16319210-New Holland F156 6 F156 6a Grader Service Repair Manual

Copyright © New Holland
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.
SUMMARY
SAFETY INSTRUCTIONS .................................................................................. SECTION 0
TECHNICAL DATA ............................................................................................. SECTION 1
ENGINE .............................................................................................................. SECTION 2
TRANSMISSION................................................................................................. SECTION 3
REAR AXLE ........................................................................................................ SECTION 4
FRONT AXLE...................................................................................................... SECTION 5
ATTACHMENT.................................................................................................... SECTION 6
HYDRAULIC SYSTEM........................................................................................ SECTION 7
BRAKE SYSTEM ................................................................................................ SECTION 8
STEERING SYSTEM .......................................................................................... SECTION 9
ELECTRICAL SYSTEM .................................................................................... SECTION 10
OPERATOR’S CAB .......................................................................................... SECTION 11

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-
- Functional Description; Grader.
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)
IN - 2 INTRODUCTION F156.6 / F156.6A
NOTES:
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
SECTION 0
SAFETY INSTRUCTIONS
INDEX
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
Information and precautionary those stated above, e.g.:
measures designed to prevent - for the transportation of persons;
damage to the machine or other - as a working platform;
property. - for pulling or transporting loads
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
3rd 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.
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.
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.
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.
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;
- attaching a warning sign. After cleaning, remove all covers and tapes applied
for that purpose.
Carry out maintenance and repair work only if the
machine is positioned on stable and level ground and After cleaning, examine all fuel, lubricant, and hy-
has been secured against inadvertent movement draulic fluid lines for leaks, loose connections, chafe
and buckling. marks and damage. Any defects found must be rec-
tified without delay.
To avoid the risk of accidents, individual parts and
large assemblies being moved for replacement pur- Always tighten any screwed connections that have
poses should be carefully attached to lifting tackle been loosened during maintenance and repair.
and secured. Use only suitable and technically per-
fect lifting gear and suspension systems with ade- Any safety devices removed for set-up, maintenance
quate lifting capacity. Never work or stand under or repair purposes must be refitted and checked im-
suspended loads. mediately upon completion of the maintenance and
repair work.
The fastening of loads and the instructing of crane
operators should be entrusted to experienced per- Ensure that all consumables and replaced parts are
sons only. The marshaller giving the instructions disposed of safely and with minimum environmental
must be within sight or sound of the operator. impact.
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.
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
- drive the machine out of the hazard zone; hoses must comply with the technical requirements.
- 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).
TRANSPORTING AND TOWING

RECOMMISSIONING
The machine must be towed, loaded and transported Use only appropriate means of transport and lifting
only in accordance with the operating instructions. gear of adequate capacity.
For towing the machine observe the prescribed The recommissioning procedure must be strictly in
transport position, admissible speed and itinerary. accordance with the operating instructions.
WARNING AND INSTRUCTION SIGNS
OKs1-00-001
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
1. The machine must not be started up unless the Op- 9. 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-
2. The equipment can be secured at this point against chine transport
inadvertent activation 12. Risk of injury through crushing. Never start up the
3. 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
4. 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
5. 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. LW A is the level of noise
the lock position. emissions specified in dBA (in acc. with standard
Read Operation and Maintenance Instructions 2000/14/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.
6. Risk of injury through hot coolant. Open cap on ra-
diator only after the radiator has cooled down -
Coolant level indicators
7. 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
8. Fuel tank, fill in diesel only
0 - 10 SAFETY INSTRUCTIONS F156.6 / F156.6A
OKs1-00-002
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
2. 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
4. 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
5. 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
6. 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
7. 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.
8. Fuel tank, fill in diesel only 18. Fixing points for fastening chains and ropes for ma-
9. 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
NOTES:
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.
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.
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.
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.

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
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.
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
ma c hine ’s g ene ra l ope ra ting
DO NOT TOW TRAILERS
permit.
The machine is not suited for towing
- Close the cab door.
trailers or other vehicles. Risk of
damage to gearboxes and axles. - The first-aid kit, the warning tri-
The tow-bar coupling is provided angle and the warning lamp must
only for towing or recovering the ma- be on board.
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
view of the hazard zone is restricted. Bring the machine to operating tem-
Therefore, seek the assistance of ex- perature as described in the "Opera-
perienced marshallers. Instruct the tion and Maintenance Istruction
marshaller in order to ensure that Manual - Warming up the machine"
you understand his signals cor- before setting off.
rectly. Never demand full performance from
the engine unless the machine is at
operating temperature.
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.
Be f or e a d ju s t i n g t h e s t e e r i ng
column:
- Stop the machine;
- Set the gearshift lever to neutral po-
sition;
- Apply the parking brake.
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

must be secured against inadvertent CRANE LOADING
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.
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° 35°
Sound the hooter to warn persons in
the immediate vicinity of the machine Longitudinal: deep / high
before starting work. 35° 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.
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.

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
this machine. • Turn off engine.
• 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-
turers subject to the EC Machine Di- • Switch off battery main switch and remove
rective 89/392 EEC may be mounted switching lever.
and put into operation only if: • Disconnect batteries before work on the electrical
- the manufacturer’s declaration of system or before welding work.
conformity, • When doing welding jobs on the machine, observe
- the declaration of compatibility "Repair work - Welding operations”.
from CNH are at hand.
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-
PERSONAL PROTECTIVE dles and handrails in a non-slip, safe
EQUIPMENT state and remove any oil, grease,
AND WORKING CLOTHING soil, clay, snow, ice and other foreign
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.
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
sources and naked flames. If you have swallowed any oil, avoid
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.
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.
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
or hospital. Check sealing elements prior to in-
If the eyes are splashed with acid, stallation and replace any that are
rinse thoroughly with running water, even slightly damaged.
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
induce a short circuit, resulting in Position the machine horizontally.
burns. Change the oil when the machine is
Dispose of used batteries separately at operating temperature.
from other waste in the interests of Warm oil flows better and carries
environmental protection. suspended particles (carbon or
abraded matter) better.
PRIOR TO WORK
ON THE ELECTRICAL SYSTEM LUBRICATING
Prior to any work on the electrical Clean the lubricating nipple, then lu-
system involving tools, spares etc. bricate as scheduled.
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.
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;
- secure the machine; REFUELLING FROM CANS
- avoid open flames; If the machine is filled up frequently
- 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.
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.
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 workin g

clothing.
Read and observe: "Inspection and

servicing - General instructions".
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.
Inspection and maintenance work on So:
brakes should only be carried out if - Never handle accumulator me-
the machine has been secured as de- chanically, never weld or solder it.
scribed in the section "Securing the - Testing and servicing work must be
machine". carried out by experts only.
- Prior to any testing and servicing
work, depressurize the hydraulic
HEALTH PRECAUTIONS part of the system.
- 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.
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
distance away until the tyre has - Use only compressed ambient air
cooled down. for inflating the tyres. Never use
- Before inflating the tyre, check the flammable gases: risk of explosion.
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
with special equipment for this kind - Excessive pressures result in poor
of work. off-road handling properties and
- Never carry out works on rims and tyres may burst;
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.
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.
AIR CONDITIONER (Option)
The present chapter describes in- WORK ON THE REFRIGERANT

spection and servicing work that can CIRCUIT (QUALIFIED PERSONNEL):
be performed by the machine oper- The refrigerating agent (R134a) used
ator. in this system is known as a safety
refrigerant. This means that it is non-
Any other work on the air conditioner combustible, non-explosive, non-
requires special knowledge and spe- toxic, non-irritating, odourless and
cial tools and may therefore be per- tasteless. Nevertheless, the fol-
formed by qualified and specially lowing points must be observed:
trained personnel only.
Av oid a ny co nta ct with l iquid
Entrust the work in these cases to a coolant. Parts of the skin that have
specialized workshop for air condi- been in contact with refrigerant must
tioners. be treated like chilblains.
Observe the following instructions Wear safety goggles to protect your

for your personal safety: eyes. In the event of refrigerant
Never stick your hand or other ob- coming into contact with your eyes
jects into the air conditioner. seek medical advice immediately.
Shut off the engine and let it cool
down before performing any serv- When carrying out repairs on the air
icing work. conditioner, the system must be
Disconnect the fan from the power emptied. Never allow refrigerant to
supply to avoid injury when the fan escape into the environment. For
starts up inadvertently. sucking off refrigerant use only ap-
Some air conditioner components proved suction units.
(e.g. heat exchanger and the resistor
on the fan) can still be very hot after It is strictly forbidden to carry out
shut-off and may cause severe welding work on parts of the closed
burns. Wait until these components system or in the immediate vicinity
have cooled down before working on thereof. Heat leads to strong over-
them when the machine is open. pressure and may cause damage or
even an explosion of the system in-
dependent of whether the system is
filled with refrigerant or empty.
When filled, refrigerant bottles must

not be handled roughly and not ex-
posed for prolonged periods to di-
rect sunlight or to other sources of
heat. The temperature to which a
filled refrigerant bottle is exposed
must not exceed 45 °C.
It is essential to keep the refrigerant

system free from chlorine and
chloric substances as well as from
oils or greases. Evacuation and
filling units for R134a should not be
used for other substances.
REPAIR WORK
WORKSHOP MANUAL BLOCKING THE AXLES

Never carry out repair work without If the machine has to be jacked up,
having read and understood the the front / rear axle must first be
Workshop Manual. wedged in place to prevent it from
moving.
Pay special attention to: When work is completed, lower ma-
"Fundamental Safety Instructions", chine and remove wedges.
"Inspection and servicing - General
instructions" and all warnings and
safety instructions attached to the PRESTRESSED UNITS
machine. Never open defective prestressed
units but replace them as an entirety.
The descriptions of job sequences
In exceptional cases, open only
provide only experienced personnel
when the system and the operating
with the necessary instructions.
sequence are precisely known and
any special tools required are avail-
The operating manual must be kept
able.
with the machine at all times.
The operating manual contains no in-
formation on this point.
REPAIR PERSONNEL
Repair personnel must have know-
how and experience relevant to re- DISMANTLING COMPONENTS
pairing this or comparable ma- Never dismantle while the machine
chines. is at operating temperature.
Oils, greases, brake fluid or coolants
In the absence of such know-how,
may have a high temperature and re-
meticulous training must be given by
sult in burning or scalding.
experienced repair personnel, e.g. by
the Manufacturer. Leave time for the machine to cool
down.
WORKING AT GREATER HEIGHTS
Before starting work, depressurize
Always wear safety harnesses when piping and hoses, cylinders, radi-
working at greater heights. ator, hydraulic tank, air-brake reser-
voir and other systems or units.
Wear an approved safety harness; it
must be equipped with stabilizers Replace defective components in
and safety cables. good time to prevent major damage.
Clean the defective component care-
fully before dismantling it.
BLOCKING THE PIVOT JOINT
When carrying out repair work in the Mark the dismantled parts in the cor-
pivoting range, block the pivot joint. rect sequence to facilitate assembly.
Remove the block on completing When dismantling the component,
work. close off exposed hose and piping
connections, exposed drill holes and
housing carefully to prevent any dust
from penetrating.
NEVER REMOVE LEAD SEALS Detailed information on the proper

Never change rated pressure of pres- execution of welding operations is
sure relief valves without the explicit given in th e technical ma nual
authorization of the Manufacturer. "Welding for maintenance and re-
pair".
Never remove lead seals from pres- Contact the Manufacturer Service
sure relief valves and accumulators. with any problems or questions
arising.
If machine components have to be
AFTER THE REPAIR WORK
dismantled, read and observe:
To prevent corrosion, coat all bright
metal machine parts with a grease Section "Attachment",
film. Chapters "Inspection and servicing -
General instructions", "Repair
On completing the work, reassemble work".
all protective devices, covers, and Before any welding operations on
sound- and vibration-insulation ma- the machine:
terial.
- Disconnect the battery, first at the
negative and then at the positive
Never start up the driving motor
pole.
while work is being done on the ma-
chine. - Disconnect the positive pole at the
alternator.
Check the repaired components and - Unplug the "control units" of the
all machine functions with a trial run. electronically controlled front-
wheel drive and the powershift
Never release the machine for re- transmission. Unplug the control
commissioning until it is fully func- console.
tioning. Protect disconnected terminals and
plugs from short-circuiting and con-
tamination by covering them with foil
WELDING OPERATIONS or adhesive strips.
Never perform welding operations
Bring the welding current terminals
unless you are qualified to do so.
as close as possible to the welding
Observe the accident prevention reg- point.
ulations.
The welding current must not flow
Any welding work on receptacles through the slewing ring, pin cou-
which contain or have contained plings, link joints or hydraulic cylin-
substances: ders.
- that are flammable or encourage Restore all electrical connections
combustion; after completion of welding opera-
- that are susceptible to explosion; tions.
- that may develop noxious gases, When connecting the battery, con-
vapours; mists or dusts during nect first the positive pole and then
welding operations; the negative pole.
may be performed only under expert
supervision and only by experienced
personnel authorized to do such
work.
NOTES:
SECTION 1
TECHNICAL DATA
INDEX
PARAGRAPH SUBJECT PAGE
1.1 DIMENSIONS .......................................................................................................... 1-1

1.1.1 Main dimensions...................................................................................................... 1-1
1.1.2 Travel dimensions.................................................................................................... 1-2
1.1.3 Working dimensions ................................................................................................ 1-4
1.2 TYRES..................................................................................................................... 1-6

1.2.1 Types and inflating pressures.................................................................................. 1-6
1.2.2 Wheel nuts tightening torque ................................................................................... 1-6
1.2.3 Max. speeds ............................................................................................................ 1-6
1.3 ENGINE ................................................................................................................... 1-7

1.3.1 Engine specifications ............................................................................................... 1-7
1.4 TRANSMISSION ..................................................................................................... 1-8

1.4.1 Transmission specifications..................................................................................... 1-8
1.4.2 Transmission ratios.................................................................................................. 1-8
1.5 HYDRAULIC SYSTEM ............................................................................................ 1-9

1.5.1 Working equipment pump........................................................................................ 1-9
1.5.2 Front wheel drive pump (only for F156.6A) ............................................................. 1-9
1.5.3 Radial piston motor (only for F156.6A) .................................................................... 1-9
1.5.4 Blade rotation motor ................................................................................................ 1-9
1.5.5 Cylinders.................................................................................................................. 1-10
1.6 BRAKES .................................................................................................................. 1-11

1.6.1 Brakes specifications ............................................................................................... 1-11
1.7 STEERING .............................................................................................................. 1-11

1.7.1 Steering specifications............................................................................................. 1-11
1.8 FLUIDS AND LUBRICANTS.................................................................................... 1-12

F156.6 / F156.6A TECHNICAL DATA 1-1
1.1 DIMENSIONS
1.1.1 MAIN DIMENSIONS
front blade + rear ripper
front blade + rear counterweight
front edge front counterweight
OKs2-01-001
Dimensions depending from tyres
1) 2) 3) 4)
17.5-25 EM 0 0 0 0
13.00-24 TG -41 -80 -160 +27
14.00-24 TG -12 -80 -140 +8
5) +5 mm for F156.6A
width of rear ripper

(from middle of tooth to middle of tooth) = 2220 mm
1-2 TECHNICAL DATA F156.6 / F156.6A
1.1.2 TRAVEL DIMENSIONS
OKs2-01-002
OKs3-01-002
OKs2-01-003
1) 2) 3) 4) 5) 6) 7) 8) 9) 9) 10) 11) 11)

F156.6 F156.6A F156.6 F156.6A
17.5-25 EM SGL 0 0 0 0 0 0 0 0 0° 0° 0° 0° 0°
17.5 R25 EM VKT 0 -50 -50 -25 0 0 0 0 0° 0° 0° 0° 0°
17.5 R25 EM XHA -7 0 0 0 0 0 0 0 -0.2° -0.1° -0.1° -0.1° -0.2°
17.5 R25 EM XHTL -7 -50 -50 -25 0 0 0 0 -0.2° -0.1° -0.1° -0.1° -0.2°
13.00-24 TG SGG -41 -80 -160 -80 +34 -34 -68 -80 -1.7° -1.6° -0.8° -0.8° -0.8°
14.00-24 TG SGG -12 -80 -140 -70 -1 +1 +2 -60 -0.3° -0.2° -0.1° -0.2° -0.2°
1.1.3 WORKING DIMENSIONS
OKs2-01-004
OKs2-01-005
1) 2) 3) 4) 5) 6) 7) 7) 8) 9) 10) 13) 14)

F156.6 F156.6A
17.5-25 EM SGL 0 0 0 0 0 0 0° +0.1° 0 0 0 0 0°
17.5 R25 EM VKT 0 -50 -50 0 0 0 0° +0.1° 0 0 0 0 0°
17.5 R25 EM XHA -7 0 0 0 +7 0 0° +0.1° +3 0 0 +2 0°
17.5 R25 EM XHTL -7 -50 -50 0 +7 0 0° +0.1° +3 0 0 +2 0°
13.00-24 TG SGG -41 -80 -160 +34 +41 -34 -1.5° -1.4° +17 -68 -80 +10 -1.5°
14.00-24 TG SGG -12 -80 -140 -1 +12 +1 0° +0.1° +5 +2 -60 +3 +0.1°
11) +5 mm for F156.6A
12) -5 mm for F156.6A
1.2 TYRES
1.2.1 TYPES AND INFLATING PRESSURES
PRESSURES
TYRES PROFILE MARK
FRONT REAR
17.5-25 EM SGL 1.5 1.75
17.5 R25 EM PG33U Dunlop 2.5 3.0
17.5 R25 EM VKT Bridgestone 2.25 2.25
17.5 R25 EM XHA Michelin 2.0 2.5
17.5 R25 EM XHTL Michelin 2.0 2.5
17.5 R25 EM XTLA Michelin 2.0 2.5
13.00-24 TG SGG 3.0 3.0
14.00-24 TG SGG 2.25 2.75
1.2.2 WHEEL NUTS TIGHTENING TORQUE
With spring washer Nm

With flat washer Nm
1.2.3 MAX. SPEEDS
Speeds for F156.6
Forward gears Reverse gears

TYRES r. dyn.
st 2nd 3rd 4th 5th 6th 1st 2nd 3rd
1
17.5-25 EM SGL 647 mm 5.2 8.0 12.2 18.4 26.7 38.8 5.5 12.8 28.2
17.5 R25 EM VKT 646 mm 5.2 8.0 12.1 18.4 26.7 38.8 5.5 12.8 28.1
17.5 R25 EM XHA 637 mm 5.2 7.9 12.0 18.1 26.3 38.2 5.4 12.6 27.7
17.5 R25 EM XHTL 632 mm 5.2 7.9 12.0 18.1 26.3 38.2 5.4 12.6 27.7
13.00-24 TG SGG 627 mm 5.1 7.8 11.8 17.9 25.9 37.6 5.3 12.4 27.3
14.00-24 TG SGG 655 mm 5.3 8.1 12.3 18.6 27.0 39.3 5.6 13.0 28.5
Speeds for F156.6A
Forward gears Reverse gears

TYRES r. dyn.
1st 2nd 3rd 4th 5th 6th 1st 2nd 3rd
17.5-25 EM SGL 622 mm 5.0 7.7 11.7 17.7 25.7 37.4 5.3 12.4 27.1
17.5 R25 EM PG33U 645 mm 5.2 8.0 12.1 18.4 26.7 38.8 5.5 12.8 28.1
17.5 R25 EM XTLA 632 mm 5.1 7.8 11.9 18.0 26.1 38.0 5.4 12.6 27.6
13.00-24 TG SGG 597 mm 4.8 7.4 11.2 17.0 24.7 35.9 5.1 11.9 26.0
14.00-24 TG SGG 629 mm 5.1 7.8 11.8 17.9 26.0 37.8 5.4 12.5 27.4
1.3 ENGINE
1.3.1 ENGINE SPECIFICATIONS
F4BE0684H
Type
*D400
Cycle 4-stroke diesel engine
Feeding Boosted by intercooler
Injection Direct
Number of cylinders In-line, 6-cylinder

Bore mm 102
Stroke mm 120
Total displacement cm3 5883
Compression ratio 17.5 : 1
kW 129
Max. rating
min-1 2100
Nm (kgm) 680 (69)

Max. torque
min-1 1400
BOOSTING With intercooler

Type of turbocompressor HOLSET HX35W
Forced by means of gear pump,

LUBRICATION
pressure relief valve, oil filter
COOLING
By fluid
Water pump drive
By means of belt
Thermostat
°C 81 ± 2
start of opening
FEEDING
PES 6A
Bosch-type injection
Pump setting 0° ± 30’

Start of delivery mm 3.1
Type of nozzle DSLA 145
Injection sequence 1-5-3-6-2-4
Injection pressure bar 245
1.4 TRANSMISSION
1.4.1 TRANSMISSION SPECIFICATIONS
Transmission
Constructor ZF
Model Ergo Power
Type 6WG160
Control unit EST 37 A
Speed range selector VTS-3
Engine power max. 129 kW
Turbine moment max. 750 Nm
Engine speed max. 2300 min-1
Starting torque multiplication 1.7 to 3.0
Mass (without oil) 360 kg about
Engine-dependent Power take-offs
Torque 680 Nm
Speed 1 x n Engine
1.4.2 TRANSMISSION RATIOS
GEARBOX TANDEM AXLE

DRIVING
Bevel gear Planet Chain OVERALL
DIRECTION Gear Ratio Overall
drive drive drive
1st 5.202 102.641
2nd 3.367 66.434
3rd 2.191 43.231

Forward 2.818 6.00 1.167 19.731
4th 1.418 27.979
5th 0.944 18.626
6th 0.611 12.056
1st 4.939 97.451
Reverse 2nd 2.078 2.818 6.00 1.167 19.731 40.001
3rd 0.895 17.659
1.5 HYDRAULIC SYSTEM
1.5.1 WORKING EQUIPMENT PUMP
Type of Grader Pump Flow Vg max

F156.6
A 10 VO 60 DFR 60 cm3
F156.6A
1.5.2 FRONT WHEEL DRIVE PUMP (only for F156.6A)
Type A4VG 71EP2

Range 0 up to 71 cm³/ U
Flow 160 L / min
1.5.3 RADIAL PISTON MOTOR (only for F156.6A)
Type MS 11
Min. Displacement 629 cm³
Max. Displacement 1229 cm³
1.5.4 BLADE ROTATION MOTOR
Type OMR 100

Displacement 99.8 cm3
Weight 7.0 kg
Max. rotating speed 600 min-1
Max. torque 200 Nm
Max. flow 60 L/min
Max. entry pressure 140 bar
Min. starting torque 170 Nm
1.5.5 CYLINDERS 1 - 10
Retracted Extended Dead

Cylinder Piston Ø Rod Ø Stroke Bottom side Rod side
length length length
mm mm mm mm mm mm mm mm
BLADE LIFT CYLINDER 100 50 1010 1467 2477 457 Two pins d = 50 Ball D = 65.3
BLADE SLEWING CYLINDER 100 50 450 947 1397 497 Two pins d = 50 Ball D = 65.3
Rod head Rod head

BLADE SHIFTING CYLINDER 80 45 1400 1832 3232 432 M36 M30
screwed screwed
TIP CYLINDER Pin with joint Pin with joint

100 50 300 615 915 315 Ø = 50 Ø = 50
(BLADE CUTTING ANGLE ADJUSTMENT) bearing bearing
Pin with joint Pin with joint

OFFSET CYLINDER 100 50 367 706 1073 339 Ø = 60 Ø = 50
bearing bearing
TECHNICAL DATA
REAR RIPPER CYLINDER Pin with joint Pin with joint

100 50 250 585 835 335 Ø = 60 Ø = 50
(OPTION) bearing bearing
FRONT GRADING BLADE CYLINDER Pin with joint Pin with joint
120 60 428 783 1211 355 Ø = 60 Ø = 60
(OPTION) bearing bearing

WHEEL RAKE CYLINDER F156.6 80 45 173 481 654 308 Ø = 40 Ø = 40
bearing bearing
WHEEL RAKE CYLINDER F156.6A 80 45 203 540 743 337 Ø = 45 Ø = 45
bearing bearing
Pin with joint Rod head

STEERIG CYLINDER 50 25 300 512 812 212 Ø = 35 M24x1.5
bearing screwed
F156.6 / F156.6A
F156.6 / F156.6A TECHNICAL DATA 1 - 11
1.6 BRAKES
1.6.1 BRAKES SPECIFICATIONS
Dual pump
Type J. Barnes Nr. WP15A2-C-230-160-L-05-KA-151/153N-E246
Displacement 23 cm3 / rev
Lamellar brake
Great friction diameter 245 mm
Small friction diameter 165 mm
Number of friction areas per wheel 8
Number of brake discs 4x4
Effective braking areas 4 x 2060 cm2
Wheel cylinder
Ring area
• Great diameter 240 mm
• Small diameter 228 mm
Ratio between brake and wheel i = 6.0
1.7 STEERING
1.7.1 STEERING SPECIFICATIONS
Wheel lean 0°
Kingpin angle 0°
Caster angle 0°
Toe-in 3 to 6 mm
Steering wheel Ø 400 mm
Dual pump J. Barnes Nr. WP15A2-C-230-160-L-05-KA-151/153N-E246
Displacement0 16 cm3 / rev
Emergency steering pump Displacement 16 cm3 / rev
max. 25 L/min
Servostat Rexroth-Nr. LAGC160n12-R-150M01-000S
Width of the rotator 21.1 mm
Displacement/Steering wheel rotation0 160 cm3
Pressure 150 bar
Steering cylinders Ø 50/25-300 mm Stroke
Valve block Nr. 4532094
1.8 FLUIDS AND LUBRICANTS 1 - 12
OUT DOOR
QUANTITY FLUIDS OR CLASSIFICATIONS CONSTRUCTOR
ITEM VISCOSITY TEMPERATURE
LITRES LUBRICANTS SPECIFICATIONS SPECIFICATIONS
OF REFERENCE (°C)
AMBRA API CH4
ENGINE OIL 12.50 NH 330 H SAE 15W - 40 -10 to 50 °C
MASTERGOLD HSP* ACEA E5
AMBRA
COOLING SYSTEM 37 NH 900 A -35 to 50 °C
AGRIFLU**
POWERSHIFT INITIAL FILLING 27 AMBRA

API CF4 NH 330 G SAE 15W - 40 -10 to 50 °C
TRANSMISSION AT OIL CHANGE 21 SUPER GOLD 15W-40
AXLE DRIVE 14 API GL5

AMBRA HYPOIDE 90 NH 520 A SAE 80W - 90 -25 to 40 °C
CHAIN BOX 2 x 26 MIL-L-2105D
TANDEM AXLE
API GL5 w/Lim.
WHEEL HUB GEAR 4 x 5.50 AMBRA STF 80W-90 SAE 80W - 90 -25 to 40 °C
Slip Additive
INITIAL FILLING F156.6 185
AMBRA MIL-H-24459
HYDRAULIC DIN 51524 T2
INITIAL FILLING F156.6A 200 HYDROSYSTEM 46 NH 646 BS ISO VG 46 -25 to 40 °C
SYSTEM
BIO-S FZG Test ≥ 10
AT OIL CHANGE 90
FUEL TANK 275 DIESEL OIL EN 590

TECHNICAL DATA
AMBRA API GL5

WORM-GEAR GROUP 2.50 NH 520 A SAE 80W - 90 -25 to 40 °C
HYPOIDE 90 MIL-L-2105D
SWING BEARING – AMBRA GR 75 MD NLGI 2 NH 720 A -40 to 50 °C
GREASE FITTINGS – AMBRA GR 75 MD NLGI 2 NH 720 A -40 to 50 °C
AIR CONDITIONER 1.75 R134a
FRONT WINDSCREEN WASHER 1.50 TUTELA
PROFESSIONAL
REAR WINDSCREEN WASHER 1.50 SC35
* Change interval: 500 hours.

** Fluid to be mixed with water at 50%.
F156.6 / F156.6A
SECTION 2
ENGINE
INDEX
2.1 ENGINE F4BE0684H .............................................................................................. 2-1

2.1.1 Engine coding .......................................................................................................... 2-2
2.1.2 Main engine features ............................................................................................... 2-3
2.1.3 Graphic indications and symbols ............................................................................. 2-4
2.1.4 Technical data ......................................................................................................... 2-5
2.1.5 Tightening torques ................................................................................................... 2-13
2.2 ENGINE REMOVAL - INSTALLATION.................................................................... 2-15

2.2.1 Removal................................................................................................................... 2-15
2.2.2 Engine - transmission separation ............................................................................ 2-18
2.2.3 Engine - transmission junction................................................................................. 2-19
2.2.4 Installation................................................................................................................ 2-20
2.3 GENERAL REMARKS............................................................................................. 2-23

2.3.1 Description of main mechanic engine components ................................................. 2-24
2.4 INJECTION ASSEMBLY ......................................................................................... 2-43
2.5 RECHARGE AND START-UP................................................................................. 2-44

2.5.1 Starter motor............................................................................................................ 2-44
2.5.2 Alternator ................................................................................................................. 2-46
2.6 DIAGNOSTICS ........................................................................................................ 2-48

F156.6 / F156.6A ENGINE 2-1
2.1 ENGINE F4BE0684H
OKs1-02-001
2-2 ENGINE F156.6 / F156.6A
2.1.1 ENGINE CODING
F 4 B E 0 6 8 4 H * D +
Emission level
Approved rating
Use
Feeding / Injection
D = TIER 2
Cylinder no.
Cylinder pattern
0 = 4 strokes, vertical
Engine
Type of crankcase:
B = non-structural 6 = 6-cylinder
Engine
group
8 = Direct injection turbo

diesel with intercooler
4 = Earthmovers
X Y Y X Y Y Y Y Y
X = 4 in-line, 2-valve injection pump Manufacturing sequence number

Y = Engine model
F156.6 / F156.6A ENGINE 2-3
2.1.2 MAIN ENGINE FEATURES
Applications
A
B F4BE0684H
*D400
C
E 5883 cm3
129 kW
F 2100 rpm
Direct injection
G
In-line injection pump

H
T.A.A.
I (Boosted by intercooler)
A Applications
B Type of engine
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
2-4 ENGINE F156.6 / F156.6A
2.1.3 GRAPHIC INDICATIONS AND SYMBOLS
Surface to be machined
Intake
Machining finish bar
Interference
Exhaust
Forced mounting
Thickness
Operation
Play
∂ Compression ratio Pressure

bar
Increase
Replacement
Genuine spares > Greater than .....
Maximum
Decrease
Preload < Smaller than .....
Minimum
Selection
Revs number Classes
Increases
F156.6 / F156.6A ENGINE 2-5
2.1.4 TECHNICAL DATA
F4BE0684H
Type
*D400
Cycle 4-stroke diesel engine

Feeding Boosted by intercooler
Injection Direct
Number of cylinders In-line, 6-cylinder
Bore mm 102
Stroke mm 120
Total displacement cm3 5883
∂ Compression ratio 17.5 : 1
kW 129
Max. rating
min-1 2100
Nm (kgm) 680 (69)

Max. torque
min-1 1400
2-6 ENGINE F156.6 / F156.6A
F4BE0684H
Type
*D400
BOOSTING With intercooler

Type of turbocompressor: HOLSET HX35W
Forced by means of gear

LUBRICATION pump, pressure relief valve,
oil filter
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
°C 81 ± 2
start of opening:
FEEDING
PES 6A
Bosch-type injection
Pump setting 0° ± 30’
Start of delivery mm 3.1
Type of nozzle DSLA 145
Injection sequence 1-5-3-6-2-4
Injection pressure bar 245
F156.6 / F156.6A ENGINE 2-7
F4BE0684H
Type
*D400
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Cylinder liners Ø1 102.01 to 102.03
Pistons: supplied with standard

spares
Measurement dimension X 61
Outer diameter Ø1 101.777 to 101.795
Pin seat Ø2 40.006 to 40.012
Piston - cylinder liners 0.215 to 0.253
Piston diameter Ø1 0.5
Gudgeon pin Ø3 39.9938 to 40.0002
Gudgeon pin-Pin seat 0.0058 to 0.0182
X1* 2.69
Piston ring slots X2 2.425 to 2.445
X3 4.04 to 4.06
* measured on ø of 99 mm
S1* 2.31 to 2.34
Piston rings S2 2.560 to 2.605

S3 3.975 to 4.000
* measured on ø of 99 mm
1 0.34 to 0.38
Piston rings - Slots 2 0.115 to 0.18
3 0.040 to 0.085
Piston rings 0.5
2-8 ENGINE F156.6 / F156.6A
F4BE0684H
Type
*D400
Piston ring end opening in

cylinder liner:
X1 0.25 to 0.55
X2 0.40 to 0.70
X3 0.25 to 0.55
Connecting rod small-end

bushing seat Ø1 42.987 to 43.013
Connecting rod bearing seat Ø2 72.987 to 73.013

bushing diameter
Outer Ø4 43.279 to 43.553
Inner Ø3 40.019 to 40.033

0.266 to 0.566
bushing-seat
Gudgeon pin - Bushing 0.0158 to 0.0362
Journals Ø1 82.99 to 83.01

Crankpins Ø2 68.987 to 69.013
Main half bearings S1* 2.456 to 2.464
Connecting rod half bearings S2* 1.955 to 1.968
* supplied with spares
Shoulder journal X1 37.475 to 37.545
F156.6 / F156.6A ENGINE 2-9
F4BE0684H
Type
*D400
Shoulder bed support X2 25.98 to 26.48
Shoulder half rings X3 37.28 to 37.38
Drive shaft shoulder 0.068 to 0.410
2 - 10 ENGINE F156.6 / F156.6A
F4BE0684H
Type
*D400
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve guide seats on

8.019 to 8.039
cylinder head Ø1
Valves:
Ø4 7.96 to 7.98
α 60°
Ø4 7.96 to 7.98
α 45°
Valve stem and respective guide 0.052 to 0.092
Seat on head for valve seat:

Ø1 46.987 to 47.013
Ø1 43.637 to 43.663
Valve seat outer diameter;

inclination of valve seats on
Ø2 47.063 to 47.089
cylinder head:
α 60°
Ø2 43.713 to 43.739
α 45°
X 0.356 to 1.102
Hollow
X 0.104 to 0.840
F156.6 / F156.6A ENGINE 2 - 11
F4BE0684H
Type
*D400
VALVE GEAR - CYLINDER ASSEMBLY mm
0.050 to 0.102
Between the valve
seat and the head
0.050 to 0.102
Valve spring height:

free spring H 63.5
under a load of:

329 N H1 49.02
641 N H2 38.20
Injector protrusion X not adjustable
Distributing shaft support pins:

Ø 53.995 to 54.045
1⇒7
Bushing inner diameter Ø 54.083 to 54.147
Bushings and support pins 0.038 to 0.162
2 - 12 ENGINE F156.6 / F156.6A
F4BE0684H
Type
*D400
VALVE GEAR - CYLINDER ASSEMBLY mm
Ø1
Seat for tappet
collar
in the crankcase Ø1 16.000 to 16.030
Ø2
Ø3 Outer diameter of Ø2 15.929 to 15.959
tappet collar: Ø3 15.965 to 15.980
Ø2
Between the tappets and the

0.020 to 0.065
seats
Ø1
Rocker arm shaft Ø1 18.963 to 18.975
Rocker arms Ø2 19.000 to 19.026

Ø2
Between the rocker arm and the

0.025 to 0.063
shaft
F156.6 / F156.6A ENGINE 2 - 13
2.1.5 TIGHTENING TORQUES
PART TORQUE
Nm (kgm)
Cylinder head fastening screw 1st phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 S 70 ± 5 (7 ± 0.5)
nd 90°
2 phase:
3rd phase: (only for screws 140 and 180 mm long) 90°
Bed cap fastening screws 1st phase: 50 ± 6 (5 ± 0.6)
2nd phase: S 80 ± 6 (8 ± 0.6)
rd 90° ± 5°
3 phase:
Connecting rod cap fastening 1st phase: 30 ± 5 (3 ± 0.5)
nd phase: S 50 ± 5 (5 ± 0.5)
2
rd 60° ± 5°
3 phase:
Engine flywheel fastening screws pre-tighten S 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Sump oil drain plug 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre-tighten 50 ± 5 (5 ± 0.5)
Angle 90° ± 5°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)
S- Lubrication with oil
2 - 14 ENGINE F156.6 / F156.6A
NOTES:
F156.6 / F156.6A ENGINE 2 - 15
2.2 ENGINE REMOVAL – INSTALLATION
2.2.1 REMOVAL
DANGER
Lift and handle all heavy parts with a lifting device of appropriate capacity.
Make sure that groups or parts are held by appropriate slings and hooks.
Make sure that no bystanders are in the vicinity of loads to be lifted.
1
LEFT SIDE
Remove the engine hood, proceeding as follows:
- Sustain the hood in an appropriate manner;
3
- Remove screw (1) securing the hood sliding bracket and
screw (2) securing the hood shock absorber.
- Remove the two screws (3) securing the hood to the rear
frame and recover plate (4).
1
2
4
2
RIGHT SIDE
- Remove screw (1) securing the hood sliding bracket and
screw (2) securing the hood shock absorber.
- Remove the two screws (3) securing the hood to the rear
frame and recover plate (4).
3
1
2
3
RIGHT SIDE
Disconnect pipes (1) (2) (3) and (4) of heat exchanger (5).
1. Hydraulic oil outlet pipe 4

2. Transmission oil inlet pipe 3
1 2
3. Coolant outlet pipe
4. Compressed air inlet pipe.
2 - 16 ENGINE F156.6 / F156.6A
4
LEFT SIDE
8 7
Disconnect pipes (6) (7) (8) and (9) of heat exchanger (5). 5
6. Hydraulic oil inlet pipe

