test on the machine.

Read and pay attention to the ‘Electrical system’

section.

CHOOSING OILS / LUBRICANTS

Only use the recommended grades, select

viscosities according to temperature level.

FILTERS

Replace all filter elements and cartridges at the

specified intervals.

All filters are carefully selected to suit the equipment

concerned. Trouble-free operation and long service

life for the engine and hydraulic assemblies can only

be ensured by using original replacement parts.

SEALS

When removing components, pay attention to their

seals.

Before installing, check the seals and replace them

even if only slightly damaged.

Check that they are correctly seated when

assembling.

CHECK OIL LEVEL / OIL CHANGE

Place the machine horizontally. Change the oil when

the machine is warm. Warm oil flows better and

carries particles in suspension better (oil carbon and

abrasion particles).

GREASE LUBRICATION

Clean the lubricating nipples, then lubricate as

indicated in the lubrication plan.

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Edition 12/2007

REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

4.2

Fuel system

FUELLING FROM CANS

If the machine is mostly or regularly fuelled from

RISK OF EXPLOSION DUE TO FUEL VAPOUR

cans or drums, there is a greater risk that dirt

Fuel vapour is highly inflammable and can burst into

particles and water will penetrate into the fuel

flame. Therefore, avoid causing sparks and do not

system.

use naked flames such as lighters or matches for

In this case:

illumination.

•

always pour in the fuel through a fine-mesh

strainer,

If you have to work on the fuel system:

•

drain the fuel filter more often than indicated

• switch off the engine and auxiliary heater,

in the maintenance plan,

• secure the machine,

•

drain the water and sediment from the fuel

• avoid using naked flames,

tank at shorter intervals,

• do not eat, drink or smoke.

•

replace all fuel filters at shorter intervals.

POSSIBLE RISKS TO HEALTH

Diesel fuel and drained water / fuel mixtures can be

injurious to health. These fluids are harmful if

swallowed.

Also, avoid prolonged contact with the skin.

Do not inhale fuel vapour. Wear protective gloves or

use a barrier cream.

AVOIDING DAMAGE TO THE ENVIRONMENT

Collect overflowing fuel in a container and dispose

of it without causing damage to the environment.

Dispose of fuel filters and fuel-soaked cleaning

cloths separately from other waste.

NOTE: NEVER FILL WITH BIODIESEL!

Biodiesel can damage the engine and injection

system.

Use only diesel fuel produced from mineral oil,

which meets EN 590 standard.

For more information, contact your dealer’s service

department.

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REPAIR INSTRUCTIONS

F106.6 / F106.6A

SAFETY INSTRUCTIONS

F156.6 / F156.6A

4.3

Electrical system

ALTERNATOR

Never disconnect the electrical connections at the

Risk of injury from battery acid and gases.

alternator, regulator or battery while the engine is

running.

Wear protective goggles, work gloves and

close-fitting work clothes.

This will damage the alternator and regulator.

BEFORE WORKING ON THE ELECTRICAL

When connecting the batteries, do not mix up the

SYSTEM

cables (check the polarities).

Switch off the engine.

Use only measuring instruments for carrying out

Turn the electrical system key switch to the 0 and

voltage tests and continuity checks.

take out the key.

Do not use test lamps.

Turn the battery main switch to the OFF position and

remove the control lever.

Do not ‘short to ground’.

Disconnect the control units and control console

The resulting short circuit will cause damage to the

from the on-board electrical system.

alternator and regulator.

Before working on the electrical system, when there

When the engine is started, the alternator is

is a possibility of tools, spare parts, etc. touching

actuated

(pre-excited) by an electronic circuit.

electric wires and contacts, disconnect the batteries.

This ensures that the alternator is able to deliver

• Disconnect the negative terminal first, then

power.

the positive.

This circuit is part of the main electronic system in

When work is complete:

the control console.

• connect the positive terminal first, then the

negative.

A LED (charge indicator) on the control console

indicates whether the alternator is functioning

Read and apply the

‘Operating instructions-

correctly. This LED must light up when the key

Alternator, control units and control console’.

switch is turned to the On position; it should go off

once the engine is running.

Read and pay attention to the section ‘Inspection

and maintenance - General information’.

If this is not the case, then there is a fault in the

alternator electrical circuit or in the control console.

Use only measuring instruments for carrying out

voltage tests and continuity checks. Do not use test

To prevent further damage, the cause of the fault

lamps.

must be found and resolved as quickly as possible.

Do not ‘short to ground’.

Contact your dealer’s service department.

The resulting short circuit will cause damage to the

alternator or to the electronics.

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