7. Transmission oil outlet pipe
8. Coolant inlet pipe
9. Cooled compressed air outlet pipe.
6
9
Disconnect the oil pipes from hydraulic motor (10) of the hy-
draulic fan.
10
5
Sling and sustain heat exchanger (5) appropriately.
Remove the four screws (1) securing the heat exchanger to its
supports.
Lift the heat exchanger to remove it.
1
5
6
Remove securing screws (1) and remove coolant tank support
(2) together with the tank. 2
F156.6 / F156.6A ENGINE 2 - 17
7
Disconnect air cleaner (2) pipes and the engine muffler.
1
Remove screws (1) securing air cleaner (2) and remove it.
Remove the muffler.
8
Disconnect propeller shaft (1) connecting the tandem axle-trans-
mission from the transmission side. 1
9
Sling and sustain in an adequate manner attachment pump (1)
and front axle pump (2) (included on F156.6A).
NOTE – On version F156.6A, the front axle pump is installed 1

between the transmission and the attachment pump. 2
3
Remove screws (3) and rest the pumps on the frame so that
they do not interfere with the removal of the engine-transmission
assembly.
10
Disconnect all electric connections on the engine.
Disconnect throttle cable (1) the fuel supply piping.
2 - 18 ENGINE F156.6 / F156.6A
11
Disconnect from the transmission the hydraulic pipes and elec-
trical connections.
Remove screws (1) securing the engine to the frame and lift the
engine-transmission assembly using a hoist of appropriate ca-
pacity.
Rest the engine-transmission assembly on an appropriate

stand.
1
1
12
2.2.2 ENGINE – TRANSMISSION SEPARATION
Remove the cover on the flywheel cover to reach the four screws
(1) securing the engine flywheel to the transmission torque con-
verter. 1
After removing the first screws (1) turn the engine manually until
the second screw reaches the hole, then remove it.
Repeat the same operation for the remaining two screws.
13
Remove the screws securing the transmission group to the en-
gine and using a hoist of appropriate capacity, separate the
transmission from the engine.
F156.6 / F156.6A ENGINE 2 - 19
1
2.2.3 ENGINE – TRANSMISSION JUNCTION
With the engine resting on an appropriate support, connect the
transmission to the engine using a hoist.
Tighten temporarily two outer securing screws.
2
Insert through the hole on the flywheel housing, the first of the
four screws (1) and tighten it temporarily.
Turn the engine manually and tighten the other three screws in
a temporary manner as well.
1
3
Tighten the outer screws securing the transmission group to the
engine in a final manner to a torque of 44 Nm.
Tighten the four inner screws securing the flywheel to the torque
converter to a torque of 44 Nm.
2 - 20 ENGINE F156.6 / F156.6A
4
2.2.4 INSTALLATION
Lift the engine-transmission assembly with appropriate lifting
devices and position it on the rear frame.
Tighten screws (1) securing the engine supports to the frame

to a torque of 170 Nm.
Connect all hydraulic pipes and electrical connections to the

transmission.
1
1
5
Connect throttle cable (1) to the injection pump.
Connect the fuel supply piping.
Connect all the electric connections to the engine.
6
Using appropriate lifting devices, install attachment pump (1)
and front axle pump (2) (provided on F156.6A) on the transmis-
sion.
1
NOTE – On version F156.6A, the front axle pump is installed 2
3
between the transmission and the attachment pump.
Tighten securing screws (3).
7
Connect tandem axle-transmission propeller shaft (1) from the
transmission side. 1
F156.6 / F156.6A ENGINE 2 - 21
8
Install air cleaner (2) and secure it with screws (1).
1
Install the exhaust muffler.
Connect air cleaner (2) piping and the muffler to the engine.
9
Install the coolant tank support together with the tank itself.
2
Tighten securing screws (1).
10
Sling and sustain heat exchanger (5) in an appropriate manner.
Install the heat exchanger correctly on the relevant supports.
Tighten the four securing screws (1).
1
5
2 - 22 ENGINE F156.6 / F156.6A
11
LEFT SIDE
8 7
Connect pipes (6) (7) (8) and (9) of heat exchanger (5). 5
6. Hydraulic oil inlet pipe

7. Transmission oil outlet pipe
8. Coolant inlet pipe
9. Cooled compressed air outlet pipe.
6
9
Connect the oil pipe from fan hydraulic motor (10).
10
12
RIGHT SIDE
Connect (1) (2) (3) and (4) of heat exchanger (5).
1. Hydraulic oil outlet pipe 5

2. Transmission oil inlet pipe
3. Coolant outlet pipe
4. Compressed air inlet pipe.
4
3
1 2
13
Using appropriate lifting devices, install correctly the engine
hood on the rear frame.
RIGHT SIDE
- Connect the hood-sliding bracket and secure it with screws
(1).
3
- Connect the hood shock absorber and secure it with screw (2). 1
- Install plate (4) and secure the engine hood to the rear frame 2
using bolts (3).
14
LEFT SIDE
- Connect the hood-sliding bracket and secure it with screws
(1).
- Connect the hood shock absorber and secure it with screw (2). 3
Install plate (4) and secure the engine hood to the rear frame
using bolts (3).
1
2
4
F156.6 / F156.6A ENGINE 2 - 23
2.3 GENERAL REMARKS
12
11
3
10
6 9
7
OKs1-02-016
1. Turbocompressor 7. Damping unit crankshaft pulley

2. Fixed guide pulley 8. Diesel oil filters
3. Alternator 9. Oil sump
4. Poly-V water pump and alternator drive belt 10. In-line injection pump
5. Automatic belt stretcher 11. Cold start air heater (Option)
6. Fixed guide pulley 12. Blow-by
2 - 24 ENGINE F156.6 / F156.6A
2.3.1 DESCRIPTION OF MAIN MECHANIC

ENGINE COMPONENTS
Crankcase
It consists of a cast-iron structure in which the fol- It also incorporates the coolant circulation chambers
lowing items are realized: cylinder liners (1); bed sup- and the engine member lubricating circuit ducts.
ports (5) and seats for: camshaft bushings (3), Plate (6) is fitted to the lower part of the crankcase
tappets, water/oil heat exchanger (7), water pump and ensures greater resistance to forces and stress.
(2) and oil pump (4).
2
7
3
OKs1-02-017
F156.6 / F156.6A ENGINE 2 - 25
Crankshaft
It is made of steel and rests on seven induction-hard- The main half bearings are made of steel with anti-
ened supports. friction alloy coating.
Inside the crankshaft are the lubricating oil ducts. The penultimate main half bearings are equipped
The following items are force-fitted on the front with a shoulder to restrain the crankshaft end play.
shank: oil pump drive gear, phonic wheel, damper Parts (1) and (3) are mounted in an interfering.
flywheel and auxiliary component drive pulley.
The following items are force-fitted on the rear shank:
camshaft drive gear and engine flywheel mounting
hub.
1
OKs1-02-018
1. Oil pump drive gear 3. Camshaft drive gear

2. Crankshaft 4. Flywheel attachment hub
2 - 26 ENGINE F156.6 / F156.6A
Connecting rods
They are steel-stamped, of the oblique cut type, with Each connecting rod is marked:
separation of the cap obtained by an advanced tech- By a number (on the connecting rod body and
nology (fracture split) instead of mechanic ma- cap) indicating its respective match and the cyl-
chining. inder in which it is mounted.
By a letter (on the connecting rod body) indi-
The connecting rod half bearings are made of steel, cating the weight class of the factory-assembled
with anti-friction alloy coating. connecting rod.
OKs1-02-019
F156.6 / F156.6A ENGINE 2 - 27
Pistons
OKs1-02-020
The combustion chamber is found on the piston The piston rings carry out different functions and
crown. The crown is cooled by the engine oil deliv- have different shapes.
ered by the nozzle fitted to the crankcase. Piston ring 1st and 2nd, trapezoidal in shape and with
Three slots (piston ring seats) are provided: the first ceramic chrome coating.
one and the second one are obtained from a cast- Piston ring 3rd, with double scraper ring shoe with
iron insert with trapezoidal section. inner spring.
The identification number and (1) are shown on the
piston crown.
FRONT
OKs1-02-021
2 - 28 ENGINE F156.6 / F156.6A
Camshaft
The camshaft rests on seven supports in the crank- A. Intake valve control
case. B. Exhaust valve control
The camshaft is controlled directly by the crankshaft
The supports (front and rear) are equipped with steel by means of straight-tooth gears.
bushings mounted in an interfering manner and
coated with anti-friction material; two control eccen-
trics are provided for each cylinder.
A
B
OKs1-02-022 OKs1-02-023
F156.6 / F156.6A ENGINE 2 - 29
Valve control
1
2
5 4
8
10
9
OKs1-02-024
1. Rocker arm 6. Cup

2. Arbour support 7. Spring
3. Adjusting screw 8. Tappet
4. Rod 9. Camshaft
5. Lock cones 10. Valve
2 - 30 ENGINE F156.6 / F156.6A
Cylinder head
The seats of the following parts are obtained on the Moreover, the following components are inserted on
cast-iron cylinder head: the heads:
Inserted valve seats (4); Single-block exhaust manifold (1);
Injectors (6); Intake manifold (2) with seat for cold start air
Thermostat (5); heater (3) (Option).
Detail of cylinder head with inserted valve seats
OKs1-02-025
F156.6 / F156.6A ENGINE 2 - 31
Valves and valve seats
OKs1-02-026
A. Intake side 1. Intake valve

S. Exhaust side stems 2. Exhaust valve
The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
45° (exhaust valves)
60° (intake valves).
Shows the oil seals mounted on valve
OKs1-02-027
2 - 32 ENGINE F156.6 / F156.6A
Valve guides
Detail of valve guides and seats
8,019
8,039
INTAKE EXHAUST
OKs1-02-028
Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen
OKs1-02-029
F156.6 / F156.6A ENGINE 2 - 33
Auxiliary component drive

The Poly - V belt (4) transmits the movement of the The belt is stretched by means of automatic belt
crankshaft (5) to the water pump (1) and alternator stretcher (3).
(2).
OKs1-02-030
1. Water pump 4. Poly - V belt

2. Alternator 5. Crankshaft pulley
3. Automatic belt stretcher
2 - 34 ENGINE F156.6 / F156.6A
LUBRICATION
Forced circulation lubrication is performed by the fol- Oil pressure regulating valve incorporated in the
lowing components: oil filter support;
Rotor-equipped oil pump housed in the crank- By-pass valve for bypassing the clogged oil filter,
case front part, controlled by the straight-tooth in the oil filter support;
gear force-fitted on the crankshaft shank; Cartridge-type oil filter.
Water / oil heat exchanger housed in the engine
crankcase, with oil filter adapter;
OKs1-02-031
Oil return drop-type path
Pressure oil path
F156.6 / F156.6A ENGINE 2 - 35
Heat exchanger
OKs1-02-031
1. Heat exchanger body 3. Water / oil heat exchanger

2. Inner gasket 4. Gasket between exchanger unit and engine block
2 - 36 ENGINE F156.6 / F156.6A
Oil pump
OKs1-02-033
OKs1-02-034
1. Crankshaft with oil pump drive gear
F156.6 / F156.6A ENGINE 2 - 37
Oil vapour recirculation

Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.
OKs1-02-035
2 - 38 ENGINE F156.6 / F156.6A
COOLING
The engine cooling system is of the forced, closed- Centrifugal water pump, housed in the engine
circuit circulation type and ismade up of the following crankcase front part;
components: Thermostat, used to regulate coolant flow.
Heat exchanger, used to cool the lubricating oil;
OKs1-02-036
Water flowing out Water flowing in
Water recirculating
F156.6 / F156.6A ENGINE 2 - 39
Water pump
Thewater pump is housed in a seat obtained from The engine temperature is controlled by a thermo-
the crankcase and is controlled by means of a poly- stat.
V belt. The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.
OKs1-02-037
OKs1-02-038
2 - 40 ENGINE F156.6 / F156.6A
MECHANIC INJECTION FEEDING SYSTEM

Fuel prefilter
The filter support (1) incorporates: manual priming
pump (4), screw (2) used to blow air off the system,
and cartridge (3).
4
2
OKs1-02-039
Fuel filters
The support (2) incorporates: fuel temperature Degree of filtration of cartridge: 10 micron.
sensor (1) (Option), heater resistors (4) (Option), air Maximum working pressure: 5 bar.
bleeding screws (3) and filter (5). Working temperature: -25 °C to + 90 °C.
2
3
1
OKs1-02-040
F156.6 / F156.6A ENGINE 2 - 41
MECHANIC FUEL PUMP

Displacement pump mounted on the injection pump
left side; it is used to feed the injection pump.
5
1
4
2 3
OKs1-02-041
1. Injection pump 4. Fuel inflow from the tank

2. Fuel outflow to the filter 5. Manual control lever
3. Fuel pump
2 - 42 ENGINE F156.6 / F156.6A
NOTES:
F156.6 / F156.6A ENGINE 2 - 43
2.4 INJECTION ASSEMBLY
6 5
3
OKs1-02-042
1. Injectors fuel pipe’s 5. Lubricating oil pipe

2. Pipe for fuel discharge from injectors 6. Engine stop
3. Injection pump 7. Injector
4. Pipe measuring the pressure inside the L.D.A. intake
manifold
2 - 44 ENGINE F156.6 / F156.6A
2.5 RECHARGE AND START-UP
2.5.1 STARTER MOTOR
BOSCH - 24 V - 4 kW
Quick diagnosis
Fault Possible causes Remedy
Dragging torque insufficient 1. Batteries run down Restore
2. Circuit connections oxidized or loose Replace the component
3. Brushes not in working order Replace the component
4. Short-circuited field windings Replace the component
5. Interruptedor short circuited armature Replace the component
6. Out-of-round collector Replace the component
Dragging torque sufficient, but the 1. Free wheel or faulty electro-magnet Replace the component
engine won’t start
Pinion won’t engage 1. Bevelled ring gear Restore
F156.6 / F156.6A ENGINE 2 - 45
Bosch 24 V - 4 kW
6-pole type with series excitation and engagement by means of a fork controlled by an electromagnet.
Clockwise direction of rotation
Rated voltage 24 V
Power 4 kW
30
50
HW EW
45
OKs1-02-043 OKs1-02-044
WIRING DIAGRAM 3/4 VIEW
P(kW) U(V) EV 24 4.000kW - 110Ah 450A +20° C PE=0% n.=6273 U/min

N(l/m) M(Nm) EV 24V 4.000kW - 110Ah 450A -20° C PE=20% n.=5622 U/min
3000 7.5 150 30
2800 7.0 140 28
2600 6.5 130 26
2400 6.0 120 24
2200 5.5 110 22
2000 5.0 100 20
1800 4.5 90 18
1600 4.0 80 16
1400 3.5 70 14
1200 3.0 60 12
1000 2.5 50 10
8000 2.0 40 8
600 1.5 30 6
400 1.0 20 4
200 0.5 10 2
l(A) 6 ±1.5
0 0.0 0 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
19 ±1.5
30 ±1
73.5 +0.5
0
OKs1-02-045 OKs1-02-046
CHARACTERISTIC CURVES PINION ADJUSTER
2 - 46 ENGINE F156.6 / F156.6A
2.5.2 ALTERNATOR
BOSCH NCBI 28 V 35-70 A
Quick diagnosis
Fault Possible causes Remedy
No recharge 1. Interruption of recharge circuit Check the recharge
(warning light, fuse, connector, etc.) circuit connections,
clean and tighten the
cable terminals on the
alternator and battery
2. Voltage regulator not in working Replace the component
order
3. Interrupted rotor winding Replace the component
4. Worn brushes Replace the component
Poor recharge 1. Loose belt Apply correct tension

2. Faulty voltage regulator Replace the component
3. Excessive wear of rotor rings or Replace the component
brushes
4. Short-circuited diodes Replace the component
5. Short-circuited rotor winding(s) Replace the component
Excessive recharge 1. Loose circuit connections Check the connections

to terminals and cable
terminals of batteries,
starter motor and
alternator
2. Voltage regulator not in working Replace the component
order
3. Earth fault Check earth connections
F156.6 / F156.6A ENGINE 2 - 47
Bosch NCBI 28 V 35-70 A

Three-phase type, claw-type rotor, 11-diode rectifier and electronic voltage regulator.
Direction of rotation (control side) clockwise
Current delivered at 6.000 min-1 ≥ 55 A
Rated voltage 28,5 V
OKs1-02-047 OKs1-02-048
WIRING DIAGRAM 3/4 VIEW
l [A]
70
x 10 [ KW ]
60
[V]
31.5
-1
U
sense
31
50
30.5
PI
30
40
29.5
29
30 28.5
28
27.5
20
27
P1
26.5
10 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100
T [°C]
A
0
1 1.5 2 2.5
3
Rpm x 10 [ min -1 ]
OKs1-02-049 OKs1-02-050
OK 1 02 017
CHARACTERISTIC CURVES OF CURRENT DELIVERY CHARACTERISTIC CURVES OF VOLTAGE
2 - 48 ENGINE F156.6 / F156.6A
2.6 DIAGNOSTICS
Main engine operating anomalies:
1 - Engine won’t start; 7 - Engine knocks irregularly;

2 - Engine overheats; 8 - Engine stops;
3 - Engine lacks power and works erratically; 9 - Engine exceeds max. revs number;
4 - Engine exhaust smoke light blue; 10 - Excessive or insufficient oil pressure;
5 - Engine exhaust smoke grey (verging on white); 11 - Excessive fuel consumption;
6 - Engine exhaust smoke black or dark grey; 12 - Engine won’t stop.
1 ENGINE WON’T START
Ø
Connections to battery terminals are in working Clean, check, tighten or replace clamp nuts
order NO
YES
Batteries in working order Carry out the checks described in the “Electric
NO system” repair manual
YES
Starter motor in working order Carry out the checks described in the “Electric
NO system” repair manual
YES
Thermal starter in working order Replace

NO
YES
Injection pump timed Verify correct timing as described in the relevant

NO chapter
(to be continued)
F156.6 / F156.6A ENGINE 2 - 49
Injectors in working order Check operation and adjust

NO
YES
The feeding circuit or injection pump does not Check and blow off
show air penetration NO
YES
The feeding circuit or pump does not show traces Check and clean the feeding circuit (including
of water NO the tank).
YES
Prescribed compression ratio Overhaul the engine or make repairs only on

NO concerned parts (valves, piston rings, etc.)
YES
Fuel filters in working order Replace

NO
YES
Automatic advance variator and electric STOP Check and replace the concerned parts
device both in working order NO
YES
Fuel pump fed correctly Check and replace (if necessary) the fuel pump
NO
YES
Fuel tank supplied correctly Refuel

NO
2 - 50 ENGINE F156.6 / F156.6A
2 ENGINE OVERHEATS
Ø
Coolant level correct Check for leaks and restore the level
NO
YES
Fan and water pump drive belts in working order Check for leaks and restore the level
NO
YES
Water pump in working order Overhaul or replace the unit

NO
YES
Thermostat in working order Replace

NO
YES
Radiator in working order Wash down thoroughly, check for fluid leaks,
NO replace (if necessary) the part
YES
Air filter and circuit piping both in working order Clean or replace faulty parts
NO
YES
Openings for coolant flow to the head in working Wash down thoroughly
order NO
(to be continued)
F156.6 / F156.6A ENGINE 2 - 51
Valve timing correct Check and perform correct timing

NO
YES
Injection pump timed Check correct timing as described in the relevant

NO paragraph
YES
Cylinder head gasket in working order Replace

NO
YES
Fan in working order Replace

NO
2 - 52 ENGINE F156.6 / F156.6A
ENGINE LACKS POWER AND WORKS

3
ERRATICALLY
Ø
Air filter in working order Clean the unit and replace (if necessary) the
NO filter element
YES
Fuel filters in working order Replace by following the instructions given in

NO the “Owner Handbook”
YES
Feeding circuit in working order Check and make (if necessary) the required
NO repairs
YES
The feeling circuit does not show impurities and/ Take off the pipes and injection pump, clean
or traces of water NO them thoroughly, then clean (if necessary) and
dry the fuel tank
YES
Thermostat in working order Replace

NO
YES
Fuel pump in working order Replace

NO
YES
Injectors in working order Check operation and adjust them

NO
(to be continued)
F156.6 / F156.6A ENGINE 2 - 53
Injection pump timed Check correct timing as described in the

NO relevant paragraph
YES
Automatic advance variator (in injection pump) in Check and bench-adjust the injection pump
working order NO
YES
Distributing plunger (in injection pump) in working Check and bench-adjust the injection pump
order NO
YES
Injection pump rate correct Check and bench-adjust the injection pump
NO
YES
Speed governor (in injection pump) in working Check and bench-adjust the injection pump
order at all speeds NO
YES
Circuit and L.D.A. device both in working order Check

NO
YES
Injection pump with peak adjusting-screw fine- Fine-tune the peak adjusting-screw
tuned NO
YES
Correct play between the valves and rocker arms Adjust the play between the valves and rocker
NO arms
(to be continued)
2 - 54 ENGINE F156.6 / F156.6A
Prescribed compression ratio Check and bench-adjust the injection pump

NO
YES
Turbocharger in working order Repair or replace the unit

NO
YES
Correct tie rod length between the accelerator Adjust the tie rod length
and injection pump NO
4 ENGINE EXHAUST SMOKE LIGHT BLUE
Ø
Excessive oil consumption Check the oil vapour vent and cylinder
YES compression. Overhaul, if necessary, the
cylinder head or engine
F156.6 / F156.6A ENGINE 2 - 55
ENGINE EXHAUST SMOKE GREY

5
(VERGING ON WHITE)
Ø
The thermostat comes into operation correctly Replace
NO
YES
Injectors in working order Check operation and adjust as described in S.I.

NO 1094
YES

NO paragraph
YES
Coolant level correct Possible flow of coolant into the combustion

NO chamber; replace the cylinder head gasket or
overhaul the engine
YES
High-quality diesel oil Clean the tank and replace the diesel oil filters
NO
2 - 56 ENGINE F156.6 / F156.6A
ENGINE EXHAUST SMOKE BLACK OR

6
DARK GREY
Ø
Air filter in working order Replace
NO
YES
Thermal starter in working order Replace

NO
YES
Automatic addition device comes into operation Check and replace (if necessary)
NO
YES
Injectors in working order Check operation and adjust them as described

NO
YES

NO paragraph
YES
L.D.A. device in working order Ad just the L.D.A. device

NO
YES
Injection pump adjusted as prescribed Check and bench-adjust the injection pump
NO
(to be continued)
F156.6 / F156.6A ENGINE 2 - 57
Injection pipes intact Check the condition of pipes and replace them
NO (if necessary)
YES
Prescribed compression ratio Check by means of a Motometer and carry out

NO the necessary operations
YES
High-quality diesel fuel Clean the tank and replace the diesel oil filter
NO
2 - 58 ENGINE F156.6 / F156.6A
7 ENGINE KNOCKS IRREGULARLY
Ø
Knock detected in the injection pump Perform correct timing of injection pump on the
YES engine
NO
Knock detected in the drive shaft Check the following items: journal play and out-
of-roundness; screw fastening for bed caps and
YES
engine flywheel; oil pressure. Replace the parts
or overhaul the engine
NO
Knock detected in the connecting rods Check the following items: crankpin play and
out-of-roundness; screw fastening for
YES
connecting rod caps; connecting rod squaring.
Replace the parts or overhaul the engine
NO
Knock detected in pistons Check the following items: play between the
pistons and the cylinder liners; integrity of piston
YES
rings; play between the pins and the piston hubs.
Replace the parts or overhaul the engine
NO
Knock detected in the cylinder head Check the following items: operation play
YES between the rocker arms and the valves;
injection pump timing; valve timing. Adjust
NO
Knock detected in the valve gear Check and replace (if necessary) the gears;
moreover, check for broken springs, for
YES excessive play between the stems and guides,
the tappets and seats. Adjust the play between
the valves and rocker arms
(to be continued)
F156.6 / F156.6A ENGINE 2 - 59
Knock detected in injectors Check and adjust as described in S.I. 1094, then
YES replace
NO
Knock detected in the engine flywheel Replace loose screws and tighten all screws to
YES the specified torque and angles
NO
Knock detected in the fuel piping Clean the pipes and replace the pipes that show
YES evident dents; clean (if necessary) the injection
pump
2 - 60 ENGINE F156.6 / F156.6A
8 ENGINE STOPS
Ø
Fuel tank filled Refuel and drain (if necessary)
NO
YES
Fuel filters in working order Replace

NO
YES
Feeling circuit in working order Check the circuit and drain

NO
YES
Regular idle speed Adjust

NO
YES
Regular injection pump rates Bench-check the flow rates

NO
YES
Injection pump controls in working order Replace worn parts and adjust
NO
YES
Correct play between the valves and rocker arms Ad just the play between the valves and rocker
NO arms
(to be continued)
F156.6 / F156.6A ENGINE 2 - 61
Intact valves Replace the valves

NO
9 ENGINE EXCEEDS MAX. REVS NUMBER
Ø
Speed governor in working order Check and replace (if necessary) the worn parts
NO
2 - 62 ENGINE F156.6 / F156.6A
EXCESSIVE OR INSUFFICIENT OIL

10
PRESSURE
Ø
Pressure control valve in working order Check and replace (if necessary)
NO
YES
Oil pump and delivery pipes both in working order Check and replace (if necessary)
NO
YES
Main bearings and connecting rod bearings both Replace the bearings and reface (if necessary)
in working order NO the drive shaft
YES
Engine oil SAE viscosity conforming to standards Replace the engine oil with equivalent of
NO adequate viscosity
F156.6 / F156.6A ENGINE 2 - 63
11 EXCESSIVE FUEL CONSUMPTION
Ø
Fuel tank and pipes in working order Eliminate leaks (if any) and replace the worn
NO parts
YES
Air filter in working order Replace

NO
YES
Correct injector adjustment Check operation and adjust them

NO
YES
Correct injection pump adjustment Check and bench-adjust

NO
YES
L.D.A. device in working order Adjust the L.D.A. device

NO
YES
Injection pump timed Check static force-fit of the injection pump

NO
2 - 64 ENGINE F156.6 / F156.6A
12 ENGINE WON’T STOP
Ø
Cut-off electromagnet in working order Replace the electromagnet
NO
YES
Speed governor in working order at all speeds Overhaul the injection pump and bench-adjust
NO it according to the relevant adjustment table
SECTION 3
TRANSMISSION
INDEX
3.1 GENERAL DESCRIPTION ...................................................................................... 3-1

3.1.1 Preface .................................................................................................................... 3-1
3.1.2 Technical data ......................................................................................................... 3-1
3.1.3 Composition............................................................................................................. 3-2
3.1.4 Important instructions .............................................................................................. 3-5
3.2 OPERATION............................................................................................................ 3-6

3.2.1 Torque converter ..................................................................................................... 3-6
3.2.2 Measuring point and connection.............................................................................. 3-8
3.2.3 Powershift transmission........................................................................................... 3-10
3.2.4 Hydraulic system ..................................................................................................... 3-12
3.2.5 Electrical system...................................................................................................... 3-16
3.2.6 Maintenance ............................................................................................................ 3-19
3.3 ZF DIAGNOSTIC SYSTEM ..................................................................................... 3-23

3.3.1 Generalities.............................................................................................................. 3-23
3.3.2 Automatic calibration of the shifting elements ......................................................... 3-23
3.3.3 Diagnosis ................................................................................................................. 3-26
3.3.4 Diagnostic inspection............................................................................................... 3-30
3.3.5 Troubleshooting ....................................................................................................... 3-31
F156.6 / F156.6A TRANSMISSION 3-1
3.1 GENERAL DESCRIPTION
3.1.1 PREFACE 3.1.2 TECHNICAL DATA
Important Informations concerning the technical re-

liability and reliability in service are accentuated by Version F156.6 F156.6A
the following Symbols: Constructor ZF
Model Ergo Power
Type 6WG160
Valid for Instructions which must be observed at Control unit EST 37 A

the Maintenance, the Performance or the Opera- Speed range selector VTS-3
tion of the vehicle!
Engine power max. 129 kW
Turbine moment max. 750 Nm
Engine speed max. 2300 min-1

Inserted at working and operating procedures
Starting torque multiplication 1.7 to 3.0
which have to be exactly respected to avoid a
damage or destruction of the unit or to exclude Engine-dependent Power take-offs
a danger to persons!
Torque 500 Nm
Speed 1 x n Engine
Connection SAE-B SAE-C
A4VG71EP2D
Hydraulic pumps LA10VO45DFR
A10VO60DFR
Mass (without oil) 360 kg about
Identification plate
OKs1-03-001
1. Transmission type 5. Oil specification

2. Transmission Serial-No. 6. List of lubricants
3. ZF-Parts List-No. 7. Oil capacity
4. Total ratio of the Gearbox 8. Customer no.
3-2 TRANSMISSION F156.6 / F156.6A
3.1.3 COMPOSITION
The ZF transmission consist of a hydrodynamic torque converter and a rear-mounted multi-speed power-shift
gearbox with integrated transfer case. The propulsion happens by direct attachment to the IVECO engine
through a diaphragm. The transmission can be shifted by means of the electronic control EST 37 manually or
automatically in six forward gears and three reverse gears and has an electronic reverse lock in gears 3 – 6.
Through a propeller shaft the front output is connected to the tandem axle. On the rear output (at the back) the
transmission is equipped with a disc brake as a parking brake.
According to the version of grader, one or two hydraulic pumps are fitted to the engine-dependent coaxial power
take-off.
On all graders the ZF fine filter is fitted directly to the gearbox housing.
In addition, the transmission is equipped with an emergency steering pump with delivery of 16 cm3/rev.
External views
1 2 1 16 1
9
10
15
3 3
14
8
8 4 13
12
3 11
3
3 3
7 6 OKs1-03-031 OKs1-03-032
Front view Rear view
1. Lifting lugs 9. Torque converter

2. Diaphragm - direct mounting 10. Electro-hydraulic control
3. Transmission suspension holes M20 11. Parking brake operated hydraulically
4. Emergency steering pump. S = M26 x 1.5. D = M22 x 1.5 12. Output flange (rear side)
5. Output flange (converter side) 13. Brake disc
6. Oil drain plug with magnet M38 x 1.5 14. Exchange filter (fine filter)
7. Model identification plate 15. Filter head with
8. Oil filler tube with oil dipstick 16. Power take-off; coaxial, engine-dependent
Section view
12
1
KR
KV AN
11
K2 K4
K3 K1 2
AB
10
3
Gearbox diagram
9
4
13
8
14
6
15
7
OKs1-03-030
1. Clutch shaft “KR” 9. Transmission pump

2. Power take-off; coaxial engine-dependent 10. Input flange - Input through universal shaft “AN”
3. Clutch shaft “KV” 11. Converter
4. Clutch shaft “K2” 12. Inductive transmitter for engine speed
5. Clutch shaft “K3” 13. Clutch shaft “K4”
6. Output flange (rear side) “AB” 14. Converter relief valve
7. Output flange (converter side) “AB” 15. Clutch shaft “K1”
8. Output shaft
Torque converter Output
The torque converter is a wear-free starting device The powershift transmission has between input and
which is infinitely variable adapting itself to the re- output shaft a center distance of 500 mm.
quired situations (necessary input torque). Through a propeller shaft the front output is con-
Unit size W 300 with torque multiplication and a Con- nected to the tandem axle.
verter Clutch. On the rear output (at the back) the transmission is
equipped with a disc brake as a parking brake.
Transmission ratios (mechanical)

Power take-off
SPEED DRIVING DIRECTION Ratio For the drive of an external hydraulic pressure pump,
an engine-dependent coaxial power take-off is ex-
1 Forward 5.202
isting.
2 Forward 3.367 According to the version of grader, one or two hy-
draulic pumps are fitted to it.
3 Forward 2.191
4 Forward 1.418
Transmission accessories
5 Forward 0.944
The transmissions is additionally equipped with the
6 Forward 0.611
following components:
1 Reverse 4.939
- Emergency steering pump with a feed rate of
2 Reverse 2.078 16 cm3/rev.
3 Reverse 0.895 - Separate mounting of the ZF-Fine filter, fitted di-
rectly to the gearbox housing.
The gear of the new driving direction will be only

3.1.4 IMPORTANT INSTRUCTIONS engaged when the programmed reversing speed
and the transmission input speed (turbine speed)
Oil level check (see 3.2.6): has fallen below.
In the cold start phase, the engine must be run- The programming is customized and can there-
ning about 2-3 minutes at idling speed and the fore be different from standard.
marking on the oil dipstick must then be lying Therefore, the exact procedure must be
above the cold start mark. taken from the Operation and Maintenance
The oil level check in the transmission must be Instructions Manual.
carried out at engine idling speed and operating
temperature of the transmission (80 to 90 °C). At stopped engine, there is on the Controller, de-
spite a preselected gear, no power flow between
At stationary engine, the oil level in the transmis- transmission and engine, i.e. the transmission is
sion is rising essentially, according to the instal- in the idling position.
lation conditions ! The parking brake must therefore be completely
actuated!
At every oil change, the ZF-Fine filter must be When leaving the vehicle, secure it additionally
replaced. In addition, ZF recommends to start the by brake blocks!
autonomous calibration of the shifting elements
(AEB). The towing speed must in no case be higher than
10 km/h, the towing distance not longer than 10
The autonomous calibration of the shifting ele- km.
ments (AEB) must be started after the initial in- It is imperative to observe this Specification be-
stallation of the transmission and the Electronics cause otherwise the transmission will be dam-
in the vehicle at the Vehicle Manufacturer and ages due to insufficient oil supply!
after every replacement of the transmission, the At a longer distance, the best solution would be
electrohydraulic control or the TCU in case of a to transport the vehicle with a low loader.
failure.
Operating temperature behind the converter at
Put the Controller at the starting of the engine least 65 °C and 100 °C in continuous operation,
always to the Neutral position. a short-time increase up to max. 120 °C is per-
At running engine and transmission in Neutral, mitted.
the parking brake must be engaged or the service Temperature in the sump 60-90 °C.
brake be actuated, to prevent the vehicle from
rolling. In case of irregularities on the transmission, put
the vehicle out of service and ask for Specialists.
Prior to every start off, loosen the parking brake.
The engagement of the speed out of Neutral is

only possible under the programmed transmis- Protective measures for the ZF-Electronics at
sion input speed (turbine speed). electrical operations on the vehicle:
Neutral position of the selector switch at higher At the following operations, the ignition must be
vehicle speeds (above stepping speed) is not ad- switched off and the control unit plug must be
missible. pulled off from the ZF-Electronics:
Either a suitable gear is to be shifted immediately,
or the vehicle must be stopped at once. - At any kind of electrical operations on the ve-
hicle.
Reversing (Standard): - At welding operations on the vehicle.
The reversing must be performed at standstill, - At insulation tests on the electric system.
resp. at very low driving speed.
Above the programmed reversing limit, the ve-
hicle will be shifted to Neutral by the Electronic
unit EST-37, and the vehicle continues rolling in
the old driving direction.
3.2 OPERATION
3.2.1 TORQUE CONVERTER
Function of a hydrodynamic Torque converter (Schematic view)
TP = Torque of the
Impeller Turbine wheel Impeller
TT = Torque of the
Turbine wheel
TR =Torque of the
TT Reaction member
(Stator)
From the
Engine
TP
To the
Transmission
NT = 0
Condition in the Vehicle is stationary
moment of the 1 1,5 TR 2,5
start off Reaction member
(Stator)
Intermediate nT < n E n g in e
condition 1 <1,5 <2,5
nT ≈ 0.8 n E n g in e
Condition in the
lock-up point 1 0 1
OKs1-03-002
The converter is working according to the Trilok- The oil which is streaming out of the impeller, enters
System, i.e. it assumes at high turbine speed the the turbine wheel and is there reversed in the direc-
characteristics, and with it the favourable efficiency tion of flow. According to the rate of reversion, the
of a fluid clutch. turbine wheel and with it also the output shaft is re-
ceiving more or less high reaction torque.
The converter is designed according to the engine
power so that the most favourable operating condi- The stator (reaction member) following the turbine,
tions are obtained for each installation case. has the task to reverse the oil, which is streaming out
of the turbine once more and to deliver it under the
The Torque converter is composed of three main suitable discharge direction to the impeller.
components: Due to the reversion, the stator is receiving a reaction
torque.
Impeller - Turbine wheel - The relation turbine torque/pump torque is called
Stator (Reaction member) torque multiplication. This is the higher, the greater
the speed difference of impeller and turbine wheel
These three impellers are arranged in such a ring- will be.
shaped system that the fluid is streaming through the
circuit components in the indicated order. Therefore, the maximum torque multiplication is cre-
ated at stationary turbine wheel.
Pressure oil from the transmission pump is con- With increasing output speed, the torque multiplica-
stantly streaming through the converter. In this way, tion is decreasing. The adaption of the output speed
the converter can fulfill its task to multiply the torque to a certain required output torque will be infinitely
of the engine and at the same time, the heat created variable and automatically achieved by the torque
in the converter is dissipated via the escaping oil. converter.
When the turbine speed is reaching about 80% of Converter clutch

the pump speed, the torque multiplication becomes
1.0 i.e. the turbine torque becomes equal to that of When the Converter clutch is closed, the slip between
the pump torque. impeller and turbine wheel, and with it the hydraulic
From this point on, the converter is working similar loss in the converter is equal to "Zero".
to a fluid clutch. The Converter clutch will be automatically shifted de-
pendent on the turbine speed.
A stator freewheel serves to improve the efficiency The pressure oil (15 + 1 bar) for the closing of the
in the upper driving range, in the torque multiplication Converter clutch, is directed via a solenoid shift valve
range it is backing-up the torque upon the housing, to the piston (6), which is compressing the plate pack.
and is released in the clutch range.
In this way, the stator can rotate freely.
1 2 1 2
6 6
Pressure oil
from the
Converter
clutch-Valve
5 5
4 3 4 3
Converter clutch - open Converter clutch - closed OKs1-03-003
1. Cup spring 4. Circuit cover/Impeller

2. Plate pack 5. Turbine wheel
3. Stator 6. Piston
Measuring point Converter clutch

Connection to Converter clutch Converter clutch Solenoid valve
Duct plate
Vent hole
System Pressure from Control unit
Converter Clutch Solenoid Shift Valve
OKs1-03-004
3.2.2 MEASURING POINTS AND CONNECTIONS
The marked position (e.g. 53) correspond with the positions of the Table on page 3-14.
The measurements have to be carried out at hot transmission (about 80-95 °C).
Marking
No. Denomination of the position Connection
on the valve block
Measuring points for hydraulic oil and temperature:
51 = In front of the converter - opening pressure 11 + 2 bar M10 x 1 H
52 = Behind the converter - opening pressure 4.3 + 3 bar M14 x 1.5
53 = Clutch Forward 16 + 2 bar KV M10 x 1 B
55 = Clutch Reverse 16 + 2 bar KR M10 x 1 E
56 = Clutch 16 + 2 bar K1 M10 x 1 D
57 = Clutch 16 + 2 bar K2 M10 x 1 A
58 = Clutch 16 + 2 bar K3 M10 x 1 C
60 = Clutch 16 + 2 bar K4 M10 x 1 F
63 = Behind the converter M14 x 1.5
Temperature 100 °C, short-time 120 °C
65 = System pressure 16 + 2.5 bar M10 x 1 K
Measuring points for delivery rates:
15 = Connection to the heat exchanger 1” 5/16 - 12 UN-2B
16 = Connection from the heat exchanger 1” 5/16 - 12 UN-2B
Inductive transmitters, speed sensor and switches:

21 = Inductive transmitter n Turbine M18 x 1.5
34 = Speed sensor n Output and Speedometer —
47 = Inductive transmitter n Central gear train M18 x 1.5
48 = Inductive transmitter n Engine M18 x 1.5
54 = Difference pressure switch for pressure filter M14 x 1.5
Connections:
10 = Breather M10 x 1.5
37 = System pressure M16 x 1.5
39 = Return line into the sump M26 x 1.5
49 = Plug connections on the electro-hydraulic control unit —
68 = System pressure (Option) M16 x 1.5 G
69 = Control (Option) M16 x 1.5 J
70 = Emergency steering pump - Pressure line M22 x 1.5
71 = Emergency steering pump - Suction line M26 x 1.5
16
37
Y 15
X
52/63
54 70
34
39
71
65 51 68 48 10 47 21
69 H J 49
K
G
57 A F
60
B E
53
55
C D
58 58 70 54
34
View X
16
15
52/63
View Y
OKs1-03-033
3 - 10 TRANSMISSION F156.6 / F156.6A
3.2.3 POWERSHIFT TRANSMISSION
The multi-speed reversing transmission in counter-

shaft design is power shiftable by hydraulically actu- K1
ated multi-disk clutches.
All gears are constantly meshing and carried on an-
tifriction bearings.
The gear wheels, bearings and clutches are cooled K4
and lubricated with oil.
5 4 3
The 6-speed reversing transmission is equipped with
6 multi-disk clutches.
At the shifting, the actual plate pack is compressed KR
by a piston, movable in axial direction, which is pres-
surized by pressure oil.
A compression spring takes over the pushing back
AN 6
of the piston, thus the release of the plate pack. As
to the layout of the transmission as well as the spec-
ifications of the closed clutches in the single speeds,
see following figures. KV
Diagram - Clutches 1 2
K2
Driving
Speed Clutch
direction
1 KV/K1 8 K3
2 K4/K1
3 KV/K2
Forward
4 K4/K2 AB 7
5 KV/K3
6 K4/K3
1 KR/K1
Reverse 2 KR/K2
KR
3 KR/K3 KV AN
Wheel Diagram
1. Torque converter
K2 K4
2. Pump
3. Stator
4. Turbine
5. Converter clutch
6. Power take-off engine dependent K1
7. Rear output for parking brake
K3
8. Emergency steering pump
KV. Clutch forward

KR. Clutch reverse
K1. Clutch 1st speed AB
K2. Clutch 2nd speed
K3. Clutch 3rd speed
K4. Clutch 4th speed
AN. Input from engine
OKs1-03-035
AB. Front output for tandem axle
F156.6 / F156.6A TRANSMISSION 3 - 11
Power Flow
FORWARD SPEED
1st speed 2nd speed 3rd speed
KR KR KR
KV AN KV AN KV AN
K4 K4 K4
K2 K2 K2
K3 K1 K3 K1 K3 K1
AB AB AB
4th speed 5th speed 6th speed
KR KR KR
KV AN KV AN KV AN
K4 K4 K4
K2 K2 K2
K3 K1 K3 K1 K3 K1
AB AB AB
OKs1-03-036
REVERSE SPEED
1st speed 2nd speed 3rd speed
KR
KR
KR
KV AN
KV
AN
KV
AN
K4

K4

K4
K2 K2
K2

K1
K1
K1
K3 K3
K3

AB
AB
AB
OKs1-03-037
= Power flow gear train

= Gears not meshing
3.2.4 HYDRAULIC SYSTEM
On Ergopower transmissions two oil circuits are dis- Oil circuit in Electro-hydraulic shift control unit
tinguished: The six clutches of the gearbox are actuated by
- Main oil circuit in transmission housing means of six pressure control units P1 to P6.
- Oil circuit in Electro-hydraulic shift control unit. Each pressure control unit consists of a filter, a dia-
phragm (B) of 0.8 mm, a damping piston (D), a sub-
Main oil circuit sequence slide valve (NFS) and a proportional valve
The transmission pump responsible for the oil feed (Y1).
of the converter and the gearbox control is fitted onto The control pressure of 9 bar for the actuation of the
the engine-dependent input shaft. subsequence slide valve is produced by the pres-
The pump delivery is Q = 85 L/min, at nen g i n e = sure-reducing valve (RV-9).
2000 min-1. It draws oil through the coarse filter from
the sump and delivers it to the fine-mesh ZF filter. CONDITION OF SPEED RANGE SELECTOR -
At the end of the oil filtering, oil stands-by at the main NEUTRAL-, IGNITION ON
delivery valve (HDV) and at each subsequence slide All proportional valves are activated by a current of
valve (NFS) of Electro-hydraulic shift control unit. 100 mA. In this position (see e.g. P6) the control oil,
From the measuring point (65) the system pressure reduced to max. 9 bar, runs through the pressure
16 – 18 bar can be detected. regulators and can flow off from the corresponding
proportional valve into the sump without performing
The main delivery valve limits the max. shift pressure any work.
at 16 – 18 bar and releases the main oil flow to the
converter and lubrication circuits. The converter CONDITION OF SPEED RANGE SELECTOR -
safety valve (WSV), fitted into the converter intake, 1st GEAR FORWARD -
protects the converter from too high inner pressures.
Opening pressure 11 bar. The proportional valves (Y3 and Y5) are activated by
From the measuring point (51) pressure can be de- the electronic control unit EST-37 with 500 mA. The
tected before the converter. corresponding proportional valve stops the free
The pressurised oil from the transmission pump runs runoff into the sump.
continuously through the converter and serves to the The control oil now generates a pressure between
torque transmission, at the same time the generated proportional valve and diaphragm 0.8 mm. This pres-
heat is conducted away by means of the oil flowing sure shifts the subsequence slide valve (NFS) in an-
off from the converter. other position. In this position the way for the main
To avoid cavitation in the converter, this should al- oil flow at 16 – 18 bar to the clutches (KV and K1) is
ways be filled up with oil. This is achieved by means opened.
of a rear-mounted converter back-pressure valve Thereby the corresponding clutch is engaged.
(WGV) with a opening pressure of 4.3 bar.
From the measuring point (63 / 52), pressure can be
detected at 1.5 bar after the converter and tempera-
ture at T = 100 °C, for a short time 120 °C, after the
converter.
The oil flowing off from the converter is conveyed to
the combined cooler through port (15).
At the end of the oil cooling, oil reaches the lubricating
oil circuit of the transmission through port (16).
WT. Heat exchanger D. Vibration damper

WGV. Converter back pressure valve (4.3 + 3 bar) B. Orifice
WSV. Converter safety valve (11 + 2 bar) P1. Proportional valve K4
HDV. Main pressure valve (16 + 2.5 bar) P2. Proportional valve KR
RV-9. Pressure reducing valve (9 ± 0.5 bar) P3. Proportional valve K1
NFS. Subsequence slide valve P4. Proportional valve K3
TEMP. Temperature sensor P5. Proportional valve KV
FDV. Filter pressure differential valve (Bypass-valve) P6. Proportional valve K2
∆p = 5.5 + 3 bar Y1...Y6. Pressure regulators
K4 KR K1 K3 KV K2
F 60 E 55 D 55 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
F156.6 / F156.6A
B D
D
B D B D B D B
D

B

Y1 NFS Y2
Y3
Y4
Y5
Y6
NFS
NFS
NFS NFS
NFS

RV-9

HDV

K
65

Oil circuit in Electro-hydraulic shift control unit
Converter
TRANSMISSION
51
ZF fine filter
H FDV
Filter grade according ISO 4572:
WSV
β30 75 β15 25 β10 5.0
Dust capacity according ISO 4572:
63

52
min. 17 g
Filter surface:
WT min. 6700 cm2
= Main pressure WGV

= Regulated main pressure
= Pilot pressure 15 Transmission pump
Bypass valve
= Converter input pressure p = 16 + 2 bar
p = 1,5 bar Qp = 85 L/min by
= Converter output perssure
16 n = Engine 2000 min -1
= Lubrication
= Return into the sump Coarse filter mesh width 0.800 mm
Oil sump
Lubrication
Main oil circuit
OKs1-03-034
3 - 13
BYPASS FUNCTION OF ZF FINE FILTER

The mounted fine filters do not have any internal by- At the same time, the pressure differential switch
pass more. The bypass function is taken over by a (FDV) can signal the maintenance condition of the
pressure differential switch (FDV) p = 5.7 bar fitted filter as an error code by means of the electronic con-
into the channel plate. trol unit EST-37 on the digital console.
This means that when oil is cold or the oil filter gets
polluted, the oil flow is directly conveyed to the con- Possible error codes:
verter and not into Electro-hydraulic shift control unit. 1. Bypass open → Filter polluted
This presents two advantages: 2. 24 V voltage interrupted
• Protection of Electro-hydraulic shift control unit 3. Earth connection interrupted
against oil pollution
• In the warming-up phase, oil circulates in a smaller
circuit, this enables oil to be more rapidly warmed
up.
Electro-hydraulic shift control unit
Pressure regulators Engaged clutches
Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
1 • • KV K1
2 • • K4 K1
3 • • KV K2
FORWARD
4 • • K4 K2
5 • • KV K3
6 • • K4 K3
1 • • KR K1
REVERSE 2 • • KR K2
3 • • KR K3
NEUTRAL
Engaged clutch K4 KR K1 K3 KV K2
Positions on the valve block F E D C B A
Current no. of the measuring points 60 55 56 58 53 57
• Pressure regulator under voltage
1 2
3
A A
Y6 Y1
Y5 Y2
B B

Y4 Y3
5 5
3 6
Electro-hydraulic shift control unit with proportional valves
OKs1-03-038
1 6 2
Y5
8 7
Section A-A
OKs1-03-039
Y5
10
Section B-B 11
OKs1-03-040
1. Main pressure valve 16 + 2,5 bar 7. Intermediate plate

2. Pressure reducing valve 9 bar 8. Ductplate
3. Housing 9. Pressure regulator
4. Plug (cable harness) 10. Vibration damper
5. Cover 11. Subsequence slide valve
6. Valve block
3.2.5 ELECTRICAL SYSTEM
Wiring diagram
ITEM DESCRIPTION
A9 Electro-hydraulic control unit
A11 Electronic control unit TCU EST-37
A100 Central electronic unit
B1 Engine speed sensor

B3 Middle wheel chain speed sensor
B4 Gear transmission speed sensor drove off
B5 Turbine speed sensor
B12 Gear selector lever
F14 Fuse 7,5 A

F22 Fuse 7,5 A
S16.1 Pressure switch parking brake

S17.9 Filter contamination switch
S26.4 Transmission neutralisation
S87.8 Automatic/Manual switch
X33 Plug open

XA5 Diagnostic interface (plug)
XCAN Can interface (plug)
XCAN.1 Can interface (plug)
NOTE – For other connections see corresponding Sheets in Section “Electrical system”.
F156.6 / F156.6A
ZF Diagnostic plug
Middle
Turbine Engine wheel chain
Gear transmission speed speed speed
speed sensor sensor sensor sensor
drove-off
Gear selector lever
brake
Inchen
Parking
TRANSMISSION
Plug open
Gearshift
Oil filter switch CAN Bus
OKs1-03-041
3 - 17
Speed range selector
With this speed selector (preselector pushbutton After shifting of a gear from the neutral position, al-
switch), the driving direction is preselected by hori- ways the automatic mode is selected.
zontally turning the speed range selector lever. Automatic shifting forward gears 1 to 6.
By pressing the speed range selector lever to the Automatic shifting reverse gears 1.
right (+) or the left (-), the gears can be preselected.
The speed range selector is provided with a function
pushbutton. Depending on the driving conditions, this For reversing to manual operation, there are two op-
pushbutton serves as Kick-Down button or unlocking tions:
button for starting and for the automatic or manual
driving operation. - Activating the function pushbutton (remaining in
the actual gear).
- Selecting a lower or higher gear by touching the
VTS-3 GEAR ASSIGNMENT gear selector lever to the left (-) or the right (+).
General
From the neutral position, a gear can only be selected
For selecting a gear, the function pushbutton must with the turbine speed below 1200 min-1
be activated.
.
FUNCTIONAL KNOB CIRCUIT DIAGRAM CONTROLLER

RT/5
N 2
ED1
V R +/VP
GEAR S1
SHIFTING WS/10 5
AD6
GATE AS/N
S2
SW/6 4
AD4
S3 F
VI/4 6
-
-
V
N
+
+
AD5
- + R
R
S6
GR/3 10
AD8
KD/E
S4
GN/1 7
AD1
T+
S5
GE/2 8
AD2
T-
CODING CONTROLLER POSITION X1

F R N T+ T- KD/E
AD1 T+ •
AD2 T- •
FUNCTION
AD4 F •
SWITCH
AD5 R •
AD6 AS/N •
AD8 KD/E •
OKs1-03-042
3.2.6 MAINTENANCE - At operating temperature of the transmission

(about 80-90 °C)
Oil grade - At engine idling speed
- Loosen oil dipstick by counterclock rotation, re-
move and clean it
Permitted for the Powershift transmissions 6 - Insert oil dipstick slowly into the oil level tube until
WG-160 are oils according to ZF-List of lubri- contact is obtained, and pull it out again
cants TE-ML 03. - On the oil dipstick, the oil level must be lying in the
zone "HOT"
- Insert the oil dipstick again, and tighten it by clock-
Oil level check wise rotation
If the oil level has dropped in operating temper-

At the oil level check, the prescribed safety di-
ature condition below the "HOT" Zone, it is ab-
rections according to § 6 of the rules for accident
solutely necessary to replenish oil according to
prevention for power plants in Germany, and in
the ZF-List of lubricants TE-ML-03.
all other countries the respective national regu-
An oil level above the "HOT" marking, is leading
lations have to be absolutely respected.
to a too high oil temperature.
For example, the vehicle has to be secured
against rolling with blocks, articulated vehicles
additionally against unintended turning-in.
The oil level check must be carried out as follows:

- Oil level check (weekly)
- At horizontally standing vehicle
- Transmission in Neutral position "N"
- In the cold start phase, the engine must be running
about 2-3 minutes at idling speed, and the marking
on the oil dipstick must then be lying above the
cold start mark "COLD MIN"
2 OKs1-03-008
1. Oil filler tube with oil dipstick

2. Oil drain plug M38x1.5
3. Exchange filter (ZF-Fine filter).
Oil dipstick
MEASURED AT LOW COLD

HOT
IDLING-NEUTRAL MIN
Limits
"HOT"
OKs1-03-043
Oil change and Filter replacement interval

At the initial filling of the transmission has to be
considered that the oil cooler, the pressure filter
First oil change after 100 operating hours in ap- as well as the pipes must get filled with oil.
plication. According to these cavities, the oil capacity to
Every further oil change after 1000 operating be filled in is greater than at the later oil fillings
hours in application, however at least once a in the course of the usual Maintenance service.
year!
At every oil change, the ZF-Fine filter (pressure
filter) has to be replaced. ZF recommends, to start the AEB at every oil
change (see 3.3.2).
OIL CHANGE AND OIL FILLING CAPACITY

FILTER REPLACEMENT
The oil change must be carried out as follows:
At the replacement of the ZF-Filter in the main oil
- At operating temperature of the transmission and stream, pay attention that no dirt or oil sludge can
horizontally standing vehicle, open the oil drain penetrate into the circuit. Besides, the parking brake
plug and drain the used oil. has to be covered, resp. protected from oil wetting.
- Clean the oil drain plug with magnetic insert and At the mounting of the filter, any exertion of force has
the sealing surface on the housing, and install it to be avoided.
along with new O-ring again.
- Fill in oil (about 21 liters) according to ZF-List of
lubricants TE-ML 03.
Treat the filter carefully at the installation, the
(Sump capacity, external oil capacities e.g. in the transport and the storage!
cooler, in the lines etc. are dependent on the vehicle). Damaged filters must no more be installed!
The indicated value is a guide value.
The filter differential pressure valve (bypass

It is imperative to pay attention to absolute clean- valve) is equipped with a filter contamination
liness of oil and filter! switch which is informing the driver about the
Binding is in any case the marking on the oil dip- contamination of the ZF-Fine filter.
stick! At the lighting up of the symbol, the ZF-Fine filter
must be replaced.
- Start the engine - idling speed
- Transmission in Neutral position "N"
- Top up oil up to the marking "COLD - MIN" The mounting of the filter must be carried out as fol-
- Brake the vehicle securely in position and warm lows:
up the transmission
- Shift all Controller positions through - Cover the gasket with a small amount of oil.
- Check the oil level again and top up oil once more - Screw the filter in until contact with the sealing
if necessary surface is obtained and tighten it now by hand
- On the oil dipstick, the oil level must be lying in the about 1/3 to 1/2 turn.
Zone "HOT"
- Insert the oil dipstick again and tighten it by clock-
wise rotation.
NOTES:
3.3 ZF-DIAGNOSTIC SYSTEMS
3.3.1 GENERALITIES 3.3.2 AUTOMATIC CALIBRATION

OF THE SHIFTING ELEMENTS
The Control electronics EST-37 for the Transmission
Series Ergopower is equipped with a diagnostic Introduction
package, which makes the Troubleshooting and the The new transmission control ERGOCONTROL con-
elimination of Repairs easier for the Service. sists of an electronic control unit EST-37 and a hy-
The Electronics is able to monitor the states of certain draulic control system with six proportional pressure
inputs and outputs. regulators which can be actuated independently of
If the Electronics recognizes during it an error, it each other.
stores an error code in the fault storage (EEPROM) It enables an individual pressure for each single
and is transmitting the error code also to the vehicle clutch to be built up.
controller of the Vehicle Manufacturer. The automatic calibration of the shifting elements
The ZF-Diagnosis and the Programming system “AEB” serves to optimise the tolerances – for disc
LAPTOP-Version are needed for the following appli- clearance and pressure level – which influence the
cations: shifting phase of each clutch by a corresponding ad-
aptation of the shifting elements “duration of quick
shifting phase” and “correct level of compensation
AEB pressure when shifting”.
- Automatic calibration of the shifting elements In order to optimise the tolerances – for disc clear-
ance and pressure level – on each clutch the shifting
elements must be detected when putting the ma-
chine into service, at every oil change and at every
Diagnosis repair on the transmission or on the respective elec-
- Actual errors tronics.
- Read fault storage
- Cancel fault storage
Testing Inputs and Outputs

- Outputs
- Check inputs
- Check systems downtime
- System test drive
AEB – Cycle OPERATION SEQUENCE

1. Warm up transmission
WHEN
2. Ignition "OFF"
- After every oil change 3. Connect connector (2) to plug connection Diag-
- 50 hours after putting the transmission into service nosis XA5 in driver’s cab
for the first time, afterwards every 1000 hours of - The plug connection Diagnosis XA5 can be
service (recommendation of ZF) found at the cable harness of the electronic con-
- After every replacement of a component of the trol unit EST-37 (driver’s seat console, right
transmission or of the respective electronics hand behind the map pocket)
- After every replacement of the transmission - The map pocket need not be removed
4. Put shift lever on "N", apply parking brake
DURATION 5. Ignition "ON", EST-37 must recognize AEB Starter
- AEB cycle ca. 3 – 4 minutes for at least 2 s
6. Adjust engine speed
EXECUTION 7. Start button (3), press on AEB starter, AEB cycle
is started
The program for AEB cycle is set down in the elec- 8. After a successful run, the display must show
tronic control unit EST-37. Terminated the AEB "O.K."
cycle, the optimised parameters are stored in 9. Ignition "OFF", disconnect AEB starter
EEPROM of EST-37.
Attachment of special tools on the plug-type connec-
tion Diagnosis XA5 The display messages of AEB starters
- AEB Starter (Part No. 0501 211 778) or are shown on the display of the dash-
- Laptop with Diagnosis Set (Windows 95/98/NT, board
Part No. 5870 211 179) and Diagnosis Software
Detailed information for starting the AEB cycle can
be taken from the attached Operating Instructions.
1
2
OKs1-03-005
1. AEB Starter
ZF Part No.: 0501 211 778
2. Connector
3. Start button
Display Messages
The AEB status information (1) is read by CAN Bus and graphically represented in the upper right corner of the
dashboard display.
AEB = Automatische Ermittlung Befüllparameter (Automatic calibration of the shifting elements)
TCU = Transmission Control Unit (EST-37)
Graph Graph
Meaning Remarks
LH RH
K1...K4 Calibration of clutch

KV, KR
OK Calibration of all clutches terminated Transmission remains in Neutral, TCU is
to be started anew (Ignition off/on) after
removing AEB-Starter
STOP AEB cleared (activation terminated) Transmission remains in Neutral, TCU is
to be started anew (Ignition off/on)
YKx Calibration of Kx was impossible, AEB Transmission remains in Neutral, TCU is
terminated to be started anew (Ignition off/on)
+E Engine speed too low → enhance engine
speed
-E Engine speed too high → reduce engine
speed
+T Transmission oil temperat. too low → warm
up transmission
-T Transmission oil temperat. too high → cool
down transmission
FO Output speed not equal to zero Transmission remains in Neutral, TCU is
FN Shift lever not in neutral position Transmission remains in Neutral, TCU is
FP Parking brake not applied Transmission remains in Neutral, TCU is
STOP AEB Starter was wrongly used or is defective Transmission remains in Neutral, TCU is
K1
OKs1-03-006
3.3.3 DIAGNOSIS
Error code description for ERGO Control EST- 37
ABBREVIATIONS REPRESENTATION IN DISPLAY

DCO Control opens drive direction clutches When a fault is recognised, the display shows a
EEC electronic engine control unit spanner symbol (g), on the display a Y (23) and in
ESG electronic transmission control unit addition Error 2000 (25). The display indicates the
ID identification error code, when the speed range selector is in neu-
OP-Mode type of service tral position.
PTO power take-off When more than one fault is recognised, each error
o.c. open current circuit code is indicated for ca. 1 second.
s.c. short circuit
23
25
OKs1-03-025
Laptop Version
Pentium Laptop min. 100 MHz

Specialized Dealers
Windows 95/98 or NT
OKs1-03-009
Basic-Software
Testman WIN 95/98 or NT
6008 308 901

OKs1-03-010
RS-232 Connecting cable

Laptop → DPA-04I
Diagnostic set
6008 308 601
OKs1-03-011 5870 221 179
WIN 95/98
or
Programming adapter NT
DPA-04I
6008 308 600

OKs1-03-012
Adapter cable
DPA-04I → EST-37
6029 017 005

OKs1-03-013
Diagnostic Software WG-160
6008 308 005 GERMAN

OKs1-03-014
6008 308 105 ENGLISH

OKs1-03-015
6008 308 205 FRENCH

OKs1-03-016
Terminal Tester 68-pin

For the test of single control
6008 304 038
signals, line interruptions etc.
OKs1-03-017
Read out Fault storage
Cable harness
Vehicle
Shift control
Transmission
EST - 37
Lap-Top
OKs1-03-023
1. Connect Lap-Top with “Diagnosis” - plug of the cable harness.

2. Select under “Diagnosis” the group “Read Fault storage”.
3. Find error, resp. Error code in the Appendix.
Tip: At step “Read out Fault storage” print out the page!
Cancel Fault storage
Cable harness
Vehicle
Shift control
Transmission
EST - 37
Lap-Top
OKs1-03-024
1. Connect Lap-Top with “Diagnosis” - plug of the cable harness.

2. Select under “Diagnosis” the group “Cancel Fault storage”.
3. Acknowledge with “YES”.
3.3.4 DIAGNOSTIC INSPECTION
Prerequisites for the Troubleshooting Data sheet for 6 WG 160
1. Oil level as well as oil quality must correspond with Data of the three Inductive transmitters of Engine,
lubricants. Turbine and Central gear train:
⇒ Resistance: 1050 Ohm (± 10%) at 20 °C
2. Transmission temperature from 80 °C to 100 °C. ⇒ Temperature range: -40 °C → + 150 °C
⇒ Torque limit: Mma x = 30 Nm
3. Please, pay attention that the prescribed Oper-
ating Instructions have been used! (i.e.: correct
connection of all lines). Data for the Hall-Sensor of the Output:
⇒ Temperature range: -40 °C → + 150 °C
4. Functional check of the electric system only with ⇒ Working range: 2 Hz → 5Hz
the Testers recommended by ZF! ⇒ Supply voltage: 24 V
5. Fuse "F14" and "F22" (7,5 Ampere; see Wiring
diagram) are O.K.! Data for the Proportional valves:
⇒ Resistance: 19 Ohm (± 10%) at 20 °C
6. At all operations on the vehicle (such as e.g. ± 0.5 Ohm allowed tolerance between them
welding) or works on the Electronic system (as ⇒ Current: 100 → 500 mA
e.g. connection of Testers), switch off the ignition ⇒ Pressure range: 0.8 bar → 8.3 bar
or separate the Electronic box, resp. disconnect
the Battery.
3.3.5 TROUBLESHOOTING
Fault
MEANING OF THE FAULT CODE
Code Reaction of the TCU Possible steps to repair Remarks
possible reason for fault detection
(hex)
11 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission • check the cables from TCU to failure cannot be detected in
F156.6 / F156.6A
TCU detected a wrong signal combination for the to neutral shift lever systems with DW2/DW3 shift
gear range OP-Mode: transmission • check signal combinations of lever
• cable from shift lever to TCU is broken shutdown shift lever positions for gear fault is taken back if TCU detects
• cable is defective and is contacted to battery range a valid signal for the position
voltage or vehicle ground
• shift lever is defective
12 LOGICAL ERROR AT DIRECTION SELECT SIGNAL TCU shifts transmission • check the cables from TCU to fault is taken back if TCU detects
TCU detected a wrong signal combination for the to neutral shift lever a valid signal for the direction at
direction OP-Mode: transmission • check signal combinations of the shift lever
• cable from shift lever to TCU is broken shutdown shift lever positions F-N-R
• cable is defective and is contacted to battery
voltage or vehicle ground
• shift lever is defective
25 S.C. TO BATTERY VOLTAGE OR O.C. AT TRANSMISSION no reaction, • check the cable from TCU to
SUMP TEMPERATURE SENSOR INPUT TCU uses default the sensor
TRANSMISSION
the measured voltage is too high: temperature • check the connectors

• cable is defective and is contacted to battery OP-Mode: normal • check the temperature
voltage sensor
• cable has no connection to TCU
• temperature sensor has an internal defect
• connector pin is contacted to battery voltage or is
broken
26 S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE no reaction, • check the cable from TCU to
SENSOR INPUT TCU uses default the sensor
the measured voltage is too low: temperature • check the connectors
• cable is defective and is contacted to vehicle OP-Mode: normal • check the temperature
ground sensor
• temperature sensor has an internal defect
• connector pin is contacted to vehicle ground
3 - 31
Fault
3 - 32
(hex)
31 S.C. TO BATTERY VOLTAGE OR O.C. AT ENGINE SPEED INPUT OP-Mode: substitute • check the cable from TCU to the
TCU measures a voltage higher than 7.00 V at speed input clutch control sensor
pin • check the connectors
• cable is defective and is contacted to battery voltage • check the temperature sensor
• speed sensor has an internal defect
• connector pin is contacted to battery voltage or has no
contact
32 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute • check the cable from TCU to the
TCU measures a voltage less than 0.45V at speed input pin clutch control sensor
• cable / connector is defective and is contacted to vehicle • check the connectors
ground • check the speed sensor
33 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute • check the cable from TCU to the This fault is reset
TCU measures a engine speed over a threshold and the clutch control sensor after power up of
next moment the measured speed is zero • check the connectors TCU
• cable / connector is defective and has bad contact • check the speed sensor
TRANSMISSION
• speed sensor has an internal defect • check the sensor gap

• sensor gap has the wrong size
F156.6 / F156.6A
Fault
(hex)
34 S.C. BATTERY VOLTAGE OR O.C. AT TURBINE SPEED INPUT OP-Mode: substitute • check the cable from TCU to the
F156.6 / F156.6A
pin if a failure is existing at • check the connectors

• cable is defective and is contacted to battery voltage output speed, • check the speed sensor
• cable has no connection to TCU TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home
contact
35 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute • check the cable from TCU to the
TCU measures a voltage less than 0.45 V at speed input pin clutch control sensor
• cable / connector is defective and is contacted to vehicle if a failure is existing at • check the connectors
ground output speed, • check the speed sensor
• speed sensor has an internal defect TCU shifts to neutral
OP-Mode: limp home
36 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute • check the cable from TCU to the This fault is reset
TCU measures a turbine speed over a threshold and at the clutch control sensor after power up of
next moment the measured speed is zero if a failure is existing at • check the connectors TCU
TRANSMISSION
• cable / connector is defective and has bad contact output speed, • check the speed sensor
• speed sensor has an internal defect TCU shifts to neutral • check the sensor gap
• sensor gap has the wrong size OP-Mode: limp home
3 - 33
Fault
3 - 34
(hex)
37 S.C. TO BATTERY VOLTAGE OR O.C. AT INTERNAL SPEED INPUT OP-Mode: substitute • check the cable from TCU to the
pin • check the connectors
• cable is defective and is contacted to battery voltage • check the speed sensor
contact
38 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute • check the cable from TCU to the
TCU measures a voltage less than 0.45V at speed input pin clutch control sensor
• cable / connector is defective and is contacted to vehicle • check the connectors
ground • check the speed sensor
39 LOGICAL ERROR AT INTERNAL SPEED INPUT OP-Mode: substitute • check the cable from TCU to the This fault is reset
TCU measures a internal speed over a threshold and at the clutch control sensor after power up of
next moment the measured speed is zero • check the connectors TCU
• cable /connector is defective and has bad contact • check the speed sensor
TRANSMISSION
• speed sensor has an internal defect • check the sensor gap

• sensor gap has the wrong size
F156.6 / F156.6A
Fault
(hex)
3A S.C. TO BATTERY VOLTAGE OR O.C. AT OUTPUT SPEED INPUT special mode for gear • check the cable from TCU to the
TCU measures a voltage higher than 12.5V at speed input selection sensor
F156.6 / F156.6A
pin OP-Mode: substitute • check the connectors

• cable is defective and is contacted to battery voltage clutch control • check the speed sensor
• cable has no connection to TCU if a failure is existing at
• speed sensor has an internal defect turbine speed,
• connector pin is contacted to battery voltage or has no TCU shifts to neutral
contact OP-Mode: limp home
3B S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear • check the cable from TCU to the
TCU measures a voltage less than 1.00V at speed input pin selection sensor
• cable /connector is defective and is contacted to vehicle OP-Mode: substitute • check the connectors
ground clutch control • check the speed sensor
• speed sensor has an internal defect if a failure is existing at
turbine speed,
TCU shifts to neutral
OP-Mode: limp home
3C LOGICAL ERROR AT OUTPUT SPEED INPUT special mode for gear • check the cable from TCU to the This fault is reset
TRANSMISSION
TCU measures a output speed over a threshold and at the selection sensor after power up of
next moment the measured speed is zero OP-Mode: substitute • check the connectors TCU
• cable /connector is defective and has bad contact clutch control • check the speed sensor
• speed sensor has an internal defect if a failure is existing at • check the sensor gap
• sensor gap has the wrong size turbine speed,
OP-Mode: limp home
3E OUTPUT SPEED ZERO DOESN'T FIT TO OTHER SPEED SIGNALS special mode for gear • check the sensor signal of output This fault is reset
if transmission is not neutral and the shifting has finished, selection speed sensor after power up of
TCU measures outputspeed zero and turbine speed or OP-Mode: substitute • check the sensor gap of output TCU
internal speed not equal to zero clutch control speed sensor
• speed sensor has an internal defect if a failure is existing at • check the cable from TCU to the
• sensor gap has the wrong size turbine speed, sensor
OP-Mode: limp home
3 - 35
Fault
3 - 36
(hex)
71 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at K1 valve is too high. If failure at another clutch • check the connectors from TCU to
• cable/connector is defective and has contact to battery is pending TCU shifts to the gearbox
voltage neutral • check the regulator resistance
• cable/connector is defective and has contact to another OP-Mode: TCU • check internal wire harness of the
regulator output of the TCU shutdown gearbox
• regulator has an internal defect
72 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the
the voltage at K1 valve is too low. If failure at another clutch • check the connectors from gearbox
• cable/connector is defective and has contact to vehicle is pending TCU shifts to to TCU
ground neutral • check the regulator resistance
• regulator has an internal defect OP-Mode: TCU • check internal wire harness of the
shutdown gearbox
73 O.C. AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the
the measured resistance value of the valve is out of limit OP-Mode: limp home gearbox
TRANSMISSION
• cable/connector is defective and has no contact to TCU If failure at another clutch • check the connectors from gearbox
• regulator has an internal defect is pending TCU shifts to to TCU
neutral • check the regulator resistance
OP-Mode: TCU • check internal wire harness of the
shutdown gearbox
F156.6 / F156.6A
Fault
(hex)
F156.6 / F156.6A
the voltage at K2 valve is too high If failure at another clutch • check the connectors from gearbox
• cable/connector is defective and has contact to battery is pending TCU shifts to to TCU
the voltage at K2 valve is too low If failure at another clutch • check the connectors from gearbox
shutdown gearbox
TRANSMISSION
shutdown gearbox
3 - 37
Fault
3 - 38
(hex)
shutdown gearbox
TRANSMISSION
shutdown gearbox
F156.6 / F156.6A
Fault MEANING OF THE FAULT CODE
(hex) possible reason for fault detection
81 S.C. BATTERY VOLTAGE AT CLUTCH K4 TCU shifts to neutral • check the cable from TCU to the
F156.6 / F156.6A
• cable/connector is defective and is contacted to battery is pending TCU shifts to to TCU
shutdown gearbox
TRANSMISSION
shutdown gearbox
3 - 39
Fault
3 - 40
(hex)
84 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the
the voltage at KV valve is too high If failure at another clutch • check the connectors from gearbox
• cable/connector is defective and is contacted to battery is pending TCU shifts to to TCU
85 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the
the voltage at KV valve is too low If failure at another clutch • check the connectors from gearbox
shutdown gearbox
86 O.C. AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the
TRANSMISSION
• cable/connector is defective and has contact to vehicle If failure at another clutch • check the connectors from gearbox
ground is pending TCU shifts to to TCU
• regulator has an internal defect neutral • check the regulator resistance
shutdown gearbox
F156.6 / F156.6A
Fault MEANING OF THE FAULT CODE
(hex) possible reason for fault detection
87 O.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the
F156.6 / F156.6A
the voltage at KR valve is too high If failure at another clutch • check the connectors from gearbox
88 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the
the voltage at KR valve is too low If failure at another clutch • check the connectors from gearbox
shutdown gearbox
89 O.C. AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the
TRANSMISSION
shutdown gearbox
3 - 41
Fault
3 - 42
(hex)
91 S.C. TO GROUND AT BACKUP ALARM DEVICE backup alarm will be on • check the cable from TCU to the
TCU detected a wrong voltage at the output pin, that looks until TCU power down backup alarm device
like a s.c. to vehicle ground even if fault vanishes • check the connectors from backup
• cable is defective and is contacted to vehicle ground (loose connection) alarm device to TCU
• backup alarm device has an internal defect OP-Mode: normal • check the resistance of backup
• connector pin is contacted to vehicle ground alarm device
92 S.C. TO BATTERY VOLTAGE AT BACKUP ALARM DEVICE no reaction • check the cable from TCU to the
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal backup alarm device
like a s.c. to battery voltage • check the connectors from backup
• cable is defective and is contacted to battery voltage alarm device to TCU
• backup alarm device has an internal defect • check the resistance of backup
• connector pin is contacted to battery voltage alarm device
93 O.C. AT RELAY BACKUP ALARM DEVICE no reaction • check the cable from TCU to the
TCU detected a wrong voltage at the output pin, that looks OP-Mode: normal backup alarm device
like a o.c. for this output pin • check the connectors from backup
• cable is defective and has no connection to TCU alarm device to TCU
• backup alarm device has an internal defect • check the resistance of backup
TRANSMISSION
• connector has no connection to TCU alarm device
F156.6 / F156.6A
Fault
(hex)
B1 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral • check pressure at clutch K1

TCU calculates a differential speed at closed clutch K1. If OP-Mode: limp home • check main pressure in the system
F156.6 / F156.6A
this calculated value is out of range, TCU interprets this as If failure at another clutch • check sensor gap at internal speed
slipping clutch is pending TCU shifts to sensor
• low pressure at clutch K1 neutral • check sensor gap at output speed
• low main pressure OP-Mode: TCU sensor
• wrong signal at internal speed sensor shutdown • check signal at internal speed
• wrong signal at output speed sensor sensor
• wrong size of the sensor gap • check signal at output speed sensor
• clutch is defective • replace clutch
TRANSMISSION
3 - 43
Fault
3 - 44
(hex)

• low pressure at clutch K4 neutral • check sensor gap at turbine speed
• wrong signal at turbine speed sensor sensor
• wrong size of the sensor gap • check signal at turbine speed sensor
B5 SLIPPAGE AT CLUTCH KV TCU shifts to neutral • check pressure at clutch KV
TCU calculates a differential speed at closed clutch KV. If OP-Mode: limp home • check main pressure in the system
• low pressure at clutch KV neutral • check sensor gap at turbine speed
TRANSMISSION
B6 SLIPPAGE AT CLUTCH KR TCU shifts to neutral • check pressure at clutch KR
TCU calculates a differential speed at closed clutch KR. If OP-Mode: limp home • check main pressure in the system
• low pressure at clutch KR neutral • check sensor gap at turbine speed
F156.6 / F156.6A
Fault
(hex)
B7 OVERTEMP SUMP no reaction • coll down machine

TCU measured a temperature in the oil sump that is over OP-Mode: normal • check oil level
F156.6 / F156.6A
the allowed threshold • check temperature sensor

B8 OVERTEMP RETARDER no reaction • coll down machine
TCU measured a temperature in the retarder oil that is over OP-Mode: normal • check oil level
the allowed threshold • check temperature sensor
BA DIFFERENTIAL PRESSURE OIL FILTER no reaction • check oil filter
TCU measured a voltage at differential pressure switch out OP-Mode: normal • check wiring from TCU to differential
of the allowed range pressure switch
• oil filter is polluted • check differential pressure switch
• cable/connector is broken or (measure resistance)
• cable/connector is contacted to battery voltage or vehicle
ground
• differential pressure switch is defective
D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS see fault codes no. 21 to • check cables and connectors to fault codes no. 21
TCU measures more than 6V at the pin AU1 (5V sensor 2C sensors, which are supplied from to no. 2C may be
supply) AU1 a reaction of this
TRANSMISSION
• check the power supply at the pin fault

AU1 (should be appx. 5V)
D2 S.C. TO GROUND AT POWER SUPPLY FOR SENSORS see fault codes no. 21 to • check cables and connectors to fault codes no. 21
TCU measures less than 4V at the in AU1 (5V sensor 2C sensors, which are supplied from to no. 2C may be
supply) AU1 a reaction of this
• check the power supply at the pin fault
AU1 (should be appx. 5V)
3 - 45
Fault
3 - 46
(hex)
D3 LOW VOLTAGE AT BATTERY shift to neutral • check power supply battery

measured voltage at power supply is OP-Mode: TCU • check cables from batteries to TCU
lower than 10V (12V device) shutdown • check connectors from batteries to
lower than 18V (24V device) TCU
D4 HIGH VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is OP-Mode: TCU • check cables from batteries to TCU
higher than 18V (12V device) shutdown • check connectors from batteries to
higher than 32.5V (24V device) TCU
D5 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral • check fuse
TCU switched on VPS1 and measured VPS1 is off or TCU OP-Mode: TCU • check cables from gearbox to TCU
switched off VPS1 and measured VPS1 is still on shutdown • check connectors from gearbox to
• cable or connectors are defect and are contacted to TCU
battery voltage • replace TCU
• cable or connectors are defect and are contacted to
vehicle ground
• permanent power supply KL30 missing
• TCU has an internal defect
TRANSMISSION
D6 ERROR VALVE POWER SUPPLY VPS2 shift to neutral • check fuse

TCU switched on VPS2 and measured VPS2 is off or TCU OP-Mode: TCU • check cables from gearbox to TCU
switched off VPS2 and measured VPS2 is still on shutdown • check connectors from gearbox to
• cable or connectors are defect and are contacted to TCU
battery voltage • replace TCU
• cable or connectors are defect and are contacted to
vehicle ground
• permanent power supply KL30 missing
• TCU has an internal defect
F156.6 / F156.6A
Fault
(hex)
E3 S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT no reaction • check the cable from TCU to the
TCU sends data to the display ad measures allways a high OP-Mode: normal display
F156.6 / F156.6A
voltage level on the connector • check the connectors at the display

• cable or connectors are defective and are contacted to • change display
battery voltage
• display has an internal defect
E4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction • check the cable from TCU to the
TCU sends data to the display and measures always a high OP-Mode: normal display
voltage level on the connector • check the connectors at the display
• cable or connectors are defective and are contacted to • change display
vehicle ground
• display has an internal defect
F1 GENERAL EEPROM FAULT no reaction • replace TCU often shown
TCU can't read non volantile memoy OP-Mode: normal together with fault
• TCU is defective code F2
F3 APPLICATION ERROR transmission stay neutral • replace TCU!! This fault occurs
something of this application is wrong OP-Mode: TCU only if an test
TRANSMISSION
shutdown engineer did

something wrong
in the application
of the vehicle
F5 CLUTCH FAILURE transmission stay neutral • check clutch TCU shows also
AEB was not able to adjust clutch filling parameters OP-Mode: TCU the affected clutch
• One of the AEB-Values is out of limit shutdown on the Display
F6 CLUTCH ADJUSTMENT DATA LOST no reaction, • execute AEB
TCU was not able to read correct clutch adjustment default values = 0 for
parameters AEB offsets used
• interference during saving data on non volatile memory OP-Mode: normal
• TCU is brand new
3 - 47
NOTES:
SECTION 4
REAR AXLE
INDEX
4.1 GENERAL INFORMATION ..................................................................................... 4-1

4.1.1 Manual use .............................................................................................................. 4-1
4.1.2 Agreements and definitions ..................................................................................... 4-1
4.1.3 General recommendations for disassembly and assembly operations .................. 4-2
4.2 GENERAL SPECIFICATIONS................................................................................. 4-5

4.2.1 Foreseen uses ......................................................................................................... 4-5
4.2.2 Product identification ............................................................................................... 4-5
4.2.3 General description.................................................................................................. 4-6
4.2.4 Technical features ................................................................................................... 4-8
4.2.5 Filling and checks .................................................................................................... 4-12
4.2.6 Service schedule ..................................................................................................... 4-15
4.2.7 Lubrication / greasing: grades and application range .............................................. 4-16
4.2.9 Special tools ............................................................................................................ 4-18
4.3 TANDEM AXLE REMOVAL - INSTALLATION ........................................................ 4-19

4.3.1 Removal................................................................................................................... 4-19
4.3.2 Installation................................................................................................................ 4-21
4.4 DISASSEMBLY AND ASSEMBLY OPERATIONS.................................................. 4-23
4.5 TROUBLESHOOTING............................................................................................. 4-25

4.5.2 Axle problem and diagnosis..................................................................................... 4-29
F156.6 / F156.6A REAR AXLE 4-1
4.1 GENERAL INFORMATION
4.1.1 MANUAL USE 4.1.2 AGREEMENTS AND DEFINITIONS
Maintenance Agreements
CONSULT THIS MANUAL THOROUGHLY, as Illustrations are supposed to point out the various
proper functioning and good efficiency of mechanical handling sequences and phases of the axle and its
organs depends mostly on constant and correct rou- components, therefore they could not display exactly
tine and extraordinary maintenance which could pro- the same group elements.
mote the integrity and duration of the axle and avoid
damages or any harm to the operator.
In case of any damages or anomalies, quick inter- Definitions
vention of specialized personnel can avoid future im-
pairment and lengthen the working life. Left side: it is the left side of the axle considering
the in vehicle running conditions.
Overhaul Right side: it is the right side of the axle considering

The disassembly/assembly procedures have been
outlined for a total group overhauling. They have also
been described in sequence through photographs
with relevant explanation for specific interventions,
thus obtaining a complete and safe guide for each
and every phase of an operation.
Moreover, the attentive group inspection leads to a
correct repair work estimation that could merely re-
quire dismounting only few components, and thus
operating partially on the group.
4-2 REAR AXLE F156.6 / F156.6A
4.1.3 GENERAL RECOMMENDATIONS Shafts seals

FOR DISASSEMBLY AND ASSEMBLY
OPERATIONS Respect the following recommendations during shaft
seal assembly:
The transmission should be checked and/or repaired
only by qualified technicians, acquainted with its pe- • Clean shaft very carefully and ensure that the part
culiar features and well aware of all safety instruc- in contact with the shaft seal is not damaged, cut
tions. or out of roundness.
• Assemble the seals so that the lip is fitted towards
Before performing any operation it is advisable to the oil side.
carry out transmission cleaning accurately by re- • Lubricate seal lips (use grease) and fill 3/4 of seal
moving oil/ grease encrustations and accumulation. cavity with grease.
• Use appropriate drivers. Do not use a hammer di-
All disassembled mechanical parts must be cleaned rectly on the seals.
accurately with suitable products to avoid possible • Do not damage the seals while assembling the
damage. Parts should be replaced if damaged, worn shaft.
out, cracked, seized, etc. as they could affect proper
functioning of the transmission.
O-rings
Rotating parts (bearings, gears, shafts) and that of
hardware/fasteners (O-Ring, oil seals) should be ex- Lubricate adequately before inserting them at the
amined carefully, as they are subject to major stress, right place and avoid rolling while inserting the shaft.
wearing and ageing.
We highly advice to replace tightening parts during Adjusting shims

every teardown or repair.
Use appropriate adjusting shims and measure each
Use appropriate spare parts, nuts and bolts to avoid one separately.
any other problems. Moreover, use metric tools for Complete group measurement or stampings on the
metric nuts and bolts and Imperial tools for the others. shims are not always reliable: check.
Please read the disassembly instructions very care-

fully because some operations are destructive for
some transmission components and in order to avoid
the elements damage operate advertently.
Before starting any disassembly and assembly op-

erations, read carefully the following recommenda-
tions.
F156.6 / F156.6A REAR AXLE 4-3
Bearings Checks
Its advisable to heat up bearings to 80 °C - 90 °C Examine accurately all bearings, external rings which
before assembling them onto their respective shafts may be still stuck in their position and pivot pins on
or to cool them (dry ice) before inserting them into which rolls rotate. Replace those which are worn out
corresponding bore. Before reassembling the bear- or damaged.
ings, clean, check and lubricate them. Gears should not be spoiled and teething should not
be excessively worn out. Teeth smoothing should not
be deteriorated.
Split pins Check all grooves: assure that they are not worn out
or damaged.
Before assembling elastic pins, make sure that the Replace spoiled parts with original spare parts.
notch is oriented towards the stressing force. Replace seals on rotating shafts, before reassembly.
Spiral elastic pins do not need orientation.
Ends of flanges and tools

Sealing
Be careful when hammering tool or flange ends, in
Use sealing as advised by specifications. Ensure that order to avoid jeopardizing functionality and integrity
parts to be sealed are clean, dry and completely of either the tools or the components on which you
grease free. are operating.
Oil drain Reassembly ways
Before disassembly, oil should be drained out. In order to reassemble the group, an appropriate fix-
ture must be used.
In order to position the group, to disassemble and
WARNING reassemble the ring gear and to support the gear
housing, a lifting system is needed.
Disposal of used oil must be done according to
To make disassembling and assembling operations
laws
easier, use a group assembly drawing.
Cleaning
Lubricant use
Wash all moving parts (gears, bearings, etc.) accu-
In order to lubricate the transmission correctly and
rately with diesel fuel or kerosene.
to reach the exact operation temperature, it is impor-
Avoid gasoline and watery alkaline solutions. Do not
tant to use the recommended lubricants, keeping
wash with steam or hot water, as it will be very difficult
their level constant as indicated in this manual.
to eliminate surface humidity.
Dry all parts with a rag or air jet to avoid scratching
from abrasive residuals.
All surfaces should be covered with lubricant so as
to protect it from future oxidation.
4-4 REAR AXLE F156.6 / F156.6A
Symbology
SYMBOLS DESCRIPTION
WARNING / DANGER
REMOVE / INSTALL
seals / gaskets / filters
OIL FILLING OR OIL LEVEL

OIL DRAIN
LUBRICATION / GREASING
ADJUSTMENTS / MEASUREMENTS
tightening torques / preloads / backlash
SPECIAL TOOLS
SEALING / LOCKING FLUIDS

APPLICATION
MARK OR INDICATE
DISASSEMBLY / ASSEMBLY OF BULKY PARTS OR

SUBASSEMBLIES
WARNING:
respect assembly orientation
CLEANING CAREFULLY
APPLY PRESSURIZED FLUID
F156.6 / F156.6A REAR AXLE 4-5
4.2 GENERAL SPECIFICATIONS
4.2.1 FORESEEN USES 4.2.2 PRODUCT IDENTIFICATION
The axle is a component that transmits the power Axle serial plate
from the engine to the wheels and that allows:
• increasing of tractive force, reducing the number

of revolutions
• adjusting of inner wheels’ speed with outer wheels’ AXLE TYPE
speed during steering.
Never mount this axle on machines different from the

ones for which it has been designed and manufac-
tured.
If the axle is used for any other purpose than the one
foreseen, the Manufacturer declines any responsi-
bility regarding damages or accidents caused by it.
All consequences will be at the expense of the client.
However, when used as foreseen, operational for-
malities as well as regular maintenance repair spec-
ifications given in this Manual are to be observed P/N AND S/N
strictly.
OKs1-4-001
4-6 REAR AXLE F156.6 / F156.6A
4.2.3 GENERAL DESCRIPTION
The axle described in this manual, designed and Additionally, the axle has its own internal braking
manufactured following the customer’s requests, system.
consists of a beam casing, housing the differential in The wheel hubs containing the braking system are
the middle and a wheel hub unit at each end. supported by two tapered roller bearings.
The differential, type “no-spin”, is supported by two Furthermore the axle has a braking system, fitted
bearings mounted on a suitable structure allowing with a mechanical drive for service braking.
the bevel gear set to be adjusted. The frame is completed with a transmission/reduc-
The ring bevel gear is adjusted by means of two ring tion box, which allows to control fully the motion pa-
nuts located opposite each other.The position of the rameters at the bevel gear entry.
bevel pinion, supported by two bearings, is adjusted
by inserting adjusting shims.
SIDE BOXES GROUP
PINION GROUP
WHEEL HUB GROUP
DIFFERENTIAL GROUP
HALF AXLE GROUP
OKs2-04-001
F156.6 / F156.6A REAR AXLE 4-7
Rear drive diagram
TO FRONT AXLE
(only for F106.6A)
Torque converter F&S W300
Iveco
ENGINE
NO-SPIN Differential
Pump
Type 250S-133
Spac
e orie
nted
bend
ing a
ngel
4.43
°
Parking brake
OKs2-04-002
4-8 REAR AXLE F156.6 / F156.6A
4.2.4 TECHNICAL FEATURES
Axle code 2810031

Axle model TG16
DIFFERENTIAL TYPE
Standard
Limited Slip
Limited Slip “Ball Type”
100% Mechanical lock, hydraulically controlled (positive or negative)
With multidisc clutch in oil bath hydraulically controlled
100% Mechanical, electromagnetically controlled
“No spin”
DESCRIPTION VALUES
Bevel gear ratio 2.818

Epicyclic ratio 6.00
Chain ratio 1.167
Total reduction 19.731
Dry weight 1511 kg
Input rotation
CLOCK WISE (C.W.)
COUNTER CLOCK WISE (C.C.W.)
Oil Specification
Centre axle SAE 80W - 90
to comply
API GL4 - GL5
Note – DO NOT USE SYNTHETIC OIL WITHOUT CONSENT OF THE MANUFACTURER respectively
MIL-L-2105
and
MIL-L-2105D
Centre axle oil capacity 14 Litres
Oil capacity of the tandem boxes 2x26 Litres
Wheel hub gear oil capacity 4x5.5 Litres
Grease POLYMER 400/L
DIN = KHER1R
ISO-I-XMR-XM2
F156.6 / F156.6A REAR AXLE 4-9
DESCRIPTION VALUES
Bevel gear set backlash 0.2 to 0.3 mm

Pinion bearings preload "P" (measured without seal) P= 2 to 3 daN
Differential lock working pressure ---
Type of brake Wet discs brake
Number of brake discs (each side) 5
Number of brake counterdiscs (each side) 6
Nominal brake disc thickness 5.5 mm
Nominal brake counterdisc thickness 4 mm
Maximum brake disc wearing (each side) 0.4 mm
Maximum piston stroke (wearing) 6+0.3 mm
Nominal brake piston stroke new 2+0.3 mm
Oil specification for brake activation Transmission oil
(Tandem oil filling) SAE 90 LS API
GL5 for new wet
brakes
(piston stroke
2 mm)
Oil displacement for brakes actuation 25.9 to 77.8 cm3
Wear limit
(piston stroke
6 mm)
Maximum operating pressure 60 bar 60 bar
Pinion flange type 6 C flanged
mechanical
connection with
four 3/8-24 UNF-
2B threaded holes
4 - 10 REAR AXLE F156.6 / F156.6A
Overall dimensions (millimeter)
OKs1-4-004
F156.6 / F156.6A REAR AXLE 4 - 11
Sealing compounds and adhesives
OKs1-4-003
4 - 12 REAR AXLE F156.6 / F156.6A
4.2.5 FILLING AND CHECKS Routine checks
If the axle lubricant should be flush with control plug

(3) and (2). If not, make up level with the same oil.
LUBRICATION POINTS POSITION If leakage or any other factor determining fall in the
oil level is found, then it is advisable to check imme-
Tandem box oil drain 1 diately, in order to avoid damages to the mechanical
Tandem box filling plug 2 parts.
Loosen and remove the drain plug for oil draining
Tandem box oil level control 3 (1 and 4).
Centre axle oil drain plug 4
Brake discs shims control 5
Brake breather 6
OKs1-4-005
F156.6 / F156.6A REAR AXLE 4 - 13
General checks
The disassembly/assembly instructions presume that the unit has been removed from the vehicle and positioned
on a suitable workbench.
Some of the following pictures may not show exactly your axle, but the procedure is the same.
1
Drain the oil from chain case, then tighten the plug with a torque
wrench to the prescribed torque (Par. 4.2.8).
2
To drain the oil of differential box, loosen the plug and tighten
again with a torque wrench to the prescribed torque (Par. 4.2.8).
3
Check oil level and top up if necessary.
Tighten the plug with a torque wrench to the prescribed torque
(Par. 4.2.8).
4 - 14 REAR AXLE F156.6 / F156.6A
4
To drain the oil of differential box, loosen the plug and tighten
again with a torque wrench to the prescribed torque (Par. 4.2.8).
5
Box oil visual level.
F156.6 / F156.6A REAR AXLE 4 - 15
4.2.6 SERVICE SCHEDULE
SEASONALLY OR EVERY
OPERATION FIRST TIME
1000 OPERATING HOURS(1)
Axle gear oil change 50 hours

Tandem gear oil change ▲ ◆
Tanden gear chain tension ● ■
Check/Adjust
Lubrication ▲ ◆
works ■ ■
Check and in case adjust oil level 50-100 hours ■ monthly

●
Clean magnetic oil plugs 150-200 hours every oil change

■ ●
Clean oil breather ▲ monthly

■ ●
Greasing 150-200 hours ● weekly

●
Tandem gear oil level check 250 hours

Axle gear oil level check ●

Chain case tension check ●
Axle gear oil level check
■

Chain case tension check ●
Axle gear oil level check
Tandem, axle, wheel hub gear oil change
Remarks
● Operation performed only by personnel authorized by the manufacturer
■ Operation performed only by trained personnel
(1)
Which of both conditions comes first
4 - 16 REAR AXLE F156.6 / F156.6A
4.2.7 LUBRICATION / GREASING: GRADES AND APPLICATION RANGE
OIL GREASE
50°C 122°F
40°C 104°F
SAE 85 W-140
30°C 86°F
NLGI Number 2
SAE 80 W-140
20°C 68°F
SAE 90 W
SAE 80 W-90
SAE 75 W-160
10°C 50°F
NLGI Number 1
SAE 80 W
SAE 75 W-90
0°C 32°F NLGI Number 0
-10°C 14°F
-20°C -4°F
SAE 75 W
-30°C -22°F
-40°C -40°F
-55°C -67°F
OKs1-4-217
F156.6 / F156.6A REAR AXLE 4 - 17
OKs1-4-006
4 - 18 REAR AXLE F156.6 / F156.6A
4.2.9 SPECIAL TOOLS
CHAPTER TO BE PREPARED
F156.6 / F156.6A REAR AXLE 4 - 19
4.3 TANDEM AXLE REMOVAL-INSTALLATION
4.3.1 REMOVAL
DANGER
Lift and handle all heavy parts with a hoisting means having adequate capacity.
Make sure that units or parts are supported by proper slings and hooks.
Make sure that there are no people in the vicinity of the load to be lifted.
1
Support vehicle with adequate hoisting means.
To detach tandem axle, perform following operations: 2
- Unscrew securing nuts and take off rear wheels (1);

- Unscrew fender (2) securing screws and take them off;
1 OKs1-4-219
2
- Take off screws and disconnect transmission shaft (3)
(tandem axle side);
TANDEM
AXLE 3
SIDE OKs1-4-220
3
- Disconnect brake oil pipings (4) from both sides (tandem axle
middle portion);
4 - 20 REAR AXLE F156.6 / F156.6A
4
Disconnect battery pins (5) and take off battery.
IMPORTANT – Make sure that battery negative pins are dis-

connected before performing repairs or replacements.
5
5
- By using adequate hoisting means, lift vehicle rear part and
position safety supports under it.
- Position a trailer-mounted hydraulic hoist with adequate ca-

pacity under tandem axle; 6
- Take off the eight bolts (6) securing tandem axle to rear chas-
sis;
- Lower tandem axle by means of the trailer-mounted hydraulic

hoist;
- With vehicle lifted, take off tandem axle.
F156.6 / F156.6A REAR AXLE 4 - 21
4.3.2 INSTALLATION
DANGER
Lift and handle all heavy parts with a hoisting means having adequate capacity.
Make sure that units or parts are supported by proper slings and hooks.
Make sure that there are no people in the vicinity of the load to be lifted.
1
To reattach tandem axle, perform following operations:
- With vehicle lifted from the ground, position tandem axle un-
der the chassis;
6
IMPORTANT – Do not align holes using your fingers.
- Lift tandem axle and align the holes of securing screws be-
tween rear chassis and tandem axle;
- Put in screws (6) and tighten nuts with 560 Nm torque;
- Take off trailer-mounted hydraulic hoist and disconnect hoist-

ing means;
6
2
- Connect brake oil pipings (4) on both sides (tandem axle mid-
dle portion);
4 - 22 REAR AXLE F156.6 / F156.6A
3
- Connect transmission shaft (3) (tandem axle side) and tighten
securing screws;
TANDEM
AXLE 3
SIDE OKs1-4-220
4
- Mount fenders (2) and tighten securing screws;
- Mount rear wheels (1) and tighten nuts. 2
1 OKs1-4-219
F156.6 / F156.6A REAR AXLE 4 - 23
4.4 DISASSEMBLY AND ASSEMBLY OPERATIONS
CHAPTER TO BE PREPARED
4 - 24 REAR AXLE F156.6 / F156.6A
NOTES
F156.6 / F156.6A REAR AXLE 4 - 25
4.5 TROUBLESHOOTING
PROBLEMS POSSIBLE CAUSES
1 2 3 4 5 6 7 8 9 10 11
- Wheel vibration; front tyre resistance; halfshaft ● ● ● ● ●

breakage.
- Steering is difficult; vehicle goes straight while ● ● ● ● ●
its turning.
- No differential action; jamming while steering. ● ● ● ●
- No differential action; jamming while steering. ● ● ● ● ● ● ● ●
- Uneven wear of tyre. ● ● ● ● ● ● ● ●
- Friction noise. ● ● ● ● ● ● ●
- Vibration during forward drive, intermittent ● ● ● ● ●

noise.
1. Incorrect installation / defective axle 4. Broken halfshaft
Correct installation or repair or replace the differential It is not advisable to operate the vehicle with a broken
in case it does not survive any one of the test phases. halfshaft. It is acceptable to move the vehicle (engine
off unloaded) a few meters away only.
2. Overloading/ incorrect weight distribution

5. Bent halfshaft
Remove excessive weight and redistribute load, fol-
lowing instructions related to the vehicle. Replace halfshaft.
3. Different rotation radius of the tyres 6. Blocked differential
If one tyre has a smaller radius, it will cause partial Abnormal functioning of the differential or breakage/
wheel slipping when force is applied.The other tyre blockage of command device. Verify assembly and
with bigger radius will have to support all the work. all components.
Replace the tyre or adjust pressure to have same Vehicles with wide steering angle may proceed with
radius on both tyre. kicks, have steering difficulty or cause pneumatic
wearing at sharp turns. Reduce the steering angle to
minimum and decelerate when the vehicle begins to
kick.
4 - 26 REAR AXLE F156.6 / F156.6A
7. Incorrect wheel adjustment 10. Incorrect adjustment of bevel gear set: Parts
of the transmission worn out.
Verify group integrity and wheel side bearings.
Adjusting according. (transmission gears, U joints, etc.)
Replace or adjust as required.
8. Spoiled or worn out axle parts

11. Incorrect use of the product
Check the condition of ring gear, pinion gear, bear-
ings etc. Replace when ever necessary. See the vehicle producer‘s instructions once again.
9. Contamination in the axle box or incorrect as-

sembly of parts
Look for foreign particles. Check assembly of the var-

ious parts of the axle.
F156.6 / F156.6A REAR AXLE 4 - 27
This chapter is a descriptive and explanatory guide to common axle problems. This guide suggests the repair
correct procedures to be followed.
Problem Cause Action

Ring gear tooth broken at the outer 1. Excessive gear load compared to Replace bevel gear set
side the one foreseen Follow carefully the recommended
2. Incorrect gear adjustment operations for the adjustment of
(excessive backlash) bevel gear set backlash.
3. Pinion nut loosened
Ring gear tooth broken side 1. Load bump Replace bevel gear set
2. Incorrect gear adjustment Follow carefully the recommended
(insufficient backlash) operations for the adjustment of
3. Pinion nut loosened bevel gear set backlash.
Pinion or ring gear teeth or worn 1. Insufficient lubrication Replace bevel gear set.
2. Contaminated oil Follow carefully the recommended
3. Incorrect lubrication or depleted operations for the adjustment of
additives bevel gear set backlash.
4. Worn out pinion bearings that Use correct lubricants, fill up to the
cause an incorrect pinion axle right levels and replace according to
backlash and wrong contact the recommended program.
between pinion and ring.
Overheated ring and pinion teeth. 1. Prolong ed functioning at high Replace bevel gear set.
See if gear teeth have faded temperatures Use proper lubrication, fill up to right
2. Incorrect lubrication level and replace at recommended
3. Low oil level program.
4. Contaminated oil
Pinion teeth pitting 1. Excessive use Replace bevel gear set.
2. Insufficient lubrication Use correct lubrication, fill up to the
right level and substitute at
recommended intervals.
Axle beam body bent 1. Vehicle over loaded Replace axle beam body.
2. Vehicle's accident
3. Load bump
Worn out or pitted bearings 1. Insufficient lubrication Replace bearings.
2. Contaminated oil Use correct lubrication fill up, to the
3. Excessive use right level and replace at
4. Normal wear out recommended intervals.
5. Pinion nut loosened
Oil leakage form gaskets and 1. Prolonged functioning at high Replace the gasket or seal and
seals temperature of the oil matching surface if damaged.
2. Oil gasket assembled incorrectly Use correct lubrication and replace
3. Seal lip damaged at recommended intervals.
4. Contaminated oil
Excessive wearing out of input 1. Exhaustive use Replace the flange.
flange spline 2. Pinion nut loosened Check that the pinion spline is not
3. Pinion axle backlash excessively worn out.
Replace bevel gear set if required.
4 - 28 REAR AXLE F156.6 / F156.6A
Fatigue failure of pinion teeth 1. Exhaustive use Replace bevel gear set.
See if the fracture line is well 2. Continuos overload
defined
(wave lines, beach lines)
Pinion and ring teeth breakage Crash load of differential Check and/or replace other
components differential components.
Side gear spline worn out. Excessive use Replace differential gear group.
Replace all scratched washers Replace halfshaft if required.
(Excessive backlash)
Thrust washer surface worn out or 1. Insufficient lubrication Use correct lubrication and fill up to
scratched 2. Incorrect lubrication right level.
3. Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm thickness lower
than the new ones.
Inner diameter of tapered roller 1. Excessive use Replace bearing.
bearing worn out 2. Excessive pinion axial backlash Check pinion axial backlash.
3. Insufficient lubrication Use proper lubrication, fill up to right
4. Contaminated oil level and replace at recommended
intervals.
Bent or broken halfshaft Vehicle intensively operated or Replace.
overloaded
Halfshaft broken at wheel side 1. Wheel support loosened Replace.
2. Beam body bent Check that wheel support is not worn
out or wrongly adjusted.
F156.6 / F156.6A REAR AXLE 4 - 29
4.5.2 AXLE PROBLEM AND DIAGNOSIS

Noise while driving 1. Excessive backlash between 1. Adjust
pinion and ring gear
2. Worn out pinion and gear ring 2. Replace
3. Worn out pinion bearings 3. Replace
4. Pinion bearings loosened 4. Adjust
5. Excessive axial pinion backlash 5. Adjust
6. Worn out differential bearings 6. Replace
7. Differential bearings loosened 7. Adjust
8. Ring gear out of roundness 8. Replace
9. Low lubricant level 9. Oil level
10. Poor or wrong lubricant 10. Replace
11. Bent halfshaft 11. Replace
Noise while driving in neutral 1. Noise coming from axle are usu- 1. Replace or adjust (see above)
ally heard when vehicle moves in
neutral gear but are not loud.
2. Incorrect backlash between pinion 2. Replace
and ring (sound heard while
decelerating disappears while
increasing the speed)
3. Pinion or input flange worn out 3. Adjust
Intermittent noise 1. Ring gear damaged 1. Replace bevel gear set
2. Differential box bolts loosened 2. Tighten to torque
Constant noise 1. Ring gear teeth or pinion damaged 1. Replace bevel gear set
2. Worn out bearings 2. Replace
3. Pinion spline worn out 3. Replace
4. Bent halfshaft 4. Replace
Noise while seering 1. Worn out differential gears 1. Replace
2. Worn out differential box or spider 2. Replace
3. Differential thrust washers worn 3. Replace
out
4. Half shaft spline worn out 4. Replace
4 - 30 REAR AXLE F156.6 / F156.6A
NOTES:
SECTION 5
FRONT AXLE
INDEX
5.1 GENERAL INFORMATION ..................................................................................... 5-1

5.1.1 Manual use .............................................................................................................. 5-1
5.1.2 Agreements and definitions ..................................................................................... 5-1
5.1.3 General recommendations for disassembly and assembly operations .................. 5-3
5.2 GENERAL SPECIFICATIONS................................................................................. 5-5

5.2.1 Foreseen uses ......................................................................................................... 5-5
5.2.2 Product identification ............................................................................................... 5-5
5.2.3 General description.................................................................................................. 5-6
5.2.4 Technical features ................................................................................................... 5-7
5.2.5 Sealing compounds and adhesives ......................................................................... 5-9
5.2.7 Special tools ............................................................................................................ 5-12
5.3 FRONT WHEEL DRIVE SYSTEM (only for F156.6A) ............................................. 5-13
5.3.1 Technical Data......................................................................................................... 5-13
5.3.2 Hydraulic system ..................................................................................................... 5-14
5.3.3 Hydraulic diagram.................................................................................................... 5-16
5.3.4 Components ............................................................................................................ 5-19
5.4 FRONT AXLE REMOVAL - INSTALLATION........................................................... 5-25

5.4.1 Removal................................................................................................................... 5-25
5.4.2 Installation................................................................................................................ 5-28
5.5 DISASSEMBLY AND ASSEMBLY OPERATIONS.................................................. 5-31

5.5.1 Hub and final drive (only for F156.6A) ..................................................................... 5-31
5.5.2 Body......................................................................................................................... 5-41
5.5.3 Steering cylinder ...................................................................................................... 5-55
5.5.4 Wheel rake cylinder ................................................................................................. 5-61
5.5.5 Hydraulic installation (only for F156.6A) .................................................................. 5-69
F156.6 / F156.6A FRONT AXLE 5-1
5.1 GENERAL INFORMATION
5.1.1 MANUAL USE 5.1.2 AGREEMENTS AND DEFINITIONS
Maintenance Agreements
CONSULT THIS MANUAL THOROUGHLY, as Illustrations are supposed to point out the various
proper functioning and good efficiency of mechanical handling sequences and phases of the axle and its
organs depends mostly on constant and correct rou- components, therefore they could not display exactly
tine and extraordinary maintenance which could pro- the same group elements.
mote the integrity and duration of the axle and avoid
damages or any harm to the operator.
In case of any damages or anomalies, quick inter- Definitions
vention of specialized personnel can avoid future im-
pairment and lengthen the working life. Left side: it is the left side of the axle considering
Overhaul Right side: it is the right side of the axle considering

The disassembly/assembly procedures have been
outlined for a total group overhauling. They have also
been described in sequence through photographs
with relevant explanation for specific interventions,
thus obtaining a complete and safe guide for each
and every phase of an operation.
Moreover, the attentive group inspection leads to a
correct repair work estimation that could merely re-
quire dismounting only few components, and thus
operating partially on the group.
5-2 FRONT AXLE F156.6 / F156.6A
5.1.3 GENERAL RECOMMENDATIONS

FOR DISASSEMBLY AND ASSEMBLY
OPERATIONS
The axle should be checked and/or repaired only by Shafts seals

qualified technicians, acquainted with its peculiar
features and well aware of all safety instructions. Respect the following recommendations during shaft
seal assembly:
Before performing any operation it is advisable to
carry out axle cleaning accurately by removing oil/ • Clean shaft very carefully and ensure that the part
grease encrustations and accumulation. in contact with the shaft seal is not damaged, cut
or out of roundness.
All disassembled mechanical parts must be cleaned • Assemble the seals so that the lip is fitted towards
accurately with suitable products to avoid possible the oil side.
damage. Parts should be replaced if damaged, worn • Lubricate seal lips (use grease) and fill 3/4 of seal
out, cracked, seized, etc. as they could affect proper cavity with grease.
functioning of the axle. • Use appropriate drivers. Do not use a hammer di-
rectly on the seals.
Rotating parts (bearings, gears, shafts) and that of • Do not damage the seals while assembling the
hardware/fasteners (O-Ring, oil seals) should be ex- shaft.
amined carefully, as they are subject to major stress,
wearing and ageing.
O-rings
We highly advice to replace tightening parts during
every teardown or repair. Lubricate adequately before inserting them at the
right place and avoid rolling while inserting the shaft.
We advice replacing the components of the bevel
gear parts automatically always in pairs.
Adjusting shims
Use appropriate spare parts, nuts and bolts to avoid
any other problems. Moreover, use metric tools for Use appropriate adjusting shims and measure each
metric nuts and bolts and Imperial tools for the others. one separately.
Complete group measurement or stampings on the
Please read the disassembly instructions very care- shims are not always reliable: check.
fully because some operations are destructive for
some axle components, that means that they should
be replaced with new ones, because when disman-
tled, they are destroied.
Please read carefully the description of the single

steps, to avoid compromising the good operation of
the whole unit.
Before starting any disassembly and assembly op-

erations, read carefully the following recommenda-
tions.
F156.6 / F156.6A FRONT AXLE 5-3
Bearings Checks
Its advisable to heat up bearings to 80 °C - 90 °C Examine accurately all bearings, external rings which
before assembling them onto their respective shafts may be still stuck in their position and pivot pins on
or to cool them (dry ice) before inserting them into which rolls rotate. Replace those which are worn out
corresponding bore. Before reassembling the bear- or damaged.
ings, clean, check and lubricate them. Gears should not be spoiled and teething should not
be excessively worn out. Teeth smoothing should not
be deteriorated.
Split pins Check all grooves: assure that they are not worn out
or damaged.
Before assembling elastic pins, make sure that the Replace spoiled parts with original spare parts.
notch is oriented towards the stressing force. Replace seals on rotating shafts, before reassembly.
Spiral elastic pins do not need orientation.
Ends of flanges and tools

Sealing
Be careful when hammering tool or flange ends, in
Use sealing as advised by specifications. Ensure that order to avoid jeopardizing functionality and integrity
parts to be sealed are clean, dry and completely of either the tools or the components on which you
grease free. are operating.
Oil drain Reassembly ways
Before disassembly, oil should be drained out. In order to reassemble the group, an appropriate fix-
ture must be used.
In order to position the group, to disassemble and
WARNING reassemble the ring gear and to support the gear
housing, a lifting system is needed.
Disposal of used oil must be done according to
To make disassembling and assembling operations
laws
easier, use a group assembly drawing.
Cleaning
Lubricant use
Wash all moving parts (gears, bearings, etc.) accu-
In order to lubricate the axle correctly and to reach
rately with diesel fuel or kerosene.
the exact operation temperature, it is important to
Avoid gasoline and watery alkaline solutions. Do not
use the recommended lubricants, keeping their level
wash with steam or hot water, as it will be very difficult
constant as indicated in this manual.
to eliminate surface humidity.
Dry all parts with a rag or air jet to avoid scratching
from abrasive residuals.
All surfaces should be covered with lubricant so as
to protect it from future oxidation.
5-4 FRONT AXLE F156.6 / F156.6A
Symbology
SYMBOLS DESCRIPTION
WARNING / DANGER
REMOVE / INSTALL
seals / gaskets / filters
OIL FILLING OR OIL LEVEL

OIL DRAIN
LUBRICATION / GREASING
ADJUSTMENTS / MEASUREMENTS
tightening torques / preloads / backlash
SPECIAL TOOLS
SEALING / LOCKING FLUIDS

APPLICATION
MARK OR INDICATE
DISASSEMBLY / ASSEMBLY OF BULKY PARTS OR

SUBASSEMBLIES
WARNING:
respect assembly orientation
CLEANING CAREFULLY
APPLY PRESSURIZED FLUID
F156.6 / F156.6A FRONT AXLE 5-5
5.2 GENERAL SPECIFICATIONS

5.2.1 FORESEEN USES 5.2.2 PRODUCT IDENTIFICATION
The axle is a component that transmits the power Axle serial plate
from the engine to the wheels and allows:
• increasing of tractive force, reducing the number

of revolutions AXLE TYPE
• adjusting of inner wheels’ speed with outer wheels’
speed during steering.
Never mount this axle on machines different from the

ones for which it has been designed and manufac-
tured.
If the axle is used for any other purpose than the one
foreseen, the Manufacturer declines any responsi-
bility regarding damages or accidents caused by it.
All consequences will be at the expense of the client.
However, when used as foreseen, operational for-
malities as well as regular maintenance repair spec-
P/N AND S/N
ifications given in this Manual are to be observed
strictly.
OKs1-5-001
5-6 FRONT AXLE F156.6 / F156.6A
5.2.3 GENERAL DESCRIPTION
The axle described in this section, consists of an axle body with a wheel hub unit at each end.
AXLE BODY FINAL DRIVE
STEERING CYLINDER WHEEL RAKE CYLINDER
UPPER VIEW
OKs1-5-002
F156.6 / F156.6A FRONT AXLE 5-7
5.2.4 TECHNICAL FEATURES
Model F156.6 F156.6A

Axle code 4519805 4519104
Axle model GF16 GF16A
5-8 FRONT AXLE F156.6 / F156.6A
Overall dimensions (millimeter)
1405
153
395
(706)
Ø280,8
R2
Ø335
90
°
,5
20 20
,5
°
65 185,1 1305
2070
(2370)
Ø65H7
363,5
462,5 -0,3
(708)
140
10,9
7°
,5° 299 463
35,33 42
°
1557,2
OKs2-05-003
F156.6 / F156.6A FRONT AXLE 5-9
5.2.5 SEALING COMPOUNDS AND ADHESIVES
B2
B2
sez. B
B2
B2
OKs1-5-003
A1= LOCTITE® 510 B2= LOCTITE® 242

A2= LOCTITE® 573 C1= LOCTITE® 405
A3= LOCTITE® 518 C2= LOCTITE® 496
B1= LOCTITE® 542 C3= LOCTITE® 638
Apply on the contact surfaces
Apply on bolt screws / on pins
5 - 10 FRONT AXLE F156.6 / F156.6A
260 Nm
C
A
270-290 Nm
Section A
C
....Nm
25 Nm
25 Nm
Section B
OKs1-5-005
F156.6 / F156.6A FRONT AXLE 5 - 11
5.2.7 SPECIAL TOOLS
Its use is recommended togheter with a suitable security handle in order to protect the hands.
Nr. Description Figure
2897043 Hubs disassembly
2897044 Steering cylinder joint
2897045 Tyres tilting cylinder joint
5 - 12 FRONT AXLE F156.6 / F156.6A
NOTES:
F156.6A FRONT AXLE 5 - 13
5.3 FRONT WHEEL DRIVE SYSTEM (only for F156.6A)
The FWD hydraulic system consists essentially of the adjustable axial piston pump and two radial piston motors.
These main components work in a closed circuit and produce the hydrostatic propulsion of the front wheels.
Adjusting pump: A4VG 71EP2

Displacement vol.: 0 to 71 cm³/ rev.
Volumetric flow: 160 L / min
Wheel motor: MS 11
Capacity: 1 259 / 629 cm³
5 - 14 FRONT AXLE F156.6A
5.3.2 HYDRAULIC SYSTEM
1. Adjusting pump A4 VG 307. Feed oil line, four-wheel pump "Fe" ➞ feed circuit
2. Wheel motors MS pressure filter
3. Flow divider 308. Backflow line, feed circuit pressure filter ➞ four-
16. 6/2-way valve for front wheel drive stop wheel pump "Fa"
17. Solenoid valve block Y8.1/Y8.2 309. Control - / flush line, four-wheel pump "MA" ➞ flush
18a. 4/2-way valve for front wheel drive ON/OFF & feed pressure valve " A "
18b. 4/2-way valve for wheel motor activation 310. Control - / flush line, four-wheel pump "MB" ➞ flush
19. Pressure limiting valve 1,5 bar & feed pressure valve " B "
20. Flush and feed pressure valve 16 bar 311. Leakage line, four-wheel pump "T1" ➞ tank "W"
21. Feed pressure filter 312. Backflow line, flush & feed pressure valve " T " ➞
22. Pressure accumulator pressure holding valve "01"
23. Distributor block with jet 313. Line, measuring point M01 " ➞ pressure holding
69. Filling line, feed circuit pressure filter ➞ pressure valve "01"
accumulator 314. Supply line, feed circuit pressure filter ➞ valve VA
300. HP-line forwards, 6/2-way valve outlet "AV" ➞ flow ON / OFF & capacity change-over "P"
divider "P" 315. Control line, valve VA ON / OFF "B" ➞ 6/2-way valve
301. HP-line forwards backflow, flow divider ➞ 6/2-way "G"
valve "AR" 316. Line, valve VA ON / OFF "A" ➞ 6/2-way valve "F",
302. Leakage line, wheel motors "1" ➞ pressure holding filling of spring chamber
valve "01" 317. Tank pipe, valve VA ON / OFF and capacity change-
303. Control line, valve chamber "A" ➞ flow divider / over "T" ➞ tank "X"
wheel motor " Y " 318. Tank pipe, pressure holding valve "1" ➞ backflow
304. Suction line of feeding pump "S" from tank "U" filter, tank "V"
305. HP-line forwards backflow, four-wheel pump "B" ➞ 319. Tank pipe, pressure holding valve "F" ➞ tank
6/2-way valve "PAR"
306. HP-line forwards, four-wheel pump "A" ➞ 6/2-way
valve "PAV"
319
308 311 317
20 304
305 21 P
307
23
L1
S
318 308 307
303
311
T2
G
310 310
309
1 22
309
304 319
313 17 18a
305
T
317 18b
306 314
315
302
316
19
301
16
300
303
OKs1-5-180
5.3.3 HYDRAULIC DIAGRAM
1. Pump unit
10. Hydraulic oil reservoir
25. Pressure limiting valve, flushing circuit
60. Wheel motor
62. 6/2-way valve
63. Flow divider
64. Solenoid valve block Y8.1/Y8.2
65. Pressure limiting valve 1,5 bar
66. Flush & feed pressure valve 16 bar
67. Feed pressure filter
68. Pressure accumulator 0,75 L
69. Distributor block with jet
All-wheel drive on/off
OKs2-05-001
5.3.4 COMPONENTS
20
23
21
22
19
17
Adjusting Pump
The delivery of the axial piston pump is controlled by The adjusted delivery and therefore the resulting
means of the proportional electromagnets (a) or re- front wheel RPM are maintained independently of
spectively (b). the pressure predetermined by road resistance and
traction. Therefore, an unloading of the front axle
Depending on a predetermined current intensity I when operating brings about a reduction of the
(200 mA to 600 mA) at the magnets, the regulating working pressure while, however, the RPM of wheels
cylinder of the pump is supplied with regulating pres- remains unchanged.
sure by means of the proportional valve. Corre-
sponding to the regulating pressure or respectively
to the actuating current intensity, the bevel disk and
therefore the delivery is continuously adjusted. Ac-
cording to the control, if carried out from "a" or from
"b", the direction of delivery is changed over.
With a predetermined wheel rotational speed, the Valve VA ON / OFF

working pressure and thus the front wheel traction
are the result of traction and road resistance condi- When engaging the front wheel drive the 4/2-way
tions. When the max. allowable working pressure of valve (18a) is activated electrically, this in its turn
420 bar is achieved, the pressure cut-off of the axial takes the 6/2-way valve (16) with the control pressure
piston pump regulates delivery backwards. The di- into the open position. In this way the pump is con-
minished delivery causes a reduction of front wheel nected to the wheel motors through the high pressure
RPM. If front wheel RPM becomes lower than rear lines. The disconnection of the 6/2-way valve hap-
wheel RPM, the working pressure of the front wheel pens by force of spring supported by the control pres-
drive drops correspondingly. sure.
A protection against pressure peaks arising when

swivelling very rapidly and the exceeding of the max- Pressure accumulator
imum high pressure of the pump is ensured by high
pressure limiting valves at 450 bar. The pressure accumulator (0,75 L) prevents solely
the feeding line Four-wheel "ON-OFF" or respec-
tively Capacity change-over from being insufficiently
Feeding pump (integrated) supplied.
Tasks:
- Supply with feeding oil for variable delivery pump

- Supply of actuating chamber with actuating pres-
sure
- Supply of valves (18a) and (18b) with controlling
oil
- Flushing oil
The feeding pump flanged to the variable delivery

pump delivers towards the feeding pressure limiting
valve of 25 bar through the feeding pressure filter.
This oil serves first to flush the hydrostatic circuit and
secondly to control various functions. The oil flow
necessary for the flushing is introduced into the low
pressure line by means of the bypass valves fitted
into the high pressure limiting valves. The heated oil
is flushed through the flushing valve (20), i.e. the
oil temperature in the closed circuit should not ex-
ceed 50-60 °C.
Flow divider
The flow divider (3) acts as a hydraulic differential The transfer jet between the two outlets "A" and "B"
lock. When riding ahead it divides the oil delivered makes possible a limited pressure compensation, in
by the pump in two equal portions for the wheel mo- this way an excessive tightening of the two front
tors. In this way the flow divider prevents a motor wheels, one to another, is avoided when cornering.
from absorbing the whole oil flow, in case of different When reversing, the flow divider is not functioning,
resistance values at the wheel motors (e.g. owing to as the flowing oil bypasses the flow divider function
different coefficients of friction at the front wheels). through the two check valves. The ports "F" and "ZB"
In this way a spinning of the wheels is avoided. have a function of leakage.
Front
view
To the right To the left

wheel motor wheel motor
HP-line, Flow
backwards divider
Wheel motors Wheel Motor Control Valve /

Chamber Change-over
Designation of ports:
The absorption volume of the wheel motors can be
A Supply line for motor in preferential rotational regulated in two stages. The actuation of ports "Y"
sense A = ahead with control pressure through the 4/2-way valve (18b)
R Backflow causes the volume to be halved, so that the wheels,
1 Leakage line with the same pump delivery, rotate at a double
Y Capacity change-over speed. This device is utilised while riding with front
wheel drive in the 4th and 5th gear in forward motion
The two wheel hub motors (2) work according to the and in 3rd reversing gear.
radial piston principle, i.e. a determined number of
working pistons are radially arranged on the motors.
When the cylinder block is rotating, they run exter-
nally along a cam path, which shifts them in a lifting
movement.
Internally the cylinder chambers are alternatively
connected to the high pressure feeding and return
ducts through the divider. If the 6/2-way valve is
switched on, the operating or feeding pressure acts
from the inside on the piston area and presses the
pistons on the cam path.
Externally on the pistons the housing or leakage

pressure prevails, which in our system is preloaded
by the pressure limiting valve (19) at 1,5 bar through
the wheel motor ports.
The preloading serves to switch the wheel motors
while disengaging the front wheel drive in the free-
wheel, i.e. to press the radial pistons inwards, as they
are no more in touch with the cam path. For this pur-
pose, the pressure in the inner side of the pistons
and therefore in the high pressure channels must
drop to the tank values. With disengaged front wheel
drive, this is carried out by connecting the high pres-
sure ports of the wheel motors to the tank through
the 6/2-way valve (16). As a relief in disconnecting
the wheel motors, this line ends in the suction line of
the working hydraulic pump (port).
The front wheel drive can be engaged and disen-

gaged only up to a driving speed of 2 km/h, as at
higher speeds damages can be caused by the wheel
motor disconnection.
Lateral view, Front
HP-line,
backwards
Control line
Chamber change-over
HP-line
forwards
16
Rear frame
19 18b
NOTES:
F156.6 / F156.6A FRONT AXLE 5 - 25
5.4 FRONT AXLE REMOVAL-INSTALLATION
5.4.1 REMOVAL
DANGER
1
Support the front axle with adequate lifting devices.
NOTE – The vehicle is shown without attachment. 2
Remove the front wheels. 1
Remove screws (1) and remove mudguards (2).
OKs1-5-169
2
Disconnect the hydraulic pipes from the steering cylinders and
wheel rake cylinder.
3
NOTE – For the front axle mounted on models F156.6A discon-
nect also the oil pipes for the flow divider.
5 - 26 FRONT AXLE F156.6 / F156.6A
4
Remove screws (3) and remove front flange (4).
3
5
Remove screws (5) and remove rear flange (6).
6
Remove nut (7) and remove the dowel of the pin connecting the
front axle to the frame.
7
Use appropriate punches to push out from the rear pin (8) con-
necting the front axle to the frame.
F156.6 / F156.6A FRONT AXLE 5 - 27
8
Remove the front axle and remove shims (9) located between
the front axle and the frame.
5 - 28 FRONT AXLE F156.6 / F156.6A
5.4.2 INSTALLATION
DANGER
1
Place the front axle so that the holes of the front frame align with
the hole on the axle itself.
Insert partially pin (8).

8
NOTE – The vehicle is shown without attachment.
2
Install special tool (10) and secure it with screws (11) on the
front frame.
11
Actuate screws (12) of the special tool to move forward as far
as possible the front axle so as to achieve the maximum clear-
ance between the front frame and the axle.
12
10
3
Insert shims (9) to obtain the prescribed clearance between the
front axle and the frame.
F156.6 / F156.6A FRONT AXLE 5 - 29
4
Remove the tool and complete the installation of the front axle
pivot pin to the frame.
Insert the pivot pin dowel and tighten lock nut (7).
5
Install rear flange (6) and tighten screws (5).
6
Install front flange (4) and tighten screws (3).
3
7
Connect all hydraulic pipes to the steering cylinders and the
wheel rake cylinder.
5 - 30 FRONT AXLE F156.6 / F156.6A
8
NOTE – For the front axle mounted on models F156.6A, connect
also the oil pipes for the flow divider.
9
Install the front wheels.
2
Install mudguards (2) and tighten screws (1).
OKs1-5-169
5.5 DISASSEMBLY AND ASSEMBLY OPERATIONS
5.5.1 HUB AND FINAL DRIVE (only for F156.6A)
4
5
6
7
8
9
10
11
12
13
14
3
15 2
18 1
16
19
17
OKs1-5-006
Disassembly
Some of the following pictures could not show exactly your axle, but the procedure is the same.
1
Unscrew and remove screw (1).
2
Remove final drive (3).
3
Disassemble the split pin and the nut and extract rod.
4
Disassemble the split pin and the nut and extract steering cyl-
inder pin.
5
6
Remove cover (5).
5
7
8
Remove plug (10).
Use tool 2897043.
10
9
Strike from the bottom in order to remove upper hub (8) com-
plete. 8
10
Unscrew and remove screws (19).
Remove feather (18).
19
18
11
Remove lower ring nut (17).
17
12
16
13
Remove plug (12).
Use tool 2897043.
12
14
Remove hub (14) complete.
14
15
Remove support (11).
11
Assembly
1
Assemble support (11).
11
2
Assemble hub (14) complete.
Assemble and tighten screw (16).
14
16
3
Assemble lower ring nut (17).
17
4
Assemble feather (18).
Screw in screws (19).
19
18
5
Assemble hub (8) complete.
6
Strike on hub (8).
7
Assemble plug (10).
Tighten screw (6).
10
6
8
Assemble cover (5).
5
9
Screw the screws (4) and tighten them at the prescribed torque
wrench (Par. 5.2.6).
10
Assemble the steering cylinder pivot and fix it by means of the
special nut and the split pin. (See Body Group).
11
Assemble the rod and fix it by means of the special nut and split
pin. (See Body Group).
12
Assemble final drive (3).
13
Apply Loctite®242 on screws (1).
14
Screw the screws (1) and tighten them at the prescribed torque
wrench (Par. 5.2.6).
1
NOTES:
F156.6 / F156.6A FRONT AXLE 5 - 41
5.5.2 BODY
24 23 29
26
27
28
13
14
15 25
18 7
17 19 10
9
8
2
16 1
11
20
12
21
6
22
21 4
3
5 1 2
OKs1-5-036
Disassembly
1
Remove split pin (1).
5 - 42 FRONT AXLE F156.6 / F156.6A
2
Remove split pin (4).
3
Untighten and remove nut (2).
4
Untighten and remove nut (5).
5
Remove rod assembly (3) by striking.
F156.6 / F156.6A FRONT AXLE 5 - 43
6
Remove cylinder (7) with connection (6) by striking.
6
7
Remove caulk on washer cover (9).
8
Remove washer cover (9) and washer (10). 8
9 10
9
Untighten connecting screws (6).
5 - 44 FRONT AXLE F156.6 / F156.6A
10
Remove connection (6) from cylinder (7).
6
11
Disassemble steering cylinder assembly (7).
12
Remove screw (14) and nut (16).
16 14
13
Remove pin (15) by striking.
15
F156.6 / F156.6A FRONT AXLE 5 - 45
14
Remove pin (17).
17
15
Remove nut (18) and its washer (19).
18 19
16
20
17
Remove pin (20).
20
5 - 46 FRONT AXLE F156.6 / F156.6A
18
Remove hub support (12).
Remove gaskets (21) from both sides of hub support (12).
12
21
19
By means of an extractor remove bearing cups (22) from both
sides of hub support (12). 22
12
20
23
25
21
24
F156.6 / F156.6A FRONT AXLE 5 - 47
22
26
28
23
Remove wheel tilting cylinder assembly (29). 29 27
5 - 48 FRONT AXLE F106.6 / F106.6A
Assembly
1
Assemble hub support (tilting cylinder side).
Position rod (13). Position wheel tilting cylinder (rod on hub sup- 27
port). Assemble pin (27).
13
2
Fasten the pin by assembling screw (26) and the relative nut.
26
3
Position the wheel tilting cylinder (liner in axle casing plates).
Assemble pin (24).
24
F156.6 / F156.6A FRONT AXLE 5 - 49
4
Fasten the pin by installing screw (23) and the relative nut (25).
23
25
5
Assemble bearings (22) on both sides of hub support (12).
22 12
6
Assemble gaskets (21) on both sides of hub support (12).
Assemble hub support (12).
12
21
7
Assemble pin (20).
20
5 - 50 FRONT AXLE F156.6 / F156.6A
8
Assemble washer (19).
Tighten nut (18).
18 19
9
Assemble pin (17).
17
10
Fit rod (13).
Assemble pin (15). 15
13
11
Assemble screw (14) with its nut (16).
16 14
F156.6 / F156.6A FRONT AXLE 5 - 51
12
Assemble steering cylinder (7) on axle casing (11).
11
13
Assemble connection (6) on steering cylinder (7).
6
14
Assemble connection (6) on wheel support.
15
Assemble washer (10) and its protection (9).
Tighten the screws (8) at the prescribed torque wrench (Par. 5- 8
2-6).
9 10
5 - 52 FRONT AXLE F156.6 / F156.6A
16
Caulk washer protection (9).
17
Assemble rod (3).
18
Screw in nut (2) and tighten at prescribed wrench torque 270-
290 Nm (Par. 5.2.6).
19
Screw in nut (5) and tighten at prescribed wrench torque (Par.
5.2.6).
F156.6 / F156.6A FRONT AXLE 5 - 53
20
Assemble split pin (4).
21
Assemble split pin (1).
5 - 54 FRONT AXLE F156.6 / F156.6A
NOTES:
F156.6 / F156.6A FRONT AXLE 5 - 55
5.5.3 STEERING CYLINDER
OKs1-5-081
Disassembly
1
Untighten head (2).
Remove rod assembly (5) from liner (11).
11 2
5 - 56 FRONT AXLE F156.6 / F156.6A
2
Remove head (2).
Remove gasket (1) from head (2). 2
3
Remove gasket (3) from head (2).
3 2
4
Remove inner gaskets (4) from head (2).
2 4
5
Disassemble rod (5), piston assembly (7) and nut (10).
10 5
F156.6 / F156.6A FRONT AXLE 5 - 57
6
Remove rings (9) from piston (7).
9 7 8 9
7
Remove O-Ring (6) from piston (7).
6 7
8
Disassemble articulated joint bearing (12) from liner (11).
Use tool 2897044.
12
11
5 - 58 FRONT AXLE F156.6 / F156.6A
Assembly
1
Assemble articulated joint bearing (12) on liner (11).
12
11
2
Assemble O-Ring (6) on piston (7).
6 7
3
Assemble rings (9) on piston (7).
9 7 8 9
F156.6 / F156.6A FRONT AXLE 5 - 59
4
Assemble nut (10), piston assembly (7) and rod (5).
10 5
5
Assemble inner gaskets (4) on head (2).
2 4
6
Assemble gasket (3) on head (2).
3 2
7
Assemble seal ring (1) on head (2).
2
5 - 60 FRONT AXLE F156.6 / F156.6A
8
Assemble head assembly (2) on rod (5) complete with piston
(7) and nut (10).
7 2
10 5
9
Assemble rod assembly on liner (11) by tightening head (2).
11 2
F156.6 / F156.6A FRONT AXLE 5 - 61
5.5.4 WHEEL RAKE CYLINDER
15
14
13
12
11
10 7
9 6
8 5
4
3
2
1
OKs1-5-099
Disassembly
1
Remove rod assembly (2) from liner (14) by untightening head
(4).
14 4
5 - 62 FRONT AXLE F156.6 / F156.6A
2
Remove articulated joint bearing (15) from liner (14).
Use tool 2897045.
14
15
3
Unscrew nut (13).
Remove piston assembly (10) and head assembly (4) from the
rod (2).
2 4 10
13
4
Remove articulated joint bearing (1) from rod (2).
Use tool 2897045.
1
5
Remove gasket (9) from piston (10).
10
F156.6 / F156.6A FRONT AXLE 5 - 63
6
Remove rings (12) and (11) from piston (10).
12 12
11 10
7
Remove inner gaskets (8) from head (4).
8
8
Remove gasket (7) from head (4).
7 4
9
Remove seal ring (6) from head (4).
4
5 - 64 FRONT AXLE F156.6 / F156.6A
10
Remove O-Ring (5) from head (4).
5
11
Remove seal ring (3) from head (4).
F156.6 / F156.6A FRONT AXLE 5 - 65
Assembly
1
Assemble seal ring (3) on head (4).
2
Assemble O-Ring (5) on head (4).
5
3
Assemble ring (6) on head (4).
4
5 - 66 FRONT AXLE F156.6 / F156.6A
4
Assemble gaskets (7) on head (4).
7 4
5
Assemble inner gaskets (8) on head (4).
8
6
Assemble rings (12) on piston (10).
12 12
10
7
Assemble O-Ring (9) on piston (10).
10
F156.6 / F156.6A FRONT AXLE 5 - 67
8
Assemble articulated joint bearing (1) on rod (2).
Use tool 2897045.
1
9
Assemble head assembly (4) and piston assembly (10) on rod
(2). Tighten nut (13).
2 4 10
13
10
Assemble articulated joint bearing (15) on liner (14).
Use tool 2897045.
14
15
11
Fit rod assembly (2) into liner (14).
Fasten head (4).
14 4
5 - 68 FRONT AXLE F156.6 / F156.6A
NOTES:
5.5.5 HYDRAULIC INSTALLATION (only for F156.6A)
6
7
13
12
14
15
16
17
18 3
8
20 5
9
21 4
2
1
10
11
24
25
19
27 26 23 22
OKs1-5-121
Disassembly
1
Disconnect hose (13) from valve (6).
13
2
12 6
3
11
4
10
5
Disconnect pipe (5) from block (4).
6
Disconnect pipe (5) from valve (6) and remove it.
7
Disconnect hose (9) from block (4).
9
8
9 6
9
Remove valve (6). 6 7
10
Remove block (4) with valve (2).
8
2 4
11
Disassemble valve (2) from block (4).
1 2
12
Remove O-Ring (3) from the valve (2).
2 3
13
Unscrew and remove screws (15) and nut (13).
Remove clamp (14).
15 14
13
14
Remove guide rod link (16) with locking nut (17) and articulated
joint (18).
18
16
17
15
Remove protection (20).
20
21
16
Untighten outer screws of bracket fastener (19).
19
17
Untighten bracket inner screws (19) to disconnect the last pipe
and remove the bracket.
19
18
Disconnect hose (11) from pipe (23).
Remove hose (11).
11
23
19
Remove bracket (25).
25
20
22
21
Remove hose (23).
Remove gasket (24) from hose (23).
23
24
22
Disconnect hose (12) from transmission drive.
Remove hose (12).
12
23
Disconnect hose (13) from transmission drive.
Remove hose (13).
13
24
27
25
Remove hose (10).
Remove O-Ring (26) from pipe (10).
26
10
Assembly
1
Connect hose (10) to transmission.
Assemble bracket (27).
10
27
27
2
13
3
12
4
Assemble pipe (23) to transmission. Fasten with bracket (22).
22
23
5
25
6
Assemble hose (11) by connecting it with the pipe (23).
11
23
7
Fit the hoses inside bracket.
19
8
Assemble protection (20).
Fasten it by tightening the screws (21).
20
21
9
Assemble clamp (14) on hoses.
Assemble articulated joint (18) with guide rod link (16) and its
nut (17) on the shaft.
18
16 14
17
10
Assemble O-Ring (3) on valve (2).
2 3
11
Assemble valve (2) with block (4) by tightening screws (1).
1 2
12
Assemble block (4) with valve (2) on the frame by tightening
screws (8).
8
2 4
13
Assemble valve (6) on frame by tightening screws (7).
6 7
14
Connect hose (9) to valve (6).
9 6
15
Connect hose (9) with block (4).
9
16
Connect pipe (5) with valve (6).
17
Connect pipe (5) with block (4).
18
10
19
11
20
12 6
21
13
NOTES:
SECTION 6
ATTACHMENT
INDEX
6.1 CENTRAL ATTACHMENT ...................................................................................... 6-1

6.1.1 Removal - Installation .............................................................................................. 6-1
6.1.2 Disassembly - Assembly.......................................................................................... 6-6
6.2 FRONT ATTACHMENT (opt) (Blade or ripper) ....................................................... 6-21

6.3 REAR ATTACHMENT (opt) (Ripper)....................................................................... 6-25

6.4 FRONT FRAME....................................................................................................... 6-29

F156.6 / F156.6A ATTACHMENT 6-1
6.1 CENTRAL ATTACHMENT

6.1.1 REMOVAL - INSTALLATION
Removal
DANGER
1
Proceed as follows:
- move the central attachment sideways, then rest it on the
ground by actuating the appropriate cylinders;
- disconnect hydraulic pipes (1) of the front frame from the
centre joint, from the swing motor and the brake valves, ex-
tract them from guide (2) on the tow bar and place them in a
position so that they do not interfere with subsequent opera-
tions;
1 2
2
- remove the securing screws and disconnect eyes (3) of the
lifting cylinder and the swivelling cylinder from the ball heads
on the central attachment, recovering the adjusting shims;
3
3
- remove the four securing screws and separate securing plate
(4) from the central attachment ball joint;
6-2 ATTACHMENT F156.6 / F156.6A
4
- support adequately with a cable and hoist, the central attach-
ment complete with blade and ripper (opt.) then remove it
using the hoist as required;
5
- disconnect hydraulic pipes (5) of the swivelling cylinder, sup-
port it adequately with a cable and hoist, then remove the four
securing screws (6) and remove the cylinder;
6
- disconnect lifting cylinder hydraulic pipes (7);
7
7
- support adequately the lifting cylinder with a cable and hoist,
then remove the four securing screws (8) and remove the
8
cylinder;
- repeat the operation for the other lifting cylinder;
8
- remove the screws securing covers (9) and remove forks (10)
of the lifting cylinders and fork (11) of the swivelling cylinder, 10
recovering bushes (12); 12
12
9
10
11
9
OK2-06-001
- remove the two screws and remove saddle locking hydraulic

cylinder (13);
- support adequately the two parts of the saddle with a cable
and hoist, then remove the six securing screws (14);
- lift and remove upper part (15) of the saddle, recovering shims
(16), shim (17) and bushing (18);
- lower the lower side (19) of the saddle.
9
Installation
15 17
18
DANGER
Lift and handle all heavy parts with a lifting device of ap- 14
propriate capacity. 16
Make sure that groups or parts are held by appropriate 13
16
slings and hooks.
Make sure that no bystanders are in the vicinity of loads to
be lifted.
19
Proceed as follows: OKs2-06-002
- support adequately lower side (19) of the saddle with a cable

and hoist and lift it until it touches the front frame;
- insert bush (18) and shim (17) in upper side (15) of the saddle;
- install shims (16), lift upper side (15) of the saddle and install
it on lower side (19) tightening securing screws (14) to a torque
of Nm;
- install saddle locking hydraulic cylinder (13) tightening the
screws to a torque of Nm;
10
- install bushes (12), forks (10) of the lift cylinders and fork (11)
of the swivelling cylinder, then install covers (9) and tighten 10
the securing screws to a torque of Nm; 12
12
9
10
11
9
OKs2-06-001
11
- support adequately the lift cylinder with a cable and hoist,
then install the bushes and caps and tighten the four securing
8
screws (8) to a torque of Nm;
12
- connect hydraulic pipes (7) of the lift cylinder;
- repeat the operation for the other lift cylinder;
7
13
- support adequately the swivelling cylinder with a cable and
hoist, then install the bushes and caps and tighten the four
securing screws (6) to a torque of Nm;
- connect hydraulic pipes (5) of the swivelling cylinder;
14
- support adequately the central attachment complete with
blade and ripper (opt.) with a cable and hoist; 20
- insert securing plate (4) and bush (20) with the two O-rings
on the central attachment ball joint greasing it freely;
15
- move middle tool complete with blade and (opt) ripper by prop-
erly operating the hoist, until ball articulated joint with bush is
fit into the seat on front frame;
16
- secure plate (4) to the front frame, tightening the four securing
screws to a torque of 350 Nm;
17
- connect eyes (3) of the lift cylinders and swivelling cylinder
to the ball heads on the central attachment, insert adjustment
shims as required and tighten the securing screws to a torque
3
of 170 Nm;
18
- insert hydraulic pipes (1) of the front frame into guide (2) on
the tow bar and connect them to the centre joint, the swing
motor and brake valves.
1 2
1
6.1.2 DISASSEMBLY - ASSEMBLY
Disassembly
DANGER
Lift and handle all heavy parts with a lifting device of ap-
propriate capacity.
Make sure that groups or parts are held by appropriate
slings and hooks.
Make sure that no bystanders are in the vicinity of loads to 3
1 2
be lifted.
Proceed as follows:
- install the central attachment on an appropriate rotary stand;
- slide blade (1) sideways to retract the cylinder piston, then 1
remove securing nut (2) of sideshift cylinder (3) and recover
the washer and shim;
- support adequately the blade with a cable and hoist, slide it

sideways and extract it from the blade support, paying atten- 4
tion to the disengagement of lower slide (4) from the guide
bush;
3
- remove pipe guard (5);
4
- disconnect the pipes from the lower side of centre joint (6)
and the blade pitch and blade sideshifting cylinders;
6
5
- disconnect the brake valves outlet pipes from the blade
slewing hydraulic motor (7) and the upper side of centre joint
(6);
7
6
OKs1-06-033
6
- remove the securing screws and remove centre joint (6) ex-
tracting lower bracket (8) from its seat on the slewing support;
8 6
7
- remove the securing screws and remove blade slewing hy-
draulic motor (7) from worm-gear group (9) recovering the O-
ring;
9
7
8
- turn the tow bar 90°, remove the securing bolt, remove the
pin and free blade pitch cylinder (10) from blade support (11)
recovering the seals and inner bushes;
11 10
IMPORTANT – To extract the pins always use appropriate
punches.
9
- turn the tow bar further 90°;
- in the event a central ripper is installed (opt.), remove stop 15
springs (12) and remove the appropriate stops (13) then place
ripper bodies (14) in working position and remove supporting
device (15); 14
12
13
- remove spring pins (16) from the pins, then rotate blade sup-
10
port (11) to extract pins (17) from their seats, recovering
spacers (18) and ripper bodies (14);
IMPORTANT – To extract the pins always use appropriate 14

punches. 18
16
11
11
- remove spring pins (19) to free shanks (20) from ripper bodies
(14);
20
14 19
12
- support adequately blade support (11) with a cable and hoist,
remove the securing screws of blade support pin (21) to
slewing support (22); 11
21
22
13
- install two M12 screws longer than 140 mm, into threaded
holes (23) to pull-out blade support pins (21);
23
21
14
- remove blade support (11) from slewing support (22) recov-
ering the shims and seals;
22 11
15
- remove the locking bolt, extract pin (24) and remove blade
pitch cylinder (10) from slewing support (22) recovering the
seals and inner bushes; 10
IMPORTANT – To extract the pins always use appropriate 24

punches. 22
16
- remove securing nut (25) recovering washer (26) and shim
(27) then extract blade sideshift cylinder (2);
2
25
27 26
6 - 10 ATTACHMENT F156.6 / F156.6A
17
- remove the securing screws, remove stops (28) then pullout
blade slide bushes (29);
29 28
18
- using an appropriate puller remove elastic bushes (30) from
the holes at the ends of the blade support (11);
11 30
19
- remove the guard, then remove the securing screws and the
two blade guide plates (31); 31
20
- remove the six securing screws and remove swivelling ring
guard (32) from tow bar (33);
32
33
F156.6 / F156.6A ATTACHMENT 6 - 11
21
- support adequately swivelling support (22) with a cable and
hoist, remove the screws securing the gear and remove swiv-
elling support (22); 22
22
- install two eyebolts at 180° to support adequately gear (34)
with a cable and hoist, then remove the securing screws to
tow bar (33) and remove the gear;
34
33
23
- turn the towbar 180°, remove the four securing bolts and re-
move worm-gear group (9);
24
- remove pipes (36) from brake valves (37) then remove the
securing screws and the two brake valves;
- support adequately towbar (33) with a cable and hoist and
free it from the rotary stand. 37 36
33
OKs1-06-052
6 - 12 ATTACHMENT F156.6 / F156.6A
1
Assembly
DANGER 37 36
propriate capacity.
slings and hooks.
be lifted.
OKs1-06-052
2
Proceed as follows:
- install towbar (33) on an adequate rotary stand;
- install the two brake valves (37) tightening the securing
screws, then install the relevant pipes (36);
- install the worm-gear screw (9) tightening the four securing

bolts to a torque of Nm;
9
3
- turn towbar (33) 180°, install gear (34) and secure it with four
screws at 90°;
- have the gear complete one full turn, then position the teeth
marked by paint in correspondence with the gear and check 34
that the teeth backlash corresponds to 0.030 mm;
33
OKs1-06-053
4
- tighten the securing screws of gear (34) to towbar (33) to a
torque of 250 Nm;
33
34
F156.6 / F156.6A ATTACHMENT 6 - 13
5
- install swivelling support (22) on the gear and tighten the se-
curing screws to a torque of 250 Nm starting a cross-tight-
ening four screws at 90°, then the other ones in a clockwise 22
direction;
6
- install gear guard (32) tightening the six securing screws to
towbar (33) then fill with grease;
32
33
7
- install the blade support on an adequate stand;
- install two blade guide plates (31) tightening the securing 31
screws to a torque of 250 Nm, then install the guard;
8
- use a mallet with a plastic head to install elastic bushes (30)
into the holes at the ends of blade support (11), then grease
freely;
11
30
6 - 14 ATTACHMENT F156.6 / F156.6A
9
- install blade slide bushes (22), then install the relevant stops
tightening the securing screws;
22
10
- install blade sideshift cylinder (2), with one of the shims (27)
inserting the two dowels (38) into the appropriate holes, then
install the other shim (27) and washer (26) and tighten strongly
securing nut (25);
38 2
27
11
2
25
27 26
12
- install blade pitch cylinder (10) with the inner bushes and
seals, on swivelling support (22) then insert pin (24) and
tighten the securing bolt; 10
IMPORTANT – To install the pins always use appropriate 24

punches. 22
F156.6 / F156.6A ATTACHMENT 6 - 15
13
- install blade support (11) with the relevant seals on swivelling
support (22);
22 11
14
- install shims (39) as required;
39
15
- install pins (21) previously cooled to - 55 °C;
21
16
- tighten the securing screws of pivot pins (21) of blade support
(11) to swivelling support (22) to a torque of Nm;
11
21
22
6 - 16 ATTACHMENT F156.6 / F156.6A
17
- in the event a central ripper (opt.) is mounted, secure shanks
(20) on ripper bodies (14) with the appropriate spring pins
(19); 20
14 19
18
- turn the blade support and install in the relevant seats pins
(17) spacers (18) and ripper bodies (14), then install the ap-
propriate spring pins (16) on the pins; 14
18
IMPORTANT – To install the pins always use appropriate
punches.
16
11
19
- install supporting device (15) of the ripper bodies (14) in rest
position;
15
14
20
- place ripper bodies (14) in rest or work position and secure
them in the position desired with the appropriate stop (13) 15
engaging stop spring (12);
14
12
13
F156.6 / F156.6A ATTACHMENT 6 - 17
21
- turn the towbar 90° to install blade pitch cylinder (10) with
inner bushes and seals, on blade support (11);
11 10
22
- install the pin and tighten the securing bolt;

punches. 11 10
23
- turn towbar (33) further 90°, install O-ring (40) and install the
blade swing hydraulic motor, paying attention to the correct
alignment between the shafts of the hydraulic motor and the
worm; 40
33
24
- tighten the securing screws of blade swing hydraulic motor
(7) to worm-gear group (9) to the torque of Nm;
9
7
6 - 18 ATTACHMENT F156.6 / F156.6A
25
- install the centre joint inserting lower bracket (8) into the ap-
propriate seat (41) on swivelling support;
41
8
26
- tighten the securing screws of centre joint (6) to towbar (33);
33
27
- connect the outlet pipes from the brake valves to blade swing
hydraulic motor (7) and to the upper part of centre joint (6);
7
6
OKs1-06-033
28
- connect the pipes between the lower side of centre joint (6)
and the blade pitch and blade sideshift cylinders;
6
F156.6 / F156.6A ATTACHMENT 6 - 19
29
- install pipe guards (5);
30
- support adequately blade (1) with a cable and hoist and ap-
proach it sideways to the blade support, paying attention that
lower slide (4) is correctly inserted into the guide bush;
1
31
- slide blade (1) sideways, inserting the upper rail on blade
guide plates (31) and the lower slide in the other guide bush,
until the cylinder piston enters the relevant hole on the blade;
1
31
32
- install the shim and washer and screw securing nut (2), then
slide blade (1) sideways in the opposite direction to extract
the cylinder piston;
- tighten blade sideshift cylinder (3) securing nut to the blade,
then loosen it slightly;
- support adequately the central attachment with a cable and
hoist and free it from the rotary stand.
1 2 3
6 - 20 ATTACHMENT F156.6 / F156.6A
NOTES:
F156.6 / F156.6A ATTACHMENT 6 - 21
6.2 FRONT ATTACHMENT (opt.) (Blade or ripper)

Removal
DANGER
1
Proceed as follows:
- disconnect hydraulic pipes (1) of the front frame from front
2
attachment lift cylinder (2);
- remove the two securing screws (3) and separate the front
attachment position monitoring rod;
3
2
- support adequately the front attachment with a cable and
hoist;
- disconnect harness joint (4), remove the two upper securing
screws and remove lights bar (5); 5
3
- remove the remaining securing screws and remove the front
attachment, handling the hoist as required.
6 - 22 ATTACHMENT F156.6 / F156.6A
Installation
DANGER
1
Proceed as follows:
hoist;
- secure the front attachment to the front frame, tightening the
securing screws to a torque of 450 Nm;
2
- install lights bar (5) tightening the two securing screws to a
torque of 450 Nm and connect harness joint (4);
3
- install the front attachment position monitoring rod, then
tighten the two securing screws (3);
2
- connect hydraulic pipes (1) of front frame to front attachment
lift cylinder (2).
F156.6 / F156.6A ATTACHMENT 6 - 23
1
1 2
Disassembly
2
DANGER
propriate capacity.
Make sure that groups or parts are held by appropriate
slings and hooks. 3
be lifted.
2
Proceed as follows:
- secure the front attachment to a support stand, then rest the 2
blade (or the ripper) on the ground;
- remove the four securing screws and remove the front towing 3
4
device;
- support adequately front attachment lift cylinder (1) with a
cable and hoist, remove securing bolts (2), extract pins (3)
and remove front attachment lift cylinder (1);

punches.
3
- support adequately the blade (or ripper) with a cable and hoist,
remove securing bolts (2) extract pins (3) and remove upper
rods (4) recovering the bushes;
2
- remove securing bolts (2), extract pins (3) and remove the
blade (or ripper) recovering the bushes and seals; 3
4
- support adequately swinging arm(5) with a cable and hoist,
remove securing bolts (2), extract pins (3) and remove
swinging arm (5) recovering bushes and seals; 5
6
- remove front attachment securing plate (6) from the support
stand.
3
2
6 - 24 ATTACHMENT F156.6 / F156.6A
1
Assembly
5
DANGER 6
propriate capacity.
slings and hooks. 2
be lifted.
2
Proceed as follows:
- secure front attachment securing plate (6) to a support stand;
- support adequately swing arm (5) with a cable and hoist, insert 2
it with bushes and seals into the seats of the securing plate,
then insert pins (3) and tighten securing bolts (2);
3
punches.
3
- support adequately the blade (or ripper) with a cable and hoist,
install it with bushes and seals into the seats on swing arm 2
(5), then install pins (3) and tighten securing bolts (2);
3
4
- install upper rods (4) with bushes in the seats of the blade (or
ripper) and on the securing plate, then install pins (3) and
tighten securing bolts (2);
4
- support adequately front attachment lift cylinder (1) with a
cable and hoist, install it with bushes and seals in the blade 1 2
(or ripper) seats, then install pins (3) and tighten securing
bolts (2); 2
- install the towing device tightening the four securing screws;
hoist, and remove it from the support stand.
F156.6 / F156.6A ATTACHMENT 6 - 25
6.3 REAR ATTACHMENT (opt.) (Ripper)
Removal
DANGER
1
Proceed as follows:
- support adequately the rear attachment with a cable and hoist;
- remove the securing bolts and extract rear attachment cyl-
inder pivot pins (1), helping the attachment during the lowering
movement;

punches.
1
2
- remove securing screws (2) and extract the rear attachment
pivot pins to the rear frame, then remove rear attachment (3)
manoeuvring the hoist as required; 2
3
- disconnect the rear frame hydraulic pipes (4) from rear at-
tachment lift cylinder (5);
- support adequately rear frame cylinder (5) with a cable and 6
hoist, remove the bush (6) securing screws and remove the
cylinder;
- repeat the operation for the other cylinder. 4
6 - 26 ATTACHMENT F156.6 / F156.6A
Installation
DANGER
4
Proceed as follows:
- support adequately the rear frame cylinder (5) with a cable
and hoist, position it in its seat, inserting the seals, install the 6
bush (6) and tighten the securing screws;
IMPORTANT – To install the pins always use appropriate 4

punches.
5
- repeat the operation for the other cylinder;
- connect the hydraulic pipes (4) of the rear frame to rear at-
tachment lift cylinders (5);
5
- support adequately the rear attachment with a cable and hoist
and install the bushes in the eyes;
- position rear attachment (3) in its seat, install the rear attach- 2
ment pivot pins to the rear frame and tighten pin securing
screws (2);
6
- install the bushes into rear attachment cylinders eyes, posi-
tion the eyes into their seats, insert the seals, install pins (1)
and tighten the securing bolts.
F156.6 / F156.6A ATTACHMENT 6 - 27
1
3
Disassembly
1
Proceed as follows:
- free springs (1), remove securing screws (2) remove ripper
bodies guard (3);
2
2
- lift ring (4), extract stop pin (5) and pull-out pin (6) securing
ripper body (7) helping the lowering movement of the body;
6
5 4
3
- support adequately the ripper body with a cable and hoist,
extract spring securing pin (8), then pull-out pivot pin (9) and
remove ripper body (7);
7
4
- extract securing spring pin (10) then separate shank (11) from
ripper body (7);
- repeat the operations with the other ripper bodies.
11
7 10
6 - 28 ATTACHMENT F156.6 / F156.6A
1
Assembly
Proceed as follows:
- install shank (11) on ripper body (7) with the relevant securing
split pin (10);
11
7 10
2
- support adequately ripper body (7) with a cable and hoist and
install it in its seat, locking it with pivot pin (9), then install
securing spring pin (8);
7
3
- place ripper body (7) in rest or work position, install pin (6)
securing the ripper body, then install stop pin (5) and lower
ring (4);
6
- repeat the operations with the other ripper bodies; 4
5
4
- install ripper bodies guard (3), tighten securing bolts (2) and
hook springs (1).
3
F156.6 / F156.6A ATTACHMENT 6 - 29
6.4 FRONT FRAME

Removal
DANGER
1
To separate the front frame from the rear one, it is recommended
that the cab and the control platform (see Section 11) be re-
moved.
Disconnect all hydraulic pipes going from the front frame to the
rear frame.
2
Remove bolt (1) securing pivot cylinder pin (2).
3
punches. 4
Remove pin (3) and separate pivot cylinders (4).
6 - 30 ATTACHMENT F156.6 / F156.6A
4
Remove nut (5) and extract the screw securing the frame con-
nection upper pin.
5
5
Support appropriately the front frame using appropriate lifting
devices.

punches. 6
Remove upper pin (6) connecting the frames.
6
Remove the screws of flange (7) securing lower pin (8).
8
7
OKs1-06-023
7
punches.
Remove lower pin (9) connecting the frames.
Separate the front frame from the rear frame.

9
F156.6 / F156.6A ATTACHMENT 6 - 31
Installation
DANGER
Check that the bushes installed in both the front and rear frame
are free from defects and lubricated.
3
punches.
Insert lower pivot pin (9).
6 - 32 ATTACHMENT F156.6 / F156.6A
4
Using two screws modified and with an appropriate length align
the lower pivot pin with the flange and insert it completely.
5
Install flange (7) securing lower pivot pin (8) and tighten the
screws to a torque of 170 Nm.
8
7
OKs1-06-023
6
punches.
Install upper pivot pin (6).

6
7
IMPORTANT – Never align holes using your fingers.
After installing upper pivot pin (6) align the pinhole with the hole
of the front frame.
F156.6 / F156.6A ATTACHMENT 6 - 33
8
Install the pin screw securing and tighten nut (5) to a torque of
250 Nm.
9
punches. 4
Install pins (3) to connect pivot cylinders (4).
10
Secure pivot cylinder pin (2) using bolt (1).
11
Connect all the hydraulic pipes between the front and the rear
frames.
Install the control platform and the cab as described in Section

11.
6 - 34 ATTACHMENT F156.6 / F156.6A
NOTES:
SECTION 7
HYDRAULIC SYSTEM
INDEX
7.1 GENERAL................................................................................................................ 7-1

7.1.1 Field of application................................................................................................... 7-1
7.1.2 Main components .................................................................................................... 7-1
7.1.3 Power generation group .......................................................................................... 7-3
7.2 HYDRAULIC DIAGRAMS........................................................................................ 7-4

7.2.1 Hydraulic diagram F156.6........................................................................................ 7-4
7.2.2 Hydraulic diagram F156.6A ..................................................................................... 7-6
7.2.3 Hydraulic diagram F156.6A Front Wheel Drive ....................................................... 7-8
7.3 MAIN FUNCTIONS.................................................................................................. 7-11

7.3.1 General .................................................................................................................... 7-11
7.3.2 Working equipments ................................................................................................ 7-11
7.3.3 Front-wheel drive (only for F156.6A) ....................................................................... 7-11
7.3.4 Brake / Steer............................................................................................................ 7-11
7.3.5 Oil cooling ................................................................................................................ 7-11
7.3.6 Special functions...................................................................................................... 7-12
7.3.7 Operation ................................................................................................................. 7-13
7.4 MAIN COMPONENTS ............................................................................................. 7-19

7.4.1 Control block............................................................................................................ 7-19
7.4.2 Double pump ........................................................................................................... 7-29
7.4.3 Valve block .............................................................................................................. 7-32
7.4.4 Hydraulic filter .......................................................................................................... 7-34
7.4.5 Hydraulic motor, blade rotating unit (geared motor orbit) ........................................ 7-35
7.4.6 Blade lift cylinder RH / LH........................................................................................ 7-36
7.4.7 Blade slewing cylinder ............................................................................................. 7-37
7.4.8 Slewing arm stop bolt cylinder ................................................................................. 7-38
7.4.9 Blade shifting cylinder.............................................................................................. 7-39
7.4.10 Tip cylinder, (blade cutting angle adjustment) ......................................................... 7-40
7.4.11 Offset cylinder.......................................................................................................... 7-41
7.4.12 Rear ripper cylinder (option) .................................................................................... 7-42
7.4.13 Front grading blade cylinder (option) ....................................................................... 7-43
7.4.14 Wheel rake cylinder ................................................................................................. 7-44
7.4.15 Steering cylinder ...................................................................................................... 7-45
7.4.16 Radial piston motor (only for F156.6A) .................................................................... 7-46
7.4.17 Oil rotating feed rotor ............................................................................................... 7-47
7.5 MAINTENANCE....................................................................................................... 7-49

7.5.1 Maintenance plan .................................................................................................... 7-49
7.5.2 Inspection operations............................................................................................... 7-49
7.5.3 Detailed description of the inspection operations .................................................... 7-50
7.6 OVERHAUL ............................................................................................................ 7-52

7.6.1 General ................................................................................................................... 7-52
7.6.2 Actuator for working equipments ............................................................................ 7-53
7.6.3 Valve block, control block (upper, lower), valves .................................................... 7-61
7.6.4 Double pump........................................................................................................... 7-64
7.6.5 Radial piston motor (only for F156.6A) ................................................................... 7-66
7.6.6 Oil rotating feed rotor .............................................................................................. 7-68
F156.6 / F156.6A HYDRAULIC SYSTEM 7-1
7.1 GENERAL
7.1.1 FIELD OF APPLICATION 7.1.2 MAIN COMPONENTS

The hydraulic system receives the control signals
from the driver and converts them in hydraulic power Working equipments
that is used by the valves and/or the hydraulic cylin- The operating of the working equipments is carried
ders in order to operate the working equipments. out hydraulically by means of the following hydraulic
The hydraulic system is made up essentially of an components:
hydraulic power generator which has to generate the 2. Blade shift cylinder
hydraulic power and of various hydraulic circuits for: 3. Hydraulic motor, blade rotating unit
- brakes, 4. Blade slewing cylinder
- steering, 5. Slewing arm stop bolt cylinder
- control of working equipments; 6. Blade lift cylinder, RH
7. Blade lift cylinder, LH
- front wheel drive (only for F156.6A).
8. Blade tip cylinder,
9. Offset cylinder
10. Rear ripper cylinder (Option)
11. Front grading blade cylinder (Option)
Steering / Front wheel drive (only for F156.6A)

The operating of the front wheel drive / steering is
achieved by means of the following hydraulic com-
ponents:
1. Wheel rake cylinder
12. Steering cylinder
13. Radial piston hydraulic motor RH / LH
Oil cooling
The oil circuit of the fan drive comprises the following
components:
- Double geared pump,
- Shut-off valve,
- Fan hydraulic motor,
- Hydraulic oil tank
7-2 HYDRAULIC SYSTEM F156.6 / F156.6A
OKs1-07-001
1. Wheel rake cylinder 8. Blade tip cylinder,

2. Blade shifting cylinder 9. Offset cylinder
3. Hydraulic motor, blade rotating unit 10. Rear ripper cylinder (Option)
4. Blade slewing cylinder 11. Front grading blade cylinder (Option)
5. Slewing arm stop bolt cylinder 12. Steering cylinder
6. Blade lift cylinder, RH 13. Radial piston hydraulic motor RH / LH
7. Blade lift cylinder, LH
F156.6 / F156.6A HYDRAULIC SYSTEM 7-3
7.1.3 POWER GENERATION GROUP

The power generation group consists basically of the On the power shaft of the Diesel engine is mounted
Diesel engine, the gearbox, the variable supply a geared double pump (5) for the brake, steering and
double pump, the geared double pump and the hy- cooling fan circuits. The hydraulic pumps mounted
draulic tank. on the different graders differ only by their design
The Diesel engine (3) is a IVECO engine, which be- and supply capacity.
longs to the New Engine Family (NEF). It is a six- The hydraulic tank (6) supplies the pumps with clean
cylinder in-line engine with turbocharger driven by and cooled oil. The feed pump integrated in the front-
the exhaust gases and with aftercooler. The exhaust wheel drive pump aspirates through the port S. The
gas values correspond to the exhaust gas Level 2 operating pump (2) aspirates oil through a separate
(TIER 2), which for this performance class applies line.
from 01.01.2004 on.
The power-shift gearbox (4) is driven by the engine.
The variable supply double pump is flanged to its
engine-dependent power take-off. It consists, for the
front-wheel drive machines, of the front-wheel drive
pump A4VG and of the operating pump (2) A10VO.
For the standard machine, only the operating pump
(2) is mounted.
3 5 4 2
7-4 HYDRAULIC SYSTEM F156.6
7.2 HYDRAULIC DIAGRAMS
7.2.1 HYDRAULIC DIAGRAM F156.6
Pos. Description
1 Pump group
4 Geared pump
10 Hydraulic tank
11 Four-circuit cooler
12 Fan motor
20 Power steering unit
21 Collecting block, steering / emergency steering with pressure switches
S17 (2.5 bar) and S17.6 (2.5 bar)
22 Steering cylinder
23 Emergency steering pump
25 Pressure relief valve, flushing circuit
30 LS valve block
31 Lower Control Block
32 Upper Control block
36 Lowering throttle valve, blade tip
40 Brake valve with pressure switch S18 (4 bar)
41 Shut-off valve with pressure switch S17.1 (90 bar)
Switch on pressure 120+8 bar,
Switch off pressure 150-8 bar
42 Hydraulic accumulator, brake system
43 Hydraulic accumulator, Parking brake 30 bar
45 Parking brake solenoid valve with pressure switch S16 (80 bar)
46 Connection with nozzle (Ø 0.8 mm)
47 Parking brake release (150 bar)
48 Wet multi-disk brake (operating pressure max 60 bar)
79 RH Blade lift cylinder
80 LH Blade lift cylinder
81 Lowering throttle valve
82 Grading blade cylinder
83 Hydraulic cylinder, offset set up
84 Hydraulic cylinder, blade tip
85 Hydraulic cylinder, shift blade
86 Hydraulic cylinder, slew blade
87 Oil rotating distributor
88 Hydraulic cylinder, wheel rake
89 Hydraulic cylinder, rear ripper
90 Hydraulic motor, rotate blade
91 Lowering throttle valve, rotate blade
92 Hydraulic cylinder, stop bolt
F156.6 HYDRAULIC SYSTEM 7-5
OKs2-07-001
7-6 HYDRAULIC SYSTEM F156.6A
7.2.2 HYDRAULIC DIAGRAM F156.6A
Pos. Description
1 Pump group
4 Geared pump
10 Hydraulic tank
11 Four-circuit cooler
12 Fan motor
20 Power steering unit
21 Collecting block, steering / emergency steering with pressure switches
S17 (2.5 bar) and S17.6 (2.5 bar)
22 Steering cylinder
23 Emergency steering pump
30 LS valve block
31 Lower Control Block
32 Upper Control block
36 Lowering throttle valve, blade tip
40 Brake valve with pressure switch S18 (4 bar)
41 Shut-off valve with pressure switch S17.1 (90 bar)
Switch on pressure 120+8 bar,
Switch off pressure 150-8 bar
42 Hydraulic accumulator, brake system
45 Parking brake solenoid valve with pressure switch S16 (80 bar)
46 Connection with nozzle (Ø 0.8 mm)
47 Parking brake release (150 bar)
48 Wet multi-disk brake (operating pressure max 60 bar)
79 RH Blade lift cylinder
80 LH Blade lift cylinder
81 Lowering throttle valve
82 Grading blade cylinder
83 Hydraulic cylinder, offset set up
84 Hydraulic cylinder, blade tip
85 Hydraulic cylinder, shift blade
86 Hydraulic cylinder, slew blade
87 Oil rotating distributor
88 Hydraulic cylinder, wheel rake
89 Hydraulic cylinder, rear ripper
90 Hydraulic motor, rotate blade
91 Lowering throttle valve, rotate blade
92 Hydraulic cylinder, stop bolt
F156.6A HYDRAULIC SYSTEM 7-7
OKs2-07-002
7-8 HYDRAULIC SYSTEM F156.6A
7.2.3 HYDRAULIC DIAGRAM F156.6A FRONT WHEEL DRIVE
Pos. Description
1 Pump group
10 Hydraulic tank
60 Wheel motor
62 6/2-way valve
63 Flow divider
64 Solenoid valve block
Y8.1 front wheel drive on/off
Y8.2 chamber change over
65 Pressure limiting valve (1.5 bar)
66 Flush & feed pressure valve (16 bar)
67 Feed pressure filter (3.5 bar)
68 Hydraulic accumulator, Front wheel drive (14 bar)
69 Distributor block with nozzle (Ø 0.8 mm)
F156.6A HYDRAULIC SYSTEM 7-9
OKs2-05-001
7 - 10 HYDRAULIC SYSTEM F156.6 / F156.6A
NOTES:
F156.6 / F156.6A HYDRAULIC SYSTEM 7 - 11
7.3 MAIN FUNCTIONS
7.3.1 GENERAL
The hydraulic system consists of the following main subsystems:
- Working equipments
- Front wheel drive (only for F156.6A)
- Brake /Steer
- Oil cooling
7.3.2 WORKING EQUIPMENTS

The operating of the working equipments is carried out hydraulically by means of hydraulic cylinders driven by
the operator via control blocks located in the cabin.
7.3.3 FRONT WHEEL DRIVE (only for F156.6A)

For the grader F156.6A a drive of the front wheels (front wheel drive) can be engaged in addition to the rear
wheel drive.
7.3.4 BRAKE / STEER

Refer to Section 8 for brakes and to Section 9 for steering.
7.3.5 OIL COOLING

The oil circuit of the fan drive comprises the following components:
- Double geared pump
- Shut-off valve
- Fan hydraulic motor
- Hydraulic oil tank
The oil circuit of the fan drive is a component of the brake and fan circuit. The oil supply is carried out through
the 1st stage of the double geared pump (Vgh = 23 cm³). It conveys the oil flow to the shut-off valve, which
controls the supply of the fan motor according to the oil demand of the braking system.
The fan motor is designed as a constant motor with predetermined sense of rotation (LH). The fan motor is
equipped with a pressure relief valve cartridge (DBV).
This valve controls the max. pressure in the fan motor. The pressure is adjusted according to the demanded
cooling capacity.
Fan motor Standard Enhanced cooling capacity
WM9A1 - 23 110 ± 5 bar 130 ± 5 bar
In case of insufficient oil supply in P channel of the motor, an integrated post-suction valve enables oil to be
aspirated from the hydraulic oil tank.
To detect the prevailing pressure, a measuring coupling is fitted to the motor housing. The return oil from the
fan motor reaches directly the tank through a hose.
OKs1-07-006
10.100. Hydraulic oil tank

15.142. Four circuits heat exchange
23.040. Shut-off valve
350. Oil supply to fan motor
351. Tank line
7.3.6 SPECIAL FUNCTIONS
Change of the working speed Emergency lowering function

The speed of the working equipments can be in- Also with a failure in the engine or control system, it
creased by selecting the fast function command. The must be still possible to lower or lift the working equip-
whole effect of the fast function command is achieved ments of graders. An emergency lowering of the
only at a higher rotational speed. As long as the fast blade is possible by operating the valves mounted
function command button remains pressed, the se- on the blade lift cylinders (RH and LH). If the machine
lected working equipments work at a faster speed. is equipped with front grading blade and/or rear
ripper, an emergency lowering is possible by means
of the control lever.
Blade setting in floating state

The Grader can be supplied with a floating position
as an option. This function allows easier working,
e.g. when the machine is used as a snow plough, as
the blade automatically follows the irregularities of
the ground.
7.3.7 OPERATION
Front wheel drive

The hydraulic subsystem concerning the front wheel The hydraulic system is protected against overpres-
drive consists of the following main devices: variable sures by means of pressure relief valves.
radial piston pump (A4VG), two radial piston motors The double variable supply pump (22.020 -
(MS11), one geared pump, 4 to 2 and 6 to 2 valves B2946289) aspirates hydraulic oil from the tank
and one oil flow divider. These main components are (10.100) mounted at the back of the rear frame. It
working in a close loop and form the front wheel drive supplies the LS valve block (22.422) with pressurised
hydraulic line. oil through a hose.
The oil flow generated by the radial piston pump is The line 205 from LS valve block is used as LS sig-
controlled by means of electro-proportional valves. nalling line and is directly connected to the pressure
The function of each single component can be ana- / supply regulator of the double pump. The pump
lysed in detail on the general hydraulic schemes re- leakage can be drained directly into the tank through
ported in the antecedent chapter. the leakage line 204.
For more detailed information refer to the Section 5. The return collector (3) is mounted on the rear frame
at the right side of the vehicle. It collects the return
oil flow of the hydraulic components as control
Working devices
blocks, blade rotation motor, stop bolt cylinder and
The working devices are operated through a Load- LS valve block.
Sensing control loop. The oil supply is provided by a
From this collecting block, oil can flow through the
pump directly controlled by a valve block which pro-
hoses 202/203 to the return flow filter (2) into the
vides as well the feedback control (load sensing).
hydraulic tank.
The system allows to perform independently at the
same time two different hydraulic commands. The oil filter, equipped with an integrated bypass
valve 1.5 bar, filters the impurities of the return oil
flow.
OKs1-07-007
2. Filter on the return line 204. Leakage hose

3. Distributor 205. Hose LS - Valves block
200. Suction hose 10.100. Hydraulic Tank
201. Hose 22.020. Double pump
202. Hose to return filter 22.422. LS-Valves block
203. Hose to return filter
The operating pump A10VO supplies the LS valve Legend of Hydraulic System, Operations:
block (Pos. 30 of hydraulic scheme) with pressurised
1 LS - Valve block
oil. In the LS valve block, the oil flow is split in two.
20.010 Return flow collector
Outlet S1 supplies the Upper Control Block and S2
supplies the Lower Control Block. The control blocks 22.501 Oil rotating distributor
are mounted one over the other in the Steering con- 61 Calibrated opening
sole. They control the oil supply to the selected 62 Plug screw
working equipments. 63 Hose
69.200 Low braking valve
The hydraulic oil reaches, through the hoses laid in
the frame, the hydraulic cylinders, mounted on the 69.230 Hydraulic cylinder
slewing arm, for the functions "lift blade, swing blade 75 Plug screw
and stop bolt slewing arm", and, on the front part of 85 Depression valve
the frame, the hydraulic cylinders for the functions 86 Pipe
"Front blade (option) and wheel rake adjustment". 210 Wheel rake cylinder - (up to - 17°)
The hoses are led through a protecting sleeve from 211 Wheel rake cylinder + (up to + 17°)
the slewing arm to the blade slewing frame. On the 212 Blade lift RH cylinder (down)
blade-slewing frame, the rotating distribution valve 213 Blade lift RH cylinder (up)
block and the hydraulic motor for the function "rotate 214 Tip cylinder (+) (blade cutting angle
blade " are linked to the Lower Control Block. The adjustment)
rotating distributor enables the oil flow to be con- 215 Tip cylinder (-) (blade cutting angle
veyed to the middle blade. The hydraulic cylinders adjustment)
for the functions "Adjust cutting angle" (tip cylinder) 216 Blade rotate (to the right)
and "Shift blade " (blade shifting cylinder) are directly 217 Blade rotate (to the left)
mounted on the blade. 218 Offset cylinder (to the right)
219 Offset cylinder (to the left)
LS SIGNAL LINES 220 Blade lift LH cylinder (up)
221 Blade lift LH cylinder (down)
The load pressure values, detected in the control 222 Blade slew cylinder (clockwise)
blocks, are sent through the LS signal lines 228/229 223 Blade slew cylinder (counterclockwise)
from the control blocks to the LS valve block. 224 Blade shifting cylinder (to the right)
225 Blade shifting cylinder (to the left)
TANK RETURN 226 Return flow line from Upper Control Block
The return lines from hydraulic cylinder stop bolt, 227 Return flow line from Lower Control Block
from the control blocks, from hydraulic motors and 228 LS signal line from Upper Control Block
from LS valve block are joined together in a collecting 229 LS signal line from Lower Control Block
block. 230 P line to Upper Control Block
This return flow collector is mounted at the right hand 231 P line to Lower Control Block
in the rear frame. From the return collector, oil 232 Offset cylinder
reaches the hydraulic tank through a hose and 233 Offset cylinder
through the return flow filter. 234 Stop bolt cylinder command line
235 Return flow line from stop bolt cylinder
236 Return flow line from LS valve block T1
237 Leakage line, hydraulic motor
239 Blade lift RH cylinder
240 Blade lift LH cylinder
right
left
OKs1-07-008
Floating position (optional)
The grader can be supplied with a floating position

as an option.
This function permits easier working, e.g. when the
machine is used as a snow plough, as the main blade
automatically follows the irregularities of the ground.
The floating position is protected by the fuse (3) and
consists of the following elements:
- two lowering throttle valves (1) with four solenoid
valves (Y3.1 to Y3.4),
- key switch (38) on control panel for activating and
deactivating the floating position function,
- button switch (S38.1) on the cab floor for setting
ON / OFF the floating position function,
- proximity switch (S38.2) mounted closed to the
stop bolt (2),
- wiring (4) with connector X68.4.
OKs1-07-048
OKs1-07-049
CCarefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)
NOTES:
7.4 MAIN COMPONENTS
7.4.1 CONTROL BLOCK
The Control Block is located in the steering console

and consists of the following two major components:
Lower LS - Control Block
Upper LS - Control Block
The main functions of the Control Blocks are:
Upper Control Block Lower Control Block

P; LS; TS - Port P; LS; TS - Port
Blade shift Blade rotate
Tip cylinder command (blade cutting angle adjustment) Rear ripper cylinder
Offset cylinder command Wheel rake adjustment
Front grading blade command Blade slew
Blade lift left cylinder Blade lift right cylinder

T; TS - Output T; TS - Output
OKs1-07-011
1. Command console
2. Lower LS - Control Block
3. Upper LS - Control Block
Upper Control Block
OKs1-07-012
Pos. Description Function

2 Input valve P; LS; TS - Port
3 Post-suction valve
4 Shift control element with load holding valve Blade shift
5 Port extension
6 Shift control element with A/B/T - connection Tip cylinder (blade cutting angle adjustment)
8 Shift control element with load holding valve Offset cylinder
10 Shift control element with load holding valve Front grading blade cylinder
11 Shift control element with load holding valve Blade lift, LH
12 Output element T; TS - Output
Lower Control Block
OKs1-07-013
Pos. Description Function

2 Input valve P; LS; TS - Port
3 Shift control element with load holding valve Blade rotate
5 Shift control element with load holding valve Ripper rear
6 Twin check valve
7 Shift control element with A/B/T- connection Wheel rake adjustment
9 Shift control element with load holding valve Blade slew
10 Shift control element with load holding valve Blade lift, RH
11 Output element T; TS - Output
12 Throttle
13 Throttle
5
2
1. P channel Input from LS-Valve Block

2. LS-Signal Output to LS Valve Block
3. TS channel Input from power steering unit
4. TS output
5. Tank channel
Control Block connections
Upper Control Block
Lower Control Block
OKs1-07-020
Upper Control Block (from the left) Lower Control Block (from the left)
226 Return line from Upper Control Block 227 Return line from Lower Control Block
220 Blade lift LH cylinder (up) 213 Blade lift RH cylinder (up)
221 Blade lift LH cylinder (down) 212 Blade lift RH cylinder (down)
Front grading blade cylinder (Option) (up) 223 Blade slew cylinder (counterclockwise)
Front grading blade cylinder (Option) (down) 222 Blade slew cylinder (clockwise)
218 Offset cylinder (to the right) 211 Wheel rake cylinder (+) (up to +17°)
219 Offset cylinder (to the left) 210 Wheel rake cylinder (-) (up to - 17°)
214 Tip cylinder (+) (blade cutting angle adjustment) Rear ripper cylinder (Option) (up)
215 Tip cylinder (-) (blade cutting angle adjustment) Rear ripper cylinder (Option) (down)
224 Blade shifting cylinder (to the right) 216 Blade rotate (to the right)
225 Blade shifting cylinder (to the left) 217 Blade rotate (to the left)
228 LS-Feedback hose from Upper Control Block 229 LS-Feedback hose from Lower Control Block
230 P-line to Upper Control Block 231 P-line to Lower Control Block
Input valve
OKs1-07-015
Input valve with intake pressure balance (7)

Input for flushing line TS
Output for load checking line to LS - valve block (LS)
Shift control element
The shift control element is a three-way valve directly The shift control element (A) controls the following
driven by the operator. The shift control element al- functions:
lows the hydraulic pressure to operate the actuators - Blade shift
(cylinders and hydraulic motors). - Offset cylinder
- Front grading blade cylinder (opt.)
The shift control element could have two different - Rear ripper (opt.)
configurations: - Blade slew
- Neutral position closed (A),
- Neutral position open (B). The shift control element (B) controls the following
functions:
- Tip cylinder (blade cutting angle adjustment)
- Blade lift, LH
- Blade rotate
- Wheel rake adjustment
- Blade lift, RH
A B
OKs1-07-050
1. Valve body
2. Shuttle
3. Control rod
Post-suction valve
This valve is fitted to the control shift valve elements:
- Function Blade shift

- Function Blade Offset
- Function grading Blade (option)
- Function rear Ripper (option)
- Function Blade slew
BALL-SPRING VERSION (OLD)
OKs1-07-016
(8) Connection to T - channel of control shift valve block

(9) Connecting channel to control shift valve block, A/B - channel
CONICAL SEAT VERSION (NEW)
OKs1-07-017
OKs1-07-018
1. Screw plug 4. O-ring

2. Valve cone 5. O-ring
3. Screw 6. Compression spring, conical
Blocking valve
Function wheel rake adjustment.

Twin no return hydraulic valve, in spherical seat version.
OKs1-07-019
1. Valve body 8. Ball

2. Screw plug 9. Cyl. Head Screw
3. Spherical guide 10. O-ring
4. Spring cap 11. O-ring
5. Valve seat 12. O-ring
6. Piston 13. O-ring
7. Spring
7.4.2 DOUBLE PUMP
General
The double pump B2946289-000 consists of the front-wheel drive (1) pump and of the operating pump (2).
Supply regulator FR
X - Port (∆p = 24 bar)
Standard adjustment:
(∆p = 24 bar)
Pressure regulator DR
Standard adjustment:
A10VODFR: 200 bar
Suction port S
High pressure port B
Leakage oil port L
OKs1-07-021
1. Four wheel drive pump

2. Operating pump
Operating pump
The supply of the hydraulic system (working equipments) is carried out by means of the variable supply pump
A10VO of the axial piston and oblique disc type. The pump operates with pressures up to 315 bar. A continuous
variation of the flow supply is obtained by changing the angle of the oblique disc. For the graders, pumps with
different flow supply are employed.
Type of Grader Pump Flow Vg max

F156.6
A 10 VO 60 DFR 60 cm3
F156.6A
The pump is equipped with a pressure / flow regulator DFR / DFR1.
PUMP TUNING
Flow controller FR
The flow controller regulates the oil supply of the pump depending on the load pressure. The piston of the
regulator - on the FR axis side - is pushed on a side by the pump pressure. The load pressure and the pre-set
force of the regulator spring counteract this pushing. When the regulator is activated on channel X by the load
pressure (LS signal), the regulator starts to change the pressure for the positioning of the oblique disc, until the
system is again in a state of equilibrium. In this manner, the pump supplies only the oil quantity required by the
user.
Pressure controller DR
The pressure controller limits the maximum allowable pressure on the pump. The pump pressure operates on
a side of the piston - on the DR axis side- of the pressure regulator. The pre-set force of the regulator spring
counteracts this pushing.
If the pump pressure exceeds the allowed value (200 bar), the piston is shifted against the spring force and
makes a direct connection between pump pressure channel and the actuating piston for the oblique disc posi-
tioning. In this way, the pressure regulator prevents the variable supply pump from being further swung out or
causes the pump to be swung back (pressure cutting-off) and holds this regulated position until the pump
pressure lies again below the pre-set pressure value of the pressure regulator.
Load signal line
LS - Load pressure
FR - Axis
DR - Axis
Actuating
supply line
High
pressure line
Diaphagm in
LS Control Block
Oil leakage line Suction line

OKs1-07-022
OK 1 07 022
DFR and DFR1 controllers

The difference between the controller types DFR and DFR1 are highlighted in the following figure.
DFR - Version
With relieving diaphragm!
(DFR: Standard: Ø 0.35 mm)
DFR1 - Version
Without relieving diaphragm!
(DFR1: closed, without Hole)
OKs1-07-023
F156.6A HYDRAULIC SYSTEM 7 - 31
Front wheel drive pump (only for F156.6A)

The oil supply to the front wheel drive motors is car- Type A4VG 71EP2
ried out by means of the variable supply pump A4VG
of the axial piston and oblique disc type. The pump Range 0 up to 71 cm³/ U
operates with pressures up to 315 bar. A continuous Flow 160 L / min
variation of the flow supply is obtained by changing
Motor MS 11
the angle of the oblique disc. For the graders, pumps
with different flow supply are employed. Displacement 1229 / 629 cm³
OKs1-07-024
21. Counterweight 302. Pression release valve

28. Nozzle 303. Valve
301. Pression release valve 401. Internal gear pump
7.4.3 VALVE BLOCK
Assembly
The valve block is assembled on the rear frame by Moreover, two solenoid valves (1) are mounted.
means of a bracket in the engine compartment at the When set in neutral position, they are open towards
left side of the vehicle. the tank. The actuation of the additional functions as
fast motion and stop bolt occurs by means of the
Function pedal switches on the driver's cab floor.
The valve block (Pos. 30, hydraulic scheme) is the If the solenoid valve Y28 is powered by the 24 V
connecting element between the variable supply supply, the pump pressure is directly conveyed to
pump and the control blocks. The variable supply the pressure / supply regulator through the check
pump conveys oil to the inlet P on the valve block. valves (5) or respectively through the shuttle valve
Relating to the maximum pressure, the operating hy- (4). The stand-by pump pressure enables the vari-
draulic system is additionally protected by the pres- able supply pump to its maximum swung out. In this
sure relief valve (2) mounted on the block. The control way, each hydraulic function can be performed at the
blocks are supplied with oil by the valve block through maximum speed. This facility provides a speeding
the outlets S1/S2. up of the working functions.
A reduced operating pressure of 25 bar is generated If the solenoid valve Y27 is activated by the 24 V line,
by the pressure reducing valve (3) for the function the pressure reduced to 25 bar is released through
stop bolt needs. outlet N3 to the secondary consumer stop bolt.
The LS signals from the control blocks are further
forwarded to the pump regulator. For the decoupling
of these LS signal pressures, two check valves (5)
and the shuttle valve (4) are fitted for each block into
the valve block body.
OKs1-07-025
1. Lower solenoid valve: speed up function,

4. Shuttle valve
Upper Solenoid valve: stop bolt,
5. Check valve
2. Pressure relief valve 215 bar
6. Nozzle Ø 2 mm
3. Pressure reducing valve 25 bar
7. Screw plug
OKs1-07-026
M1. Measuring point 200 bar Valve block

M2. Measuring point 25 bar 1. Solenoid valve Y28 (fast function)
XV1. LS line from Upper control block Solenoid valve Y27 (Stop bolt)
XV2. LS line from Lower control block 2. Pressure relief valve 215 bar
XP. LS output to the pump regulator 3. Pressure reducing valve 25 bar
P. Input flow from the pump 4. Shuttle valve
S1. Output to Upper control block 5. Check valve
S2. Output to Lower control block 6. Nozzle
T1/T2. Tank line
7.4.4 HYDRAULIC FILTER
Technical characteristics
Max. allowed pressure 10 bar
Allowed temperatures -40 °C to +100 °C
Dirt absorption capacity (∆p 1.5 bar) approx. 93 g, according to ISO 4572 (ISO MTD)
Junction G 1" ¼
OKs1-07-027
101. Filter element 104. O-ring

102. Cover 800. Repair set
103. O-ring
7.4.5 HYDRAULIC MOTOR, BLADE ROTATING UNIT (GEARED MOTOR ORBIT)
Type OMR 100
Displacement 99.8 cm3
Weight 7.0 kg
Max. rotating speed 600 min-1
Max. torque 200 Nm
Max. flow 60 L/min
Max. entry pressure 140 bar
Min. starting torque 170 Nm
OKs1-07-029
1. Screw 14. Propeller shaft

2. Lock washer 15. O-ring
3. Sealing ring 16. Plate
4. Flange 17. Spur gear set
5. Sealing ring 18. Cover
6. O-ring 19. Washer
7. Shaft collar 20. Screw
8. Needle bearing 23. Valve
9. Feather 24. O-ring
10. Bearing 25. Sealing ring
11. Housing 26. Screw plug
12. Separator 29. Repair set
13. Shaft
7.4.6 BLADE LIFT CYLINDER RH / LH
Piston Ø 100 mm
Rod Ø 50 mm
Stroke 1 010 mm
Retracted Length 1 467 mm
Extended Length 2 477 mm
Dead Length 457 mm
Bottom side
Two pins Ø d = 50 mm
Rod side
Ball D = 65.3 mm
Drawing to be completed
OKs1-07-032
7.4.7 BLADE SLEWING CYLINDER
Piston Ø 100 mm
Rod Ø 50 mm
Stroke 450 mm
Retracted Length 947 mm
Dead Length 497 mm
Bottom side
Two pins Ø d = 50 mm
Rod side
Ball D = 65.3 mm
OKs1-07-030
2. Piston rod 16. Lock washer

3. Guide 17. Lubricating nipple
4. Piston 19. Hex nut
14. Hex nut 20. Retaining ring
15. Hex. head screw 50. Sealing set
7.4.8 SLEWING ARM STOP BOLT CYLINDER
Chapter to be completed
OKs1-07-031
1. Slewing arm stop bolt Cylinder

2. Slewing arm
3. Front frame
7.4.9 BLADE SHIFTING CYLINDER
Piston Ø 80 mm
Rod Ø 45 mm
Stroke 1 400 mm
Retracted Length 1 832 mm
Dead Length 432 mm
Bottom side
Rod head screwed M36
Rod side
Rod head screwed M30
OKs1-07-028
2. Piston rod 12. Serrated lock washer

3. Guide 13. Dowel pin
4. Piston 15. Washer
6. Flange 16. Retaining ring
10. Hex nut 50. Sealing set
11. Cyl. head screw
7.4.10 TIP CYLINDER, (BLADE CUTTING ANGLE ADJUSTMENT)
Piston Ø 100 mm
Rod Ø 50 mm
Stroke 300 mm
Extended Length 915 mm
Dead Length 315 mm
Bottom side
Pin with joint bearing Ø 50 mm
Rod side
OKs1-07-033
2. Piston rod 14. Retaining ring

3. Guide 15. Hex nut
4. Piston 16. Lubricating nipple
12. Retaining ring 50. Sealing set
13. Joint bearing
7.4.11 OFFSET CYLINDER
Piston Ø 100 mm
Rod Ø 50 mm
Stroke 367 mm
Dead Length 339 mm
Bottom side
Rod side
OKs1-07-034
2. Piston rod 14. Retaining ring

3. Guide 15. Retaining ring
11. Retaining ring 17. Lubricating nipple
12. Joint bearing 50. Sealing set
13. Joint bearing
7.4.12 REAR RIPPER CYLINDER (OPTION)
Piston Ø 100 mm
Rod Ø 50 mm
Stroke 250 mm
Dead Length 335 mm
Bottom side
Rod side
OKs1-07-035
2. Piston rod 23. Joint bearing

3. Piston 25. Retaining ring
4. Guide 26. Supporting washer
5. Spring ring 27. Retaining ring
21. Retaining ring 28. Hex nut
7.4.13 FRONT GRADING BLADE CYLINDER (OPTION)
Piston Ø 120 mm
Rod Ø 60 mm
Stroke 428 mm
Dead Length 355 mm
Bottom side
Rod side
OKs1-07-036
10. Cylinder pipe 130. Scraper

20. Piston rod 140. Rod sealing
60. Joint bearing 160. Guide ring
70. Guide 170. Groove ring
80. Piston 210. Guide ring
120. Lubricating nipple 220. Sealing set
7.4.14 WHEEL RAKE CYLINDER
F156.6 F156.6A
Piston Ø 80 mm 80 mm
Rod Ø 45 mm 45 mm
Stroke 173 mm 203 mm
Retracted Length 481 mm 540 mm
Extended Length 654 mm 743 mm
Dead Length 308 mm 337 mm
Bottom side
Pin with joint bearing Ø 40 mm 45 mm
Rod side
Pin with joint bearing Ø 40 mm 45 mm
OKs1-07-037
2. Piston rod 14. Lubricating nipple

3. Guide 15. Retaining ring
12. Joint bearing 19. Retaining ring
7.4.15 STEERING CYLINDER
Piston Ø 50 mm
Rod Ø 25 mm
Stroke 300 mm
Dead Length 212 mm
Bottom side
Rod side
Rod head screwed M24x1.5
OKs1-07-038
2. Piston rod 9. Hex nut

3. Guide 50. Sealing set
4. Piston
7 - 46 HYDRAULIC SYSTEM F156.6A
7.4.16 RADIAL PISTON MOTOR

(only for F156.6A)
The two radial piston motors work on the radial piston Technical characteristics
principle: i.e. the radial position of the pistons de- Connections:
pends on the rotating speed of the motor. Because A Supply hose to motor with default rotation direc-
of the rotating of the cylinder block the pistons move tion A = Forward
on a camshaft and the movement is converted to a R Return hose
radial movement. 1 Leakage hose
From inside the cylinders are connected via the valve Y Change of displacement
controlling the partitioning of the flow with the high
pressure and return channels. The enabled 6/2 con-
trol valve operates from the inside on the piston sur-
faces by means of the pressure on the control line,
which pushes the pistons on the camshaft.
Chapter to be completed
OKs1-07-039
3. Cover 6. Covering
4. Control plate 7. Cover assy.
5. Cylinder block 800. Sealing set
7.4.17 OIL ROTATING FEED ROTOR
Max rotating speed 12 rpm
Starting torque 100 Nm
Running torque 80 Nm
Allowed temperatures - 20 °C to +90 °C
Junctions M22 x 1.5
STATOR ROTOR
OKs1-07-040
A Hose 247 from lowering throttle valve, blade tip 1 Hose 242 to Blade tip cylinder (-)
B Hose 225 from upper Control Block 2 Hose 245 to Blade shifting cylinder (to the left)
C Hose 224 from upper Control Block 3 Hose 244 to Blade shifting cylinder (to the right)
D Hose 246 from lowering throttle valve, blade tip 4 Hose 243 to Blade tip cylinder (+)
NOTES:
7.5 MAINTENANCE
7.5.1 MAINTENANCE PLAN
Maintenance operations
Component Maintenance stage
and main inspection
1 Hydraulic motor, blade rotating unit Check Visual
2 Cylinders (all) Check Visual
3 Valve block Check Visual
4 Control Block (Upper, Lower) Check Visual
5 Valves (all) Check Visual
6 Double pump Check Visual
7 Radial piston motor Check Visual
8 Oil rotating feed rotor Check Visual
9 Hydraulic motor, blade rotating unit Complete inspection Inspection
10 Cylinders (all) Complete inspection Inspection
11 Valve block Complete inspection Inspection
12 Control Block (Upper, Lower) Complete inspection Inspection
13 Valves (all) Complete inspection Inspection
14 Double pump Complete inspection Inspection
15 Radial piston motor Complete inspection Inspection
16 Oil rotating feed rotor Complete inspection Inspection
7.5.2 INSPECTION OPERATIONS Hydraulic actuators

This paragraph contains indications and technical The check of the hydraulic motor and cylinders must
data for the execution of the most important checks be carried out in compliance with the directives of the
when inspecting the hydraulic system of the grader. corresponding specifications.
Cleaning Valve Block, Control Block, Valves

After the specified operating time carry out a visual The check on the valves must be carried out in com-
check of the external state of the device. In case this pliance with the directives of the corresponding spec-
check cannot be carried out because of dirt or grease, ifications.
first clean it up.
- Do not clean with oil types, which could possibly Radial piston motor
damage seals or coatings. The check on the motor must be carried out in
- Before cleaning with chemical products, ascertain compliance with the directives of the corresponding
that these could not cause any damages on rubber specifications.
parts. No product containing hydrocarbons must
be used. Oil rotating feed rotor
- When cleaning, the temperature of the liquid must The check on the rotor must be carried out in com-
be kept under 80 °C. pliance with the directives of the corresponding spec-
- Avoid directing the water jet against the labyrinth ifications.
rings of the gearbox and the wheel set bearings.
7.5.3 DETAILED DESCRIPTION OF THE INSPECTION OPERATIONS
Component Action to be taken Cross reference

1 Hydraulic motor, blade rotating
unit
After the specified operating time, carry out
a visual check on the external appearance
of the device
In case this check cannot be carried out
because of dirt or grease, first clean it up
Clean up the body by means of a steam jet
on the required points, or clean up with a
brush soaked with petrol and then dry up with
compressed air
To remove the dirt from the body, no
sharp or pointed tool must be used
If necessary, replace the hydraulic motor

2 All Cylinders
a visual check of the external state of the
cylinders
because of dirt or grease, first clean them up
Cylinder body
The external appearance of the cylinder must
not show any compression points or
deformations on the surface of the cylinder
liner
Clean up the cylinder body by means of a
steam jet on the required points, or clean up
with a brush soaked with petrol and then dry
up with compressed air
To remove the dirt from the cylinder
body, no sharp or pointed tool must
be used
If necessary, replace the cylinder
3,4,5 Valve Block, Control Blocks
(Upper, Lower), Valves
a visual check of the external state of the
valves
because of dirt or grease, first clean them up
compressed air
If necessary, replace the valve

6 Double pump
of the double pump
compressed air
If necessary, replace the pump

7 Radial piston motor
of the device
compressed air
If necessary, replace the Radial piston motor

8 Oil rotating feed rotor
of the device
compressed air
If necessary, replace the Oil rotating feed

rotor
7.6 OVERHAUL
7.6.1 GENERAL
Overhaul plan
Component Main inspection Cross reference

1 Actuators for working equipments remove, disassemble and check
2 Valve block remove, disassemble and check
3 Control Block (Upper, Lower) remove, disassemble and check
4 Valves (all) remove, disassemble and check
5 Double pump remove, disassemble and check
6 Radial piston motor remove, disassemble and check
7 Oil rotating feed rotor remove, disassemble and check
Actuators for working equipments

The working equipments are driven by the following components:
- Hydraulic motor, blade rotating unit (geared motor Orbit)
- Blade lift cylinders RH/LH
- Blade slewing cylinder
- Slewing arm stop bolt cylinder
- Blade shifting cylinder
- Tip cylinder (blade cutting angle adjustment)
- Offset cylinder
- Rear ripper cylinder (Option)
- Front grading blade cylinder (Option)
OKs1-07-041
1. Working equipment, assembly centre

10. Blade lift cylinders (RH / LH)
11. Blade slewing cylinder
7.6.2 ACTUATOR FOR WORKING EQUIPMENTS

1 Hydraulic motor, blade rotating When necessary the hydraulic motor shall
unit be removed and overhauled
Remove the hydraulic motor from the Section 6
working equipment Page 7-57
Disassemble the hydraulic motor Page 7-35
All components shall be accurately cleaned
up and the parts referred to positions 29
(repair set) shall be replaced
In addition, a visual check of spur gear set,
plate, cover etc. is to be carried out, faulty
items shall be replaced
Assemble the hydraulic motor Page 7-35
Mount the hydraulic motor in its position onto Section 6
the working equipment, fasten it with the Page 7-57
screws
2 Blade lift cylinder When necessary the cylinder shall be
removed and overhauled
Remove the cylinder from the frame Section 6
Page 7-56
Disassemble the cylinder Page 7-36
(sealing set) shall be replaced
In addition, a visual check of piston rod,
guide, piston etc. is to be carried out, faulty
Assemble the cylinder Page 7-36
Mount the cylinder in its position onto the Section 6
frame, fasten it with the screws, complete Page 7-56
with washers on the threaded pins
3 Blade slewing cylinder When necessary the cylinder shall be
Page 7-56

4 Slewing arm stop bolt cylinder When necessary the cylinder shall be
Page 7-56
5 Blade shifting cylinder When necessary the cylinder shall be
Remove the cylinder from the working Section 6
equipment Page 7-57
working equipment, fasten it with the screws, Page 7-57
complete with washers on the threaded pins
6 Tip cylinder When necessary the cylinder shall be
Remove the cylinder from the working Section 6
equipment Page 7-57
working equipment, fasten it with the screws, Page 7-57
complete with washers on the threaded pins

7 Offset cylinder When necessary the cylinder shall be
Page 7-58
8 Rear ripper cylinder When necessary the cylinder shall be
Page 7-59
9 Front grading blade cylinder When necessary the cylinder shall be
Page 7-60
OKs2-07-003
1. Lift cylinder 4. Slewing arm

2. Blade slewing cylinder 5. Fork
3. Slewing arm stop bolt cylinder
OKs1-07-042
2. Rotating rim 240. Hose (Geared motor Orbit)

3. Blade shifting cylinder 241. Hose (Geared motor Orbit)
4. Blade tip cylinder 242. Hose (Blade tip cylinder)
5. Oil rotating feed rotor 243. Hose (Blade tip cylinder)
6. Protecting metal sheet 244. Hose (Blade shifting cylinder)
7. Worm gear pair 245. Hose (Blade shifting cylinder)
22.501. Oil rotating feed rotor 246. Hose (from lowering throttle valve, blade tip)
23. Roller rotating rim 247. Hose (from lowering throttle valve, blade tip)
24. Geared motor Orbit
OKs1-07-044
2. Rear frame 22. Cyl. head screw

3. Offset cylinder 30. Lubricating nipple
4. Drawbar 34. Bolt
5. Plug bolt 35. Dowel pin
6. Bolt 36. Hex. head screw
12. Ring 37. Washer
14. Connector 38. Oil control ring
18. Cover 39. Ring
19. Oil control ring 40. Chain
20. Hex nut
OKs1-07-046
1. Shift lever 381. Hose

2. Threaded rod 382. Hose
3. Control Block, Lower 383. Hose
4. Hose bracket 384. Hose
5. Rear ripper cylinder 385. Hose
6. Tap spanner 386. Hose
380. Hose 387. Hose
OKs1-07-045
1. Shift lever 4. Lower Control Block

2. Cylinder, grading blade 5. Hose
3. Upper Control Block 7. Throttle
7.6.3 VALVE BLOCK, CONTROL BLOCK (UPPER, LOWER), VALVES

1 Valve Block When necessary the Valve Block shall be
Remove the Valve Block from the frame Page 7-63
Disassemble the Valve Block Page 7-32
up and checked
The sealings shall be replaced
Faulty items shall be replaced
Assemble the Valve Block Page 7-32
Mount the Valve Block in its position onto the Page 7-63
frame, fasten it with the screws, complete
with washers and seals
2 Control Block When necessary the Control Block shall be
Remove the Control Blocks from the frame Page 7-63
Disassemble the Control Blocks Page 7-20/21
up and checked
Assemble the Control Blocks Page 7-20/21
Mount the Control Blocks in its position onto Page 7-63
the frame, fasten it with the screws, complete
3 Valves When necessary the valves shall be removed
and overhauled
Remove the valves from the control blocks Page 7-20/21
Disassemble the valves Page 7-24 to 7-28
up and checked
Assemble the valve Page 7-24 to 7-28
Mount the valve in its position onto the control Page 7-20/21
blocks, fasten it with the screws, complete
1 LS - Valve block
20.010 Return flow collector
22.501 Oil rotating distributor
61 Calibrated opening
62 Plug screw
63 Hose
69.200 Low braking valve
69.230 Hydraulic cylinder
75 Plug screw
85 Depression valve
86 Pipe
210 Wheel rake cylinder - (up to - 17°)
211 Wheel rake cylinder + (up to + 17°)
212 Blade lift RH cylinder (down)
213 Blade lift RH cylinder (up)
214 Tip cylinder (+) (blade cutting angle adjustment)
215 Tip cylinder (-) (blade cutting angle adjustment)
216 Blade rotate (to the right)
217 Blade rotate (to the left)
218 Offset cylinder (to the right)
219 Offset cylinder (to the left)
220 Blade lift LH cylinder (up)
221 Blade lift LH cylinder (down)
222 Blade slew cylinder (clockwise)
223 Blade slew cylinder (counterclockwise)
224 Blade shifting cylinder to the right
225 Blade shifting cylinder to the left
226 Return flow line from Upper Control Block
227 Return flow line from Lower Control Block
228 LS signal line from Upper Control Block
229 LS signal line from Lower Control Block
230 P line to Upper Control Block
231 P line to Lower Control Block
232 Offset cylinder
233 Offset cylinder
234 Stop bolt cylinder command line
235 Return flow line from stop bolt cylinder
237 Leakage line, hydraulic motor
239 Blade lift RH cylinder
240 Blade lift LH cylinder
right
left
OKs1-07-008
7.6.4 DOUBLE PUMP

1 Double pump When necessary the Double pump shall be
Remove the Double Pump Section 2
Page 7-65
Disassemble the Double pump Page 7-31
Inspect Pump (1) and Pump (2).
up and checked. The sealings shall be
replaced. Faulty items shall be replaced
Insert a new seal on Pump (2). Assemble Page 7-31
Pump (2) and Pump (1)
Mount the Double Pump in its position onto Section 2
the transmission, fasten it with the screws, Page 7-65
complete with washers and seals
OKs1-07-051
1. Front-wheel drive pump

2. Operating pump
OKs1-07-007
2. Filter on the return line 204. Leakage hose

3. Distributor 205. Hose LS - Valves block
200. Suction hose 10.100. Hydraulic Tank
201. Hose 22.020. Double pump
202. Hose to return filter 22.422. LS-Valves block
203. Hose to return filter
7 - 66 HYDRAULIC SYSTEM F156.6A
7.6.5 RADIAL PISTON MOTOR

(only for F156.6A)

1 Radial piston motor When necessary the Radial piston motor
shall be removed and overhauled
Remove the Radial piston motor Section 5
Page 7-67
Disassemble the Radial piston motor
up and checked
Assemble the Radial piston motor
Mount the Radial piston motor in its position, Section 5
fasten it with the screws, complete with Page 7-67
washers and seals
OKs1-07-039
3. Cover 6. Covering
4. Control plate 7. Cover assy.
5. Cylinder block 800. Sealing set
F156.6A HYDRAULIC SYSTEM 7 - 67
7
11
11
9
OKs1-07-047
7. Wheel rake cylinder 9. Radial piston motor RH

8. Radial piston motor LH 11. Steering cylinder
7.6.6 OIL ROTATING FEED ROTOR

1 Oil rotating feed rotor When necessary the Oil rotating feed rotor
shall be removed and overhauled
Remove the Oil rotating feed rotor Section 6
Disassemble the Oil rotating feed rotor
up and checked
Assemble the Oil rotating feed rotor
Mount the Oil rotating feed rotor in its position Section 6
onto the working equipment, fasten it with the
screws, complete with washers and seals
STATOR ROTOR
OKs1-07-040
A Hose 247 from lowering throttle valve, blade tip 1 Hose 242 to Blade tip cylinder (-)
B Hose 225 from upper Control Block 2 Hose 245 to Blade shifting cylinder (to the left)
C Hose 224 from upper Control Block 3 Hose 244 to Blade shifting cylinder (to the right)
D Hose 246 from lowering throttle valve, blade tip 4 Hose 243 to Blade tip cylinder (+)
SECTION 8
BRAKE SYSTEM
INDEX
8.1 SYSTEM OPERATION............................................................................................ 8-1

8.1.1 Generalities.............................................................................................................. 8-1
8.1.2 Technical data ......................................................................................................... 8-1
8.1.3 Service brake........................................................................................................... 8-2
8.1.4 Parking brake........................................................................................................... 8-4
8.1.5 Brake diagram ......................................................................................................... 8-6
8.2 BRAKE SYSTEM COMPONENTS - OPERATION DESCRIPTION ........................ 8-9

8.2.1 Accumulator loading valve - cut-off valve ................................................................ 8-9
8.2.2 Brake valve .............................................................................................................. 8-12
8.2.3 Warning and signalling devices ............................................................................... 8-14
8.2.4 Assembly position.................................................................................................... 8-15
8.3 TROUBLESHOOTING............................................................................................. 8-17

F156.6 / F156.6A BRAKE SYSTEM 8-1
8.1 SYSTEM OPERATION
8.1.1 GENERALITIES The braking pressure can be tested by measuring

points on the tandem housings. In this case, one
The new grader generation F156.6 is equipped with measuring point for each lamellar brake.
a hydraulic two-circuit braking system with 4 oil-
cooled lamellar brakes operating on the tandem
wheels. After the end of the braking operation, the braking
pressure escapes through the brake valve and the
The braking system is fed by the 2nd gear of the dual return pipe pressureless into the hydraulic reservoir.
gear pump on the Diesel engine with a constant
volume flow rate. See braking diagram
The feed rates is 23 cm3 / rev.
The braking system is divided into
- Service brake
- Parking brake.
Lamellar brake
Great friction diameter: 245 mm
Small friction diameter: 165 mm
Number of friction areas per wheel: 8
Number of brake discs: 4x4
Effective braking areas: 4 x 2060 cm2
Wheel cylinder
Ring area:
• Great diameter: 240 mm
• Small diameter: 228 mm
Ratio between brake and wheel: i = 6.0
8-2 BRAKE SYSTEM F156.6 / F156.6A
8.1.3 SERVICE BRAKE 2. Cut-off valve

4. Pressure accumulators, 50 bar pre-load pressure
The cut-off valve, applied separately (under the 10. Dual gear pump
landing platform at the left), regulates the pressurized 101. Brake valve
filling of the pre-loaded nitrogen accumulator up to 102. Stop lamp switch S 18
50 bar in the braking system. The oil feeding is inter- 275. Inlet pipe, braking system / fan
276. Delivery pipe, pump - cut-off valve
rupted at a pressure of 150 - 8 bar; if pressure drops
277. Feeding pipe, to pressure accumulator brake circuit I
to 120 + 8 bar, a new filling is carried out. The switch
278. Feeding pipe, to pressure accumulator brake circuit II
on-off pressure can be tested by a measuring point 279. Connection pipe, cut-off valve - brake valve brake
on the cut-off valve (output 28). circuit II
280. Connection pipe, cut-off valve - brake valve brake
Two nitrogen accumulators are installed in driving circuit I
direction at the left of the front of the rear frame. 281. Brake pipe, brake valve - Tandem, brake circuit I
They provide the two brake circuits with the storage 282. Brake pipe, brake valve - Tandem, brake circuit II
pressure. The 3rd nitrogen accumulator is directly 283. Brake pipe, brake valve - Tandem, brake circuit II
fitted to the cut-off valve. It absorbs any shocks while 284. Brake pipe, brake valve - Tandem, brake circuit I
switching in the valve and provides the braking cir- 285. Brake pipe, brake valve - Tandem, brake circuit I
286. Tank pipe
cuits with additional storage pressure.
292. Tank pipe, brake valve
The brake valve is directly operated by the brake
pedal. While actuating the brake pedal, a pressure
switch 4 bar on the brake valve activates the power
supply for the stop lamps. A maximum braking pres-
sure of 60 ± 4 bar is ensured inside the brake valves.
286
292
282 101
281
283 280
2.1
1.1
2.2 275
1.2
5.2 279
2.3
104
292 2.5
102 18
276
10
283 286
285
22
275
285
279 284
281
276
280 2
5
282 284
278
4 277
OKs1-08-001
8.1.4 PARKING BRAKE 2. Cut-off valve

10. Dual gear pump
A disc brake fitted near the rear output of the power 30. Parking brake solenoid valve, Y 16
31. Pressure accumulator, 90 bar pre-load pressure
shift gearbox is used as a parking brake. In the idle
32. Pressure accumulator, 30 bar pre-load pressure
position, it is closed by spring force. (Spring force
33. Pressure switch 80 bar, S 16.1
accumulator principle). 39. Throttle valve diam. 0.8 mm
65. Latching switch P - Brake, S 16
Like the service brake, the parking brake is fed by 101. Brake valve
the dual gear pump. 275. Inlet pipe, braking system / fan
276. Delivery pipe, pump - cut-off valve
The cut-off valve regulates the pressurized filling of 286. Tank pipe
the nitrogen accumulator, pre-loaded at 90 bar, of 287. Feeding pipe, pressure accumulator - parking brake
the parking brake (in driving direction at the right 288. Feeding pipe, parking brake solenoid valve -
hand) and provides P-Channel of solenoid valve Y16 pressure accumulator
289. Feeding pipe, cut-off valve - parking brake solenoid
with oil.
valve
290. Feeding pipe, cut-off valve - parking brake solenoid
If the solenoid valve is activated, first the pressure valve
accumulator 30 bar is filled and then the brake cyl- 291. Feeding pipe, cut-off valve - pressure switch
inder P - Brake is supplied with oil. The parking brake
is released.
In no voltage condition of the solenoid valve, the

brake cylinder is connected with the tank. The pres-
sure accumulator 30 bar and a return throttle fitted
into the tank channel of the valve, diam. 0.8 mm,
bring about a checked outlet of the brake oil from the
brake cylinder. The parking brake falls down in a sof-
tened way and closes.
286
32 286
39 288
32 30
39290 Y16 288
33
S16.1
30
290 Y16
101 287
33 288
S16.1 287
101 287
288
287
275
275
10 276
291
65 286
S16 10 276
291
31
65 286
290 S16
31 291
275
290
291289
289 275
289 276
2
289
5
276
2
5
OKs1-08-002
8.1.5 BRAKE DIAGRAM
2. Cut off valve

switch off pressure 150 - 8 bar
switch on pressure 120 + 8 bar
4. Pressure accumulators 0.75 Liters
pre-loaded pressure 50 bar
8. Pressure switch 90 bar
10. Dual gear pump
11. Steering circuit
12. Multi disc inside Ø 245 mm
operating pressure max 60 ± 4 bar
13. Parking brake
30. Parking brake solenoid valve, Y16
31. Pressure accumulator 0.75 Liters
32. Pressure accumulator 0.08 Liters
33. Pressure switch 80 bar
101. Brake valve 60 bar
102. Stop lamp pressure switch 4 bar
30 32
8 31
Ø 0.8
4 33
13
1 28 27
24
23
11 21
21
11
22
25
23
2 5 10
22
12
16
101
23
102
12
12 bar
0.04 bar
0. 7 bar
1.5 bar
OKs2-08-001
8.2 BRAKE SYSTEM COMPONENTS - OPERATION DESCRIPTION
8.2.1 ACCUMULATOR LOADING VALVE - CUT-OFF VALVE
Purpose
The cut-off valve regulates the pressure level in the stand-by accumulators.
OKs1-08-004
A. Main slide valve 1. Pump flow input

B. Control slide valve with 2 latching positions 5. Output to fan motor
C. Spring pile 21. Output to brake valve 11 & hydraulic accumulator,
D. Check valve brake circuit I
E1. Latching positions 22. Output to brake valve 12 & hydraulic accumulator,
E2. Latching positions brake circuit II
F. Connecting hole 23. Output to solenoid valve, parking brake
G. Bore 27. Output to hydraulic accumulator on cut-off valve
H. Check valve to brake valve 28. Port, braking pressure warning switch 90 bar
8 - 10 BRAKE SYSTEM F156.6 / F156.6A
Mode of operation
POSITION "ON"
When the braking system is ready for operation (i.e. output 5 through borehole (G).
the stand-by accumulators are filled up), the pump The check valve (D) in the borehole to port 27 en-
flow stands by directly at port 1 of cut-off valve. Be- sures the storage pressure of the shift accumulator.
tween port 1 and port 5 there is a connection, so that This is available as an additional braking volume for
the pump flow is directly forwarded to the steering the braking system and prevents the device from
system with a slight difference in pressure. The back being too frequently shifted in case of leakage. In
space of main slide valve (A) is pressureless. The addition, the check valves (H) prevent every single
braking system pressure holds the control slide valve brake circuit from having a pressure decrease in case
(B) in latching position (E1), in which the back space of pipe breakage.
of main slide valve (A) is directly connected with
Pressure accumulator 3
Spring
Fan Motor
OKs1-08-005
• Control slide valve B in latching position E1

• Hydraulic accumulator filled up, cut-off pressure 150 - 8 bar attained
• F & D closed
F156.6 / F156.6A BRAKE SYSTEM 8 - 11
LOADING OPERATION
If the accumulator pressure drops to the specified flow can continue to reach, through output 5, the
value of 120 bar, the control slide valve (B) over- steering system, while the remaining flow can arrive,
comes the existing latching position (E1) by the force through the check valve (D) to ports 21; 22; 23, at
of the spring pile (C) and moves to a new latching the braking system, till the pressure in the braking
position (E2). Through the connecting borehole (F), system attains the value of ca. 150 bar. The control
an oil flow moves in the back space of the main slide slide valve (B) moves to the latching position (E1),
valve (A). The pressure produced in the back space in which the connection of port 1 to port 5 is made.
of main slide valve (A) and the pressure standing- The whole pump flow goes directly to the steering
by under the main slide valve (A) move the main system. The check valve (D) ensures again the shift
slide valve (A) to a floating position, so that a partial accumulator pressure.
Hydraulic accumulator 3
Spring
Fan motor
OKs1-08-006
• Control slide valve B in latching position E2

• Main slide valve A in floating position
• F / D open
• Switch-on pressure 120 + 8 bar achieved
8 - 12 BRAKE SYSTEM F156.6 / F156.6A
8.2.2 BRAKE VALVE 3 FULL BRAKING POSITION

If the pedal (B) is fully actuated, a position of braking
Purpose
termination is achieved and the accumulator ports
11/112 are connected to brake cylinder ports 21/22.
The brake valve has the purpose of producing or re-
In this case, the return ducts 51/52 are shut off.
ducing, with a fine adjustment, the braking pressure
by operating the pedal (or the control lever).
At the termination of the braking operation, the brake
cylinder ports 21/22 are again connected to the return
duct ports 51/52 and the accumulator ports 11/12 are
Mode of operating
closed.
1 POSITION "ON"
In case of one brake circuit failure, the other is still
When the braking system is ready for service, the fully in working order due to the slide valve arrange-
accumulator pressure stands-by directly at port 11/ ment in the valve. This happens owing to the me-
12 of foot brake valve. Between ports 21/22 and ports chanical control of both slide valves and requires a
51/52 there is a connection, so that the wheel brakes bit longer pedal travel.
(ports 21/22) are operated pressureless through the
return ducts (ports 51/52).
4 BRAKING PRESSURE LIMITATION
The pedal stop screw (D) on the support plate (E)
2 PARTIAL BRAKING
under the pedal (B) serves to limit the braking pres-
When operating the brake valve, a corresponding hy- sure.
draulic braking pressure is produced, which is pro-
portional to the applied foot force. The spring pile (A)
under the support plate (E) is configurated in such a 5 CIRCUIT FAILURE
way that the braking pressure varies according to the
In case of failure of the lower circuit, the upper brake
angular adjustment. In the lower range of the braking
circuit is still working. The slide valve (C1) is mechan-
pressure, the vehicle can be decelerated gradually
ically operated by the spring pile (A). In case of failure
and precisely.
of the upper circuit, the lower circuit is still working.
In this case, the lower slide valve (C2) is mechanically
To start the braking operation, the upper slide valve
actuated by the spring pile (A) and by the slide valve
(C1) is actuated by the spring pile (A) mechanically
(C1).
and the lower slide valve (C2) by the slide valve (C1)
hydraulically.
The slide valves (C1 & C2), which move downwards,
close first the return ducts 51/52 by the control edges
and then connect the accumulator ports 11/12 to the
wheel brake cylinder ports 21/22. The introduced foot
force determines now the braking pressure to be pro-
duced. The control slide valves (C1 & C2) are held
in the regular position (force equilibrium) by the foot
force (spring pile) through the slide valves and by the
hydraulic pressure under the slide valves. At the end
of the braking pressure introduction, the slide valves
(C1 & C2) are in a partial braking position, so that
ports 11/12 and 51/52 close and hold the standing-
by pressure in ports 21/22.
F156.6 / F156.6A BRAKE SYSTEM 8 - 13
OKs1-08-007
A. Spring pile 1.1. Input from cut-off valve

B. Pedal 1.2. Input from cut-off valve
C1. Control slide valve 2.1. Brake circuit, front
C2. Control slide valve 2.2. Brake circuit, rear
D. Pedal stop screw 2.4. Void
2.5. Port, stop lamp switch 4 bar
5.2. Return to the Tank
8 - 14 BRAKE SYSTEM F156.6 / F156.6A
8.2.3 WARNING AND SIGNALLING

DEVICES
Pressure Switch (8, S 17.1)
The pressure switch (S17.1) is fitted to the output sure" on the console and, while the engine is
(DS2) at the left side of the brake accumulator running, by a continuous buzzer tone about a too low
loading valve. The pressure switch is set to 90 brake accumulator pressure. While loading the ac-
bar, if the storage pressure drops under 90 bar, cumulator, the pressure switch turns off the warning
the pressure switch closes und warns the driver signals only after achieving a pressure of 115 bar.
by means of the tell-tale "Brake accumulator pres-
X4
4
8
S17.1
2
28
23
22 1
21
27
23
22
21
OKs1-08-008
Pressure Switch (33, S 16.1) Pressure Switch (102, S 18)
The pressure switch (33) is fitted into the feeding pipe At the right side of the brake valve, on output (2.5),
to the pressure accumulator of the parking brake. If there is the pressure switch (102). If pressure in brake
in the hydraulic circuit P - Brake there is a pressure circuit II increases over 4 bar, the pressure switch
over 80 bar, the switch is closed. closes und stop lamps are activated.
In this way, the tell-tale "Parking Brake" on the con-
sole is deactivated.
F156.6 / F156.6A BRAKE SYSTEM 8 - 15
8.2.4 ASSEMBLY POSITION
Service brake
Representation of the service brake components under the landing platform:
1 2
4
3
1. Brake valve with pressure switch S 18

2. Cut-off valve with pressure accumulator
3. Pressure switch S 17.1
4. Feeding pipe for the braking system 276
8 - 16 BRAKE SYSTEM F156.6 / F156.6A
Parking brake
Representation of the parking brake components fitted to the gearbox.
Parking brake solenoid valve Y 16

with pressure accumulator 30 bar
1
3 4
OKs1-08-010
1. Tank 3. Parking brake cylinder

2. Brake 4. Pressure switch S 16.1
F156.6 / F156.6A BRAKE SYSTEM 8 - 17
8.3 TROUBLESHOOTING
The chapter is still to be completed
8 - 18 BRAKE SYSTEM F156.6 / F156.6A
NOTES:
SECTION 9
STEERING SYSTEM
INDEX
9.1 SYSTEM OPERATION............................................................................................ 9-1

9.1.1 Generalities.............................................................................................................. 9-1
9.1.2 Technical data ......................................................................................................... 9-1
9.1.3 Steering hydraulic system........................................................................................ 9-2
9.1.4 Emergency steering system .................................................................................... 9-2
9.1.5 Steering diagram ..................................................................................................... 9-4
9.2 STEERING SYSTEM COMPONENTS - OPERATION DESCRIPTION.................. 9-7

9.2.1 Collecting block steering / emergency steering ....................................................... 9-7
9.2.2 Steering servostat.................................................................................................... 9-8
9.2.3 Transverse flushing ................................................................................................. 9-11
9.2.4 Safety valve 12 bar .................................................................................................. 9-11
F156.6 / F156.6A STEERING SYSTEM 9-1
9.1 SYSTEM OPERATION
9.1.1 GENERALITIES
The graders are equipped with a hydrostatic front-

wheel steering, which is actuated by the steering
wheel. The steering systems of the grader types are
distinguished mainly by their components and rele-
vant dimensions. The functional principle is equal.
The steering system is composed of the following:
- steering Servostat (consisting of metering pump

and control valve as a unit),
- two steering cylinders,
P1 P2
- steering pump (P1),
- collecting block,
- emergency steering pump (P2),
- cooler, P1. Steering pump: 16 cm3 / rev
- safety valve 12 bar, P2. Emergency steering pump on gearbox: 16 cm3 / rev
- hydraulic oil reservoir.
Wheel lean: 0°
Kingpin angle: 0°
Caster angle: 0°
Toe-in: 3 to 6 mm
Steering wheel Ø: 400 mm
Dual pump: J. Barnes Nr. WP15 A2-C-230-160-L-05-KA-151/153N-E246
Displacement0 16 cm3 / rev
Emergency Displacement 16 cm3 / rev
steering pump: max. 25 L/min
Servostat: Rexroth-Nr. LAGC160n12-R-150M01-000S
Width of the rotator 21.1 mm
Displacement/Steering wheel rotation0 160 cm3
Pressure 150 bar
Steering cylinders: Ø 50/25-300 mm stroke
9-2 STEERING SYSTEM F156.6 / F156.6A
9.1.3 STEERING HYDRAULIC SYSTEM 9.1.4 EMERGENCY STEERING SYSTEM
The pressurised oil feeding for both grader types is In case of failure of the steering pump or of the en-
carried out by a separate gear pump. The steering gine, the grader remains still steerable. The emer-
pump (1) fitted to the PTO (Power Take-off) of the gency steering pump at ERGO - POWER undertakes
Diesel engine draws oil from the hydraulic tank then the oil supply. The failure of the steering system
through the pipe line (266) and delivers it through supply is signalled on the console - beginning from
the collecting block to input (P) of the steering "Ser- ca. 3 km/h - by the warning tell-tale "Steering / Emer-
vostat". gency Steering" and by a continuous warning tone.
Depending on the steering motion, the steering "Ser-

vostat" controls the oil feeding of both steering cyl- 1. Steering pump
inders. 2. Emergency steering pump
3. Pressure switch S 17
To check pressure in each steering cylinder and to 4. Pressure switch S 17.6
10. Safety valve 12 bar
monitor the correct function of the steering pump,
11. Collecting block
measuring points are designed in the frame.
13. Control blocks of operating hydraulic system
In this case, the prevailing steering pressure can be 18. Steering Servostat
tested (max. 150 ± 5 bar) 22. Measuring points - steering pressure
250. Connection pipe, to right steering cylinder for left
steering
251. Connection pipe, to right steering cylinder for right
steering
252. Connection pipe, to left steering cylinder for right
steering
253. Connection pipe, to left steering cylinder for left
steering
254. Connection pipe, steering Servostat - steering cyl-
inders for right steering
255. Connection pipe, steering Servostat - steering cyl-
inders for left steering
256. Delivery pipe, steering pump - collecting block
257. Delivery pipe, collecting block - steering Servostat
258. Tank pipe, steering Servostat - safety valve
259. Tank pipe
260. Tank pipe, control blocks - safety valve
261. Tank pipe, control blocks - safety valve
262. Tank pipe, control blocks - cooler
263. Tank pipe, control blocks - cooler
The oil return flow from the steering "Servostat" is 264. Tank pipe
conducted through a safety valve (10) - depending 265. Tank pipe, control blocks - cooler
on oil temperature - to the flushing channels TS of 266. Feeding pipe, steering system
the control blocks or into the tank. The 2 return pipe 267. Feeding pipe, emergency steering pump
268. Delivery pipe, emergency steering pump - col-
lines (262 / 263) from the TS channels bring the oil
lecting block
into the 4-circuit cooler. After being cooled, the un-
filtered oil achieves the hydraulic oil reservoir (259).
18
265 262 10
264
261
13
255 258
263 260 260
258
251 254 257 254
22
252
250
22 255 261
251
253
250
252
253
259
264
265
266
267
1
256
266
267
268 2
11 268
256
257 3
4
OKs1-09-003
9.1.5 STEERING DIAGRAM
1. Steering pump
2. Emergency steering pump
3. Pressure switch S 17 (open 2 bar)
4. Pressure switch S 17.6 (open 2 bar)
6. Oil tank
10. Safety valve 12 bar
11. Collecting block
13. Control blocks of operating hydraulic system
18. Steering Servostat
A. At the dashboard
B. Gauge = 1920 mm (R=96) - 405/70 R20
C. Wheel lean adjustable range
D. Direction of travelling
OKs2-09-001
9.2 STEERING SYSTEM COMPONENTS - OPERATION DESCRIPTION
9.2.1 COLLECTING BLOCK STEERING /

EMERGENCY STEERING
The pressurized oil is supplied by the steering pump pump, prevents oil from being drained from the
through input (A). The correct functioning of the steering system in case of breakage of the delivery
steering pump is monitored by the pressure switch pipe. The volume flow achieves the input channel (P)
(D1). The safety valve (VR1), i.e. a spring-loaded of steering Servostat through output (C) and the de-
check valve in the pressurized channel of the steering livery pipe (257).
Characteristic values:
Denomination: Collecting block

Operating pressure:150 bar
Nominal flow rate: 58 L/min
∆ p total.: 7.3 bar
OKs1-09-005
A. Delivery pipeline port, steering pump

B. Delivery pipeline port, emergency steering pump
C. Output to steering Servostat
D1. Pressure switch , Warning switch S 17- Steering pump failure
D2. Pressure switch, Warning switch S 17.6 - Emergency steering pump
RV1. Safety valve
RV2. Safety valve
9.2.2 STEERING SERVOSTAT Configuration of ZF -Steering Servostat:
The steering cylinders on the front axle are activated In the Servostat housing the following is integrated:
by the steering Servostat. On all graders a steering
Servostat of "open type" is employed. • Metering pump (1),
delivering in link and right sense of rotation
Open Type: • Control slide valve (2),

axially adjustable
In the idle position of the control valve the control
edges of the channels make free a ring clearance, • 2 Post-suction valves (3),
so that both channels of the steering cylinders L and to prevent cavitation in steering system
R can be connected to those of the metering pump.
In this way the steering system can be moved from • Short circuit valve (4),
the steered wheels of the vehicle, e.g. by the return by which the metering pump can draw from the
movement when cornering. return duct, if steering operations are carried out
The Servostat is protected at a steering pressure of without any hydraulic assistance
150 ± 5 bar.
• Check valve (5),
in pressurized connection, it prevents oil from be-
ing drained in case of breakage in the delivery
pipeline
• Pressure control valve (6),

it limits the delivery pressure of the engine-con-
trolled steering pump at the required max. value
of 150 bar.
Description of function - Idle position of control

valve
With released steering wheel the control slide valve into the tank. In this case, the oil existing in the other
(2) takes the idle position, in this way the volume flow channels is not in motion. With the "open design"
produced by the steering pump is allowed to be there is a direct connection between metering pump
drained from pressurized channel P to return channel and steering cylinder.
T - through TS channels of the two slide valve blocks
Servostat
OKs1-09-006
9 - 10 STEERING SYSTEM F156.6 / F156.6A
Description of function - Operating position of

control valve:
Corresponding to the rotational motion of the steering likewise assigned to corresponding outputs (L or R
column the control slide valve (2) is axially shifted to - in the figure it flows through R = command to the
the right or to the left. Oil flows now from the steering right), in this way the steering cylinders of front axle
pump channel (P) through the distributor grooves of are activated. The side of the steering cylinders, from
the control slide valve (2) to the suction side of the time to time not pressurized by oil, can be relieved
metering pump (1). From the pressure side of the by opening the return channel (T).
metering pump oil flows through distributor grooves
Servostat
OKs1-09-007
F156.6 / F156.6A STEERING SYSTEM 9 - 11
9.2.3 TRANSVERSE FLUSHING
The return of the steering oil is carried out by the

steering cylinders through Servostat (258) first to the
cross bolted joint, which acts as a distributor.
Through pipeline (260) the upper slide valve block
and through pipeline (261) the lower slide valve block
are supplied with flushing oil. By running through the
transverse flushing channels (TS) the return oil heats
the slide valve housing. In this way, a too high differ-
ence of temperature between the oil of the operating
hydraulic system and housing temperature is
avoided. At the end of the transverse flushing, oil
(262 / 263) achieves the combinated cooler (265) in
the engine compartment. There oil is cooled down in
the hydraulic oil cooler from ca. 90 °C by means of
the engine exhaust air and returns through pipeline
(259) into the hydraulic tank.
9.2.4 SAFETY VALVE 12 BAR
To ensure a definite return pressure from steering

Servostat, a safety valve is fitted into the return pipe-
line (258) of Servostat. In cold service condition the
valve at 22 bar of return pressure releases almost
the complete oil flow and at 12 bar a partial flow into
the tank. In warm service condition the return oil flow
is conveyed through the control slide valve blocks.
9 - 12 STEERING SYSTEM F156.6 / F156.6A
NOTES:
SECTION 10
ELECTRICAL SYSTEM
INDEX
10.1 WIRING DIAGRAM.................................................................................................. 10-1

10.1.1 Control panel ........................................................................................................... 10-1
10.1.2 Indicator module ...................................................................................................... 10-2
10.1.3 Key module.............................................................................................................. 10-4
10.1.4 Right side console ................................................................................................... 10-6
10.1.5 Fuses ....................................................................................................................... 10-7
10.1.6 Relays...................................................................................................................... 10-8
10.1.7 Wiring diagram sheets ............................................................................................. 10-8
10.1.8 Connectors tables.................................................................................................... 10-26
10.1.9 Connectors chart ..................................................................................................... 10-51
10.2 CAN-BUS SYSTEM................................................................................................. 10-53

10.2.1 Description............................................................................................................... 10-53
10.2.2 Functional test ......................................................................................................... 10-54
10.2.3 Components of can-bus system .............................................................................. 10-54
10.2.4 Description of connections....................................................................................... 10-55
10.2.5 Electric functions...................................................................................................... 10-56
F156.6 / F156.6A ELECTRICAL SYSTEM 10 - 1
10.1 WIRING DIAGRAM
10.1.1 CONTROL PANEL
B A
F1 15 A 15 A F7
F2 10 A 15 A F8
F3 5A 10 A F9
F4 15 A D E 10 A F10
F5 5A 15 A F11
F6 15 A 10 A F12
H K81.2
N M
+ + +
N
R
A. Indicator module
B. Key module
C. Right side console
D. Instrument panel fuse strip, left
E. Instrument panel fuse strip, right I
F. Right side console fuse strip, top
G. Right side console fuse strip, bottom
H. Instrument panel relays (*)
I. Right side console relays (**)
J. Gear selector lever ZF VTS-3
F
K. Battery main switch S1.1
L. Diagnostic plug A10x4 (EDS Tester); CAN Interface K
M. Key Switch S1
N. Cigarette lighter E20 G
(*)* Relays into the cluster below the plastic cover.

(**) Relays below toggle switches. OKs1-10-001
10 - 2 ELECTRICAL SYSTEM F156.6 / F156.6A
10.1.2 INDICATOR MODULE
H F
23
20 21
KM / H
110 22
C
°C
4 5
3 1
2 6
11 8
12 7
10 9
13 18
14 17
15 16
OKs1-10-002
1. Steering pump / Emergency steering pump warning light 14. (*) Pre-heating indicator light
2. Generator warning light 15. Air filter warning light
3. Engine oil pressure warning light 16. Warning light
4. Parking brake warning light 17. Main beam indicator light
5. Brake accumulator pressure warning light 18. Direction indicator light
6. Hazard system indicator light 19. Display
7. Gearbox oil pressure warning light 20. Coolant temperature bar
8. Gearbox oil temperature warning light 21. Fuel level bar
9. V-belt warning light 22. Gearbox oil temperature display
10. Coolant level warning light 23. Travel speed display
11. Coolant temperature warning light
12. Engine oil temperature warning light
13. Direction indicator light (*) Special equipment.
Warning lights
1. Steering pump / Emergency steering pump 11. Coolant temperature warning light
warning light It lights up when the coolant temperature is
It lights up when steering pump fails and too high.
when emergency steering pump is activated Stop grader immediately and run engine
(approx. 3 km/h). Stop grader and rectify at idling speed to cool down.
fault.
12. Engine oil temperature warning light
2. Generator warning light Not connected.
It lights up when the battery is not being
charged and when the alternator is defective.
Shut off engine and rectify fault.
13. - 18. Direction indicator lights
It lights up when the direction indicator is on.
3. Engine oil pressure warning light
It lights up when the engine oil pressure is
too low.
Shut off engine and rectify fault. 14. Pre-heating indicator light (optional)
It lights up when the grid heater is on and
goes out when intake air preheating is termi-
4. Parking brake warning light
nated. Only then can the engine be run at full
It lights up when the parking brake is applied. load.
15. Air filter warning light

5. Brake accumulator pressure warning light It lights up when the filter cartridge is contam-
It lights up when the brake accumulator pres- inated.
sure is too low.
Stop grader immediately and rectify fault.
16. Warning light
Not connected.
6. Hazard system indicator light
It lights up when the hazard system is on.
17. Main beam indicator light

It lights up when the headlamps are on main
7. Gearbox oil pressure warning light
beam.
It lights up when the gearbox oil pressure is
too low.
Stop grader immediately and rectify fault. 19. Display
The display shows the following functions:
8. Gearbox oil temperature warning light - fuel gauge,
It lights up when the gearbox oil temperature - operating hours,
is too high. - travel speed,
Stop grader immediately and rectify fault. - gearbox oil temperature,
- gearbox oil filter contamination,
- time,
9. V-belt w arning light - fault messages,
Not connected. - immobiliser,
- engine speed,
- gears,
10. Coolant level warning light - automatic mode.
Not connected.
10.1.3 KEY MODULE
31 32
30 33
35 36
34 37
39 40
38 41
43 44
42 45
46 48
47
OKs1-10-003
30. Lighting button 41. Front wheel drive button (only for F156.6A)
31. Front windscreen wiper button 42. (*) Cab floor additional working lights button
32. Heating blower button 43. Rear windscreen washer button
33. Service button 44. (*) Rear additional working lights button
34. Working lights button 45. (*) Back-up alarm switch off button
35. Front windscreen washer button 46. Code/Time/Contrast button
36. (*) Roof fan button 47. Hazard warning blinker button
37. Display button 48. Code/Time/Contrast button
38. (*) Floating position button
39. Rear windscreen wiper button
40. (*) Rotary beacon button (*) Special equipment.
Buttons
30. Lighting button 41. Front wheel drive button (only for F156.6A)
LED off = lighting OFF LED off = front wheel drive OFF
LED 1 = parking lights ON LED flash = front wheel drive
LED 2 = low beam ON cannot be switched on
or off
31. Front windscreen wiper button LED on = front wheel drive ON
LED off = windscreen wiper OFF
LED J = intermittent wiping 42. Cab floor additional working lights button
LED I = permanent wiping (optional)
LED off = cab floor additional
32. Heating blower button working lights OFF
It switches the blower OFF and selects inten- LED on = cab floor additional
sities 1, 2, 3. working lights ON
(only when parking lights or low beam are
ON)
33. Service button
It allows to show the different functions of the
display (see “Service functions” on Operation 43. Rear windscreen washer button
and Maintenance Instructions Manual). LED off = windscreen washer OFF
LED on = windscreen washer ON
34. Working lights button
LED off =working lights OFF 44. Rear additional working lights button (optional)
LED on LED on=working lights ON LED off = rear additional working
(only when parking lights or low beam are lights OFF
ON) LED on = rear additional working
lights ON
35. Front windscreen washer button (only when parking lights or low beam are
LED off = windscreen washer OFF ON)
LED on = windscreen washer ON
45. Back-up alarm switch off button (optional)
36. Roof fan button (optional) It activates the acoustic reversing signal.
LED off = roof fan OFF LED off = acoustic reversing
LED on = roof fan ON signal activated.
LED on = acoustic reversing
37. Display button signal deactivated.
It allows to show the time and the engine rpm on
the display (see “Display functions” on Opera- 46. Code/Time/Contrast button
tion and Maintenance Instructions Manual). It allows to set the immobiliser code, the time
and the contrast.
38. Floating position button (optional)
LED off = floating position OFF 47. Hazard warning blinker button
LED on = floating position ON Button depressed: hazard system ON, indi-
cator light (6) flashes.
39. Rear windscreen wiper button Button depressed a second time: hazard
LED off = windscreen wiper OFF system OFF.
LED J = intermittent wiping
LED I = permanent wiping 48. Code/Time/Contrast button
It allows to set the immobiliser code, the time
40. Rotary beacon button (optional) and the contrast.
LED off = rotary beacon OFF
LED on = rotary beacon ON
10.1.4 RIGHT SIDE CONSOLE
84. Rotary switch (only for F156.6A)

87. Rocker switch Parking brake
88. Rocker switch Transmission switchover
89. (*) Rocker switch Transmission neutralisation
90. Blind switch
91. (*) Rocker switch Air conditioner
84
92. (*) Rocker switch with lock Refuelling system
93. Blind switch
91 90 89 88 87 94. Blind switch
95. Blind switch
96. Blind switch
(*) Special equipment.
96 95 94 93 92
OKs1-10-004
Switches
84. Rotary switch (only for F156.6A) 89. Rocker switch Transmission neutralisation
Selection of lead or lag levels of the (optional)
front-wheel drive. Depress symbol face of switch: symbol
face lit up, Transmission neutralisation ON
Depress blank face of switch: symbol face
extinguished, Transmission neutralisation
OFF
87. Rocker switch Parking brake
Depress blank face of switch (rocker switch 91. Rocker switch Air conditioner (optional)
is being locked at the same time): indicator Depress symbol face of switch: Air condi-
light (4) lights up, Parking brake locked. tioner ON
Unlock switch and depress symbol face of Depress blank face of switch: Air condi-
switch: indicator light (4) goes out, Parking tioner OFF
brake released.
92. Rocker switch with lock Refuelling system
88. Rocker switch Transmission switchover (optional)
Switches the transmission into the manual Set switch surface with symbol to neutral
or the automatic mode. position, unlock switch and press switch
Depress symbol face of switch: symbol lit surface with symbol briefly (switch goes
up, Manual mode ON back to neutral position when released):
Depress blank face of switch: symbol ex- Refuelling system ON
tinguished, Automatic mode ON Press blank face of switch: Refuelling
system OFF
90. - 93. - 94. - 95. - 96. Blind plaques

Free for optional equipment.
10.1.5 FUSES
Instrument panel fuse strip, left

15 A F1
F1 15A Central electronic unit
F2 10A Parking position relay, Horns, (*) Back-up alarm 10 A F2
F3 5A Brake lights, Brake lights relay, FWD Control
(only for F156.6A), (*) Floating position mouldboard, 5A F3
(*) Transmission neutralisation
F4 15A Front windscreen wiper, Rear windscreen wiper, 15 A F4
FWD Control (only for F156.6A)
F5 5A Tank sensor, (*) Rear scarifier position sensor 5A F5
F6 15A Blower heating
15 A F6
OKs1-10-005
Instrument panel fuse strip, right
F7 15A Start relay, Central electronic unit, (*) Grid Heater
controller
F8 15A Cigarette lighter
F9 10A CAN Diagnostic plug
F10 10A Headlight flasher
F11 15A Direction indicator lights, (*) Operator’s seat, 15 A F7
(*) Cab floor/rear additional working lights
F12 10A Cab interior light, (*) Radio voltage transformer 15 A F8
(*) Special equipment. 10 A F9
Right side console fuse strip, top 10 A F10
F13 25A Engine stop magnet
F14 7,5A Gear control EST-37
15 A F11
F15 20A (*) Refuelling system 10 A F12
F16 10A (*) Grid Heater controller, (*) Filter heaters relays
F17 15A (*) Filter heater OKs1-10-006
F18 15A (*) Filter heater
Right side console fuse strip, bottom

F19 7,5A Engager pin, Hydraulic working fast speed
F22 7,5A ZF Diagnostic plug, Gear control
EST-37, Switching automatic/manual
F23 15A Parking brake solenoid valve, (*) Hydraulic control,
(*) Air conditioner (main fuse), (*) Front side marker
lights
F24 5A (*) Air conditioner (relays)
F25 15A (*) Air conditioner (liquefier blower)
F26 5A (*) Air conditioner (compressor magnetic clutch)
Maxi fuse
F20 125A(*) Grid heater
OKs1-10-007
10.1.6 RELAYS
Instrument panel relays
K1 Start interlock
K14 Horns
K17 Parking position
K81.2
K53.1 (*) Cab floor additional working lights
K53.2 (*) Rear additional working lights
K81.2 (*) Back-up alarm
OKs1-10-008
Right side console relays
K1.9 (*) Front side marker lights

K19 Brake lights
K20.3 (*) Filter heater
K20.4 (*) Filter heater
K67 (*) Refuelling system
K67.1 (*) Refuelling system
E19K2 (*) Air conditioner
E19K3 (*) Air conditioner (liquefier blower)
E19K4 (*) Air conditioner
(compressor magnetic clutch)
Other relays
OKs1-10-009
K1.5 Starter
K1.7 (*) Grid Heater
10.1.7 WIRING DIAGRAM SHEETS
Cables colours
BK = Black
BN = Brown
BU = Blue
GN = Green
GY = Grey
OG = Orange
PK = Pink
RD = Red
TQ = Turquoise
VT = Violet
WH = White
YE = Yellow
SHEET 7 - Power supply / Starter engine
Engine stop magnet

Start relay
Cold-starting system
(*) Grid heater
Power supply
OKs1-10-010
SHEET 8 - Power supply / Parking brake
Start interlock relay

Central electronic unit
automatic/manual
Switching
Solenoid valve
Parking brake
Lock near on
OKs1-10-011
SHEET 9 - (*) Grid heater / (*) Filter heaters
(*) Filter Heater

(*) Filter Heater
(*) Grid Heater Controller
Grid Heater relay

IVECO / 504038671
temperature
Coolant
Wait to start
Battery charge (L)

(*) Special equipment
OKs1-10-012
10 - 12

Key Module 30
SHEET 10 - Lighting
Lights
ELECTRICAL SYSTEM
(*) Front side-marker (*) Front side- Licence plate Left tail Left parking Right Right Right Low Left Low
lamp marker lamp relay light lamp light tail lamp parking light beam / Full beam /
Right Left beam Full beam
OKs1-10-013
F156.6 / F156.6A
F156.6 / F156.6A
Key Module 47 Indicator Module 6 Key Module 34
Working lights
Hazard warning blinker
SHEET 11 - Brake lights / Blinker / Working lights
ELECTRICAL SYSTEM
Brake light Brake lights (*) Transmission Rear Front Operator’s Rear Front Operator’s Working lights operator’s cab
relay neutralization (Inchen) cab cab
Leftt Right Front Rear
- Blinker Left - - Blinker Right -
OKs1-10-014
10 - 13
10 - 14

Key Module 42 Key Module 44 Key Module 45
Cab floor working Rear working Back-up alarm

lights lights switch-off
SHEET 12 - Diagnostic plug / (*) Back-up alarm
Diagnostic plug
ELECTRICAL SYSTEM
Cigarette (*) Additional working lights (*) Back-up Reversing lights
lighter alarm
(*) Additional Cab floor Rear
Left RIght
working lights relays Left Right Left Right
OKs1-10-015
F156.6 / F156.6A
F156.6 / F156.6A
Indicator Module
SHEET 13 - Pressures / Temperature Engine/Gearbox
ELECTRICAL SYSTEM
Battery Charge (L) Parking brake Emergency steering Engine coolant Transmission oil Pre-glow
temperature temperature
Engine oil Brake fluid Steering Transmission oil Air filter
pressure pressure pressure
OKs1-10-016
10 - 15
10 - 16
Central electronic unit Central electronic unit
Key Module 31 Key Module 35 Key Module 39 Key Module 43

SHEET 14 - Wiper and washer
Front Front Front Front

wiper washer wiper washer
ELECTRICAL SYSTEM
Front windscreen wiper Front windscreen washer Rear windscreen wiper Rear windscreen washer
OKs1-10-017
F156.6 / F156.6A
F156.6 / F156.6A

Key Module 32 Key Module 40 Key Module 36
SHEET 15 - Horns / Blower heating
Heating blower Rotary beacon Roof fan

ELECTRICAL SYSTEM
Horns relay Horns Heating blower (*) Air conditioner (*) Rotary (*) Roof fan
Release beacon
Right Left
OKs1-10-018
10 - 17
SHEET 16 - EST 37 Transmission control unit
ZF Diagnostic plug
Plug open
Inchen
wheel chain
sensor
Middle
speed
CAN Bus
Engine
sensor
speed
Turbine
sensor
speed
brake
Gear transmission
Parking
speed sensor
Gearshift
drove-off
Gear selector lever
Oil filter switch
OKs1-10-019
F106.6A ELECTRICAL SYSTEM 10 - 19
SHEET 17 - Front Wheel Drive Control (only for F156.6A)
FWD
Key Module 41
Front Wheel
Drive on/off
Hub motor
proportional
forward
Pump
FWD Control
proportional
reverse
Pump
Switching contacts
(*) = Switching contact closed

Contact holding S88
Switch position
OKs1-10-020
SHEET 18 - (*) Floating position / (*) Rear scarifier
(*) Rear scarifier position indicator
Down
Up
Floating
position
Key Module 38
(*) Blade floating position
OKs1-10-021
F156.6 / F156.6A
Indicator Module 18 Indicator Module 17
Blinker Horn Full beam

SHEET 19 - Steering wheel switch / Parking position
(*) Operator’s seat
(*) Operator’s seat

ELECTRICAL SYSTEM
(*) Operator’s seat Blinker Horn Full beam Headlight Parking position
flasher
Left Right
OKs1-10-022
10 - 21
SHEET 20 - (*) Air conditioner
(*) Compressor
magnetic
clutch
(*) Liquefier
blower under-overpressure
magnetic clutch
(*) Compressor
(*) Freezing,
protection
relay
(*) Liquefier
blower
relay
(*) Air conditioner
on/off
OKs1-10-023
SHEET 21 - Engager pin / Hydraulic rapid working
(*) Floating
position
Rear hydraulic control
2nd actuator
(*) Floating
position
Front hydraulic control
2nd actuator
Hydraulic rapid
working
Engager pin
OKs1-10-024
SHEET 22 - Tank sensor / (*) Refuelling system
Lock push button

2 pushed on
1 switched
(*) Refuelling system

Tank sensor
Display Module
Bar-graph
fuel level
OKs1-10-025
SHEET 23 - Interior light / (*) Radio
(*) Voltage transformer

(*) Radio
Cab interior light
OKs1-10-026
10.1.8 CONNECTORS TABLES
TABLE 24 - STOPPING BLOCK
X4
4
S17.1
28
23
22
1
21
27
23
22
1
2
OKs1-10-027
Connector Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet Table Table Table Table Table
X44 13,3 24 34
TABLE 25 - HEATING
X2
3
M12
OKs1-10-028
X23 15,4 27 34 45
10 - 28 ELECTRICAL SYSTEM F156.6A
TABLE 26 - ELECTRONIC CONTROL FRONT WHEEL DRIVE (only for F156.6A)
XA
8.2
XA
8.1
XC
AN
.1
A8.1
S88
OKs1-10-029
XA8.1 17,2 26
XA8.2 17,2 17,3 17,4 17,5 17,6 26 34
XCAN.1 16,6 26 34
TABLE 27 - ELECTRICAL SYSTEM OPERATOR’S CAB
XM E3 E4
82 6 .6 W9.4
A9
0.2 W9.5 C3 X1
W56 5
3.1 E3
.6
XM
E9
X1
2.3
X1 X1
2 2.1
.2 E4
X1 W9.3
.1
2.4 3
X1 XM
2.5
W9.2 X1
2.2
1.3
X3 W9.1
E3
.1
E8
X3
2.5
W9 X3
2.6
E7
OKs1-10-030
X12.1 11,5 11,7 27
X12.2 23,3 27
X12.3 11,8 14,6 15,7 27
X12.4 15,6 18,8 27 46
X12.5 23,5 27 47
X15 11,8 27
X23 15,4 27 34 45
X31.3 15,6 15,7 23,3 27 47
X32.5 14,2 14,6 23,3 30 34 40
X32.6 11,5 11,7 11,9 15,6 15,7 18,8 23,5 27 30 40
XM3 14,2 27 42
XM3.1 14,6 27 41
XM82 15,7 27 43
TABLE 28 - ELECTRICAL SYSTEM ACTUATING ELEMENT 1.-6. GEAR
B12
B1
2X
2
B1
2X
3
1
XA
A11
OKs1-10-031
B12X2 16,3 28 34
B12X3 16,2 16,4 28 34
TABLE 29 - STEERING WHEEL SWITCH
S23
X2
1
OKs1-10-032
X21 19,1 19,2 19,3 19,4 19,5 19,6 29 30 40
TABLE 30 - DASHBOARD
X4
00
A1
X3
00
S1 A1
X4 X1
0 00 X2
A1 A1 00
A1
S1
0
E2
4
K3 K1 .1
3
K5 53.2
K 4
K1 1.2
K8 K17 XC
AN
5 W1
1. .5
X3 1
X3
X3
.1
X3
2 .5
X3 X3
4 X
2.6 X1 33.
0 1
X3 X1
2 .1 X3 08
3 .2 X1
X1 0 .6
15
X3
8 X X1 X3 X2
25 09 2 .4 1
OKs1-10-033
X10 7,2 30 34 35 37 40
X10.6 7,7 30 34 35 37 40
X21 19,1 19,2 19,3 19,4 19,5 19,6 29 30 40
X25 13,8 18,1 18,2 30 34 40
7,6 8,1 8,9 9,4 9,5 10,3 10,6 11,7
11,8 12,0 12,1 12,3 12,5 12,7 12,8 12,9
13,3 13,4 13,5 13,6 13,7 13,8 14,8 15,1
X31.5 30 34 35 40
15,4 15,8 16,1 16,9 17,2 17,3 17,4 17,5
17,6 17,7 17,8 18,2 18,7 19,0 19,7 20,6
20,7 21,1 22,2
X32.1 10,4 10,6 10,8 11,4 11,6 15,1 30 34 40
X32.4 11,2 12,3 13,3 14,4 14,8 15,4 15,5 19,0 30 34 40
X32.5 14,2 14,6 23,3 30 34 40
X32.6 11,5 11,7 11,9 15,6 15,7 18,8 23,5 27 30 40
7,1 7,8 10,3 10,6 11,0 11,3 11,5 12,4
X33.1 30 34 40
12,8 13,1 13,5
X33.2 7,6 7,7 13,6 13,7 13,8 18,6 18,7 22,1 30 34
X38 8,8 17,2 17,6 17,7 30 34 40
XCAN 16,7 30 34 40
TABLE 31 - CABLE HARNESS ILLUMINATION FRONT FRAME
X6
8.0
X6
X6 8.4
8
OKs1-10-034
10,0 10,1 10,4 10,6 10,8 11,4 11,6 15,1
X68 31
15,2
10,0 10,4 10,6 10,8 11,4 11,6 15,1 15,2
X68.0 31 34
18,2 18,3
X68.4 18,2 18,3 31
TABLE 32 - CABLE HARNESS ENGINE TRANSMISSION GEAR
Y8 Y8.
R3 .5 6
9 Y16
XA
5
K1. M1
7
K1.
5 3
XB XB
XY
1.4
1
S1 XB
7 .2
71. S1 6 6.1 4
X1 5.1 B11 21 S1 XB
.2 G1 G1/X R
X17 1 R1
9
B13 S12 .9
.1 S17
Y1
E19
1
X33 9 /R2
.10 R1
X3
3.11
2
XB
OKs1-10-035
E19Y1 20,8 32
8,1 9,5 13,6 13,7 13,8 16,4 16,5 16,6
X33.10 32 34
17,3 17,4 20,8 22,1 22,2 22,7
7,1 7,2 7,4 7,6 7,7 7,8 9,1 9,2
X33.11 32 34
9,3 9,7 9,8 13,1 13,5
XY1.4 7,7 7,8 32
TABLE 33 - CABLE HARNESS REAR FRAME
X4
6 .2
E4
.8
E1
2
H8 E3
1 .8
.2
M8 Y8
5 .1
Y8 X4
6.1
8
M6 Y2 7.6 S3
7 S1 2.2
1
7
S1
7
Y2
E19
X1
X3
8.8
OKs1-10-036
E19X1 20,6 20,7 33 44
10,3 10,6 11,0 11,1 11,3 11,5 12,4 12,8
X38.8 12,9 13,4 17,5 17,6 18,6 18,7 20,6 20,7 33 34
21,1 21,2 22,4
X46.1 10,3 11,0 11,3 12,8 33 38
X46.2 10,6 11,1 11,5 12,9 33 38
TABLE 34 - ELECTRICAL SYSTEM CAB FLOOR CABLE HARNESS
XA
5 88
XS
XC
A
X3 N.1 X1
3 .4
XA
3 8.2
2 2X
2X B1
X1
OKs1-10-037
B12X2 16,3 28 34
B12X3 16,2 16,4 28 34
E19X2 20,6 34 45
X1.4 7,4 7,7 34 36
X10 7,2 30 34 35 37 40
X10.6 7,7 30 34 35 37 40
X23 15,4 27 34 45
X25 13,8 18,1 18,2 30 34 40
7,6 8,1 8,9 9,4 9,5 10,3 10,6 11,7
11,8 12,0 12,1 12,3 12,5 12,7 12,8 12,9
13,3 13,4 13,5 13,6 13,7 13,8 14,8 15,1
X31.5 30 34 35 40
15,4 15,8 16,1 16,9 17,2 17,3 17,4 17,5
17,6 17,7 17,8 18,2 18,7 19,0 19,7 20,6
20,7 21,1 22,2
X32.1 10,4 10,6 10,8 11,4 11,6 15,1 30 34 40
X32.4 11,2 12,3 13,3 14,4 14,8 15,4 15,5 19,0 30 34 40
X33 16,7 16,8 34
7,1 7,8 10,3 10,6 11,0 11,3 11,5 12,4
X33.1 30 34 40
12,8 13,1 13,5
X33.2 7,6 7,7 13,6 13,7 13,8 18,6 18,7 22,1 30 34
8,1 9,5 13,6 13,7 13,8 16,4 16,5 16,6
X33.10 32 34
17,3 17,4 20,8 22,1 22,2 22,7
7,1 7,2 7,4 7,6 7,7 7,8 9,1 9,2
X33.11 32 34
9,3 9,7 9,8 13,1 13,5
X38 8,8 17,2 17,6 17,7 30 34 40
10,3 10,6 11,0 11,1 11,3 11,5 12,4 12,8
X38.8 12,9 13,4 17,5 17,6 18,6 18,7 20,6 20,7 33 34
21,1 21,2 22,4
X44 13,3 24 34
10,0 10,4 10,6 10,8 11,4 11,6 15,1 15,2
X68.0 31 34
18,2 18,3
8,4 10,5 11,0 11,2 16,1 16,4 16,8 20,6
X102 34 36
20,7 22,2 22,7
X104 9,2 9,5 9,7 9,8 15,5 20,6 21,1 22,8 34 36
X110 19,0 34
X124 7,4 8,1 9,5 10,0 10,2 20,8 22,2 22,4 34 36
XA8.2 17,2 17,3 17,4 17,5 17,6 26 34
XCAN 16,7 30 34 40
XCAN.1 16,6 26 34
XM4 14,4 34
XM4.1 14,8 34
XS88 17,4 17,8 34 36
TABLE 35 - ELECTRICAL SYSTEM CAB FLOOR
W24
X10
.6
X10
X31.5
X31.5
X31.5
S28
S27
OKs1-10-038
X10 7,2 30 34 35 37 40
X10.6 7,7 30 34 35 37 40
7,6 8,1 8,9 9,4 9,5 10,3 10,6 11,7
11,8 12,0 12,1 12,3 12,5 12,7 12,8 12,9
13,3 13,4 13,5 13,6 13,7 13,8 14,8 15,1
X31.5 30 34 35 40
15,4 15,8 16,1 16,9 17,2 17,3 17,4 17,5
17,6 17,7 17,8 18,2 18,7 19,0 19,7 20,6
20,7 21,1 22,2
TABLE 36 - CABLE HARNESS CONSOLE
OKs1-10-039
X1.4 7,4 7,7 34 36
8,4 10,5 11,0 11,2 16,1 16,4 16,8 20,6
X102 34 36
20,7 22,2 22,7
X104 9,2 9,5 9,7 9,8 15,5 20,6 21,1 22,8 34 36
X124 7,4 8,1 9,5 10,0 10,2 20,8 22,2 22,4 34 36
XS88 17,4 17,8 34 36
TABLE 37 - ELECTRICAL SYSTEM OTHER CONSOLE
X1
0.6
X1
0
OKs1-10-040
X10 7,2 30 34 35 37 40
X10.6 7,7 30 34 35 37 40
TABLE 38 - ILLUMINATION REAR TAILLIGHT
E5/E6
/2
6.1 X4
X4 6.5
/6
X1
.1
OKs1-10-041
X46.1 10,3 11,0 11,3 12,8 33 38
X46.2 10,6 11,1 11,5 12,9 33 38
X46.5 12,8 38
X46.6 12,9 38
TABLE 39 - ILLUMINATION REAR BACKUP LAMP
E50/E51
X4
6.5
/6
OKs1-10-042
X46.5 12,8 38
X46.6 12,9 38
TABLE 40 - CABLE HARNESS CONTROL PANEL
OKs1-10-043
X10 7,2 30 34 35 37 40
X10.6 7,7 30 34 35 37 40
X21 19,1 19,2 19,3 19,4 19,5 19,6 29 30 40
X25 13,8 18,1 18,2 30 34 40
7,6 8,1 8,9 9,4 9,5 10,3 10,6 11,7
11,8 12,0 12,1 12,3 12,5 12,7 12,8 12,9
13,3 13,4 13,5 13,6 13,7 13,8 14,8 15,1
X31.5 30 34 35 40
15,4 15,8 16,1 16,9 17,2 17,3 17,4 17,5
17,6 17,7 17,8 18,2 18,7 19,0 19,7 20,6
20,7 21,1 22,2
X32.1 10,4 10,6 10,8 11,4 11,6 15,1 30 34 40
X32.4 11,2 12,3 13,3 14,4 14,8 15,4 15,5 19,0 30 34 40
X32.5 14,2 14,6 23,3 30 34 40
X32.6 11,5 11,7 11,9 15,6 15,7 18,8 23,5 27 30 40
7,1 7,8 10,3 10,6 11,0 11,3 11,5 12,4
X33.1 30 34 40
12,8 13,1 13,5
X33.2 7,6 7,7 13,6 13,7 13,8 18,6 18,7 22,1 30 34
X38 8,8 17,2 17,6 17,7 30 34 40
XCAN 16,7 30 34 40
TABLE 41 - REAR WINDSCREEN WIPER
M3.1
XM
3.1
OKs1-10-044
XM3.1 14,6 27 41
TABLE 42 - FRONT WINDSCREEN WIPER
M3
3
XM
OKs1-10-045
XM3 14,2 27 42
TABLE 43 - ROOF FAN
M82
XM
82
OKs1-10-046
XM82 15,7 27 43
TABLE 44 - AIR CONDITIONER - CONDENSER MOUNTING PARTS
E19B1
E19X1
OKs1-10-047
E19X1 20,6 20,7 33 44
TABLE 45 - AIR CONDITIONER
X23
E19M1
E19
X2
E19B2
OKs1-10-048
E19X2 20,6 34 45
X23 15,4 27 34 45
TABLE 46 - ROTARY BEACON
E36
W56
X1
2.4
OKs1-10-049
X12.4 15,6 18,8 27 46
TABLE 47 - RADIO
A90.2
X3
1.3
X1
W60.1 2.5
W6 0
A90.1
OKs1-10-050
X12.5 23,5 27 47
X31.3 15,6 15,7 23,3 27 47
10.1.9 CONNECTORS CHART
B12X2 16,3 28 34
B12X3 16,2 16,4 28 34
E19X1 20,6 20,7 33 44
E19X2 20,6 34 45
E19Y1 20,8 32
X1.4 7,4 7,7 34 36
X10 7,2 30 34 35 37 40
X10.6 7,7 30 34 35 37 40
8,4 10,5 11,0 11,2 16,1 16,4 16,8 20,6
X102 34 36
20,7 22,2 22,7
X104 9,2 9,5 9,7 9,8 15,5 20,6 21,1 22,8 34 36
X110 19,0 34
X12.1 11,5 11,7 27
X12.2 23,3 27
X12.3 11,8 14,6 15,7 27
X12.4 15,6 18,8 27 46
X12.5 23,5 27 47
X124 7,4 8,1 9,5 10,0 10,2 20,8 22,2 22,4 34 36
X15 11,8 27
X21 19,1 19,2 19,3 19,4 19,5 19,6 29 30 40
X23 15,4 27 34 45
X25 13,8 18,1 18,2 30 34 40
X29 21,4
X29.1 21,6 21,7
X29.2 21,4 21,5
X29.3 21,6
X3.8 12,4
X31.3 15,6 15,7 23,3 27 47
7,6 8,1 8,9 9,4 9,5 10,3 10,6 11,7
11,8 12,0 12,1 12,3 12,5 12,7 12,8 12,9
13,3 13,4 13,5 13,6 13,7 13,8 14,8 15,1
X31.5 30 34 35 40
15,4 15,8 16,1 16,9 17,2 17,3 17,4 17,5
17,6 17,7 17,8 18,2 18,7 19,0 19,7 20,6
20,7 21,1 22,2
X32.1 10,4 10,6 10,8 11,4 11,6 15,1 30 34 40
X32.4 11,2 12,3 13,3 14,4 14,8 15,4 15,5 19,0 30 34 40
X32.5 14,2 14,6 23,3 30 34 40
X32.6 11,5 11,7 11,9 15,6 15,7 18,8 23,5 27 30 40
X33 16,7 16,8 34
7,1 7,8 10,3 10,6 11,0 11,3 11,5 12,4
X33.1 30 34 40
12,8 13,1 13,5
8,1 9,5 13,6 13,7 13,8 16,4 16,5 16,6
X33.10 32 34
17,3 17,4 20,8 22,1 22,2 22,7
7,1 7,2 7,4 7,6 7,7 7,8 9,1 9,2
X33.11 32 34
9,3 9,7 9,8 13,1 13,5
X33.2 7,6 7,7 13,6 13,7 13,8 18,6 18,7 22,1 30 34
(continue)
X38 8,8 17,2 17,6 17,7 30 34 40
10,3 10,6 11,0 11,1 11,3 11,5 12,4 12,8
X38.8 12,9 13,4 17,5 17,6 18,6 18,7 20,6 20,7 33 34
21,1 21,2 22,4
X4.8 12,4
X44 13,3 24 34
X46.1 10,3 11,0 11,3 12,8 33 38
X46.2 10,6 11,1 11,5 12,9 33 38
X46.5 12,8 38
X46.6 12,9 38
10,0 10,1 10,4 10,6 10,8 11,4 11,6 15,1
X68 31
15,2
10,0 10,4 10,6 10,8 11,4 11,6 15,1 15,2
X68.0 31 34
18,2 18,3
X68.4 18,2 18,3 31
XA8.1 17,2 26
XA8.2 17,2 17,3 17,4 17,5 17,6 26 34
XA17 9,1
XB2 22,1
XCAN 16,7 30 34 40
XCAN.1 16,6 26 34
XM3 14,2 27 42
XM3.1 14,6 27 41
XM4 14,4 34
XM4.1 14,8 34
XM82 15,7 27 43
XR3 13,6
XS88 17,4 17,8 34 36
XY1.4 7,7 7,8 32
10.2 CAN-BUS SYSTEM
10.2.1 DESCRIPTION
A Bus system (Controller Area Network - CAN) An existing CAN Bus can be prepared by modifying
serves as a communication medium for sensors, the software parameters of the existing participants
control units, controllers, input and output units on to record new transmitters / addressees. By modi-
different points of the machines. fying the parameters deposited in the software, the
In this case, stations / participants, equally entitled, machine can be relatively adapted to different re-
are together connected through a serial data bus. In quirements.
this way, the interlinking and simultaneous commu-
nication of several sensors, control units and indica- Another advantage of CAN in comparison with con-
tors are possible. ventional cabling lies in the fact that transmission er-
rors, which can occasionally arise as a result of
electromagnetic irradiation, can be recognised and,
Advantages: after repeating the transmission, automatically cor-
rected. Moreover, the operator-friendly CAN-Bus
Control pipelines relatively thin
lacing enables a self-diagnosis to be made.
Data exchange more rapid
Information utilisation for all participants through se-
cure information exchange
Simple extensibility of Bus System
Fault recognition and diagnosis possibilities
Block diagram CAN-Bus
Front-Wheel-Drive Gearbox control unit Digital console Diagnostic plug

control system
FWD-controller EST-37 Central electronic unit
A 8.1 A 11 A 100 A 10X4
OKs1-10-051
The Bus System of the graders consists of two-core cables with the designation CAN and CAN1.
Data Exchange
The gearbox control unit makes the following avail- The Front-Wheel-Drive controller utilises the data
able: about rotational speed and the selected driving di-
• the data of the gear selector (Component B12), rection to control the front-wheel-drive.
• the driving mode, The console display indicates the data about
• the gear engaged at the moment, gearbox controlling. At the same time, it can indicate
• the engine speed, the fault signals of the single control systems. The
• the gearbox output shaft RPM (rotational speed console makes available the data set of the machine.
signal), By means of the diagnostic plug, data can be read
• the gearbox oil sump temperature XA9 : 8/9. through a tester and modified.
10.2.2 FUNCTIONAL TEST 10.2.3 COMPONENTS OF CAN-BUS

SYSTEM
The permanent data transmission through the CAN-
Bus can carry out tests with the tester menu “Grader CAN-Bus system of Graders F156.6 - F156.6A
- devices data” and “FWD-Controller”. In both test according to E - Diagram Part - N°: 3004180:
menus, 2 number columns, increasing constantly by
the same amount, are represented. These columns - Digital Console / Central electronic unit A 100
symbolise the data exchange by means of the CAN- - Diagnostic plug A 10x4
Bus. In this case, the decisive test criterion is the - Gearbox control unit EST 37 A 11
constant variation of the number columns. - FWD - Controller A 8.1
10.2.4 DESCRIPTION OF CONNECTIONS
- The central electronic unit A 100 is connected directly to diagnostic plug A10X4.
Wiring
- The on-board voltage of 24 V stands by at the diagnostic plug at PIN 2 through fuse F9 10 A.
Diagram
- Through connector X31.5, PIN 1 is connected to the vehicle earth cable 31.
- PIN 4 cable CAN+, connection to central electronic unit and to EST 37
Sheet 12
- PIN 5 cable CAN-, connection to central electronic unit and to EST 37
- The central electronic unit A 100 is connected through the data cable CAN+/- in parallel to
EST - 37.
- In the connector of EST - 37, PINs 25/26 (CAN_H/CAN_L) are provided to plug-in the data
cables.
- On all Front-Wheel-Drive-Graders, no connection between PIN 26 (CAN_L) and PIN
Wiring
27(CAN_T) must exist. The connector X33 must remain open.
Diagram
- The gearbox control system EST 37 A11 has an own diagnostic interface: the diagnostic
connector XA5.
Sheet 16
- The on-board voltage of 24 V stands by at the diagnostic connector at PIN 1 through fuse F22
7,5 A.
- PIN 3 is connected through connector X31.5 to the vehicle earth cable 31
- PINs 2/4 make the connection to the gearbox control unit EST 37. By means of these connec-
tions, AEB - Start is activated.
- Through the data cable CAN 1, the FWD controller is connected to the CAN-Bus system.
Wiring
- The EST - 37 PIN 25/26 (CAN_H/CAN_L) is connected to the FWD - controller PIN 21/22
Diagram
through CAN1.
- The on-board voltage of 24 V stands by at the FWD Controller at PIN 1 through fuse F4 15 A.
Sheet 17
- PIN 25 of FWD-controller is connected through connector X31.5 to the vehicle earth cable 31.
10.2.5 ELECTRIC FUNCTIONS
Brake pressure dependent gearbox neutralisation (Option)
POWER SUPPLY
Ignition ON
Wiring
Terminal 15 brings 24 V to fuse F3
Diagram
This fuse protects the circuits :
• Stop light,
Sheet 18
• Floating position, ploughshare single with min. 5 A.
ACTUATION
From fuse F3, a voltage 24 V stands by through X 32.4 : 3 at pressure switch S 18. A voltage 24
V stands by through X 33.1 : 5 and X 102 : 13 at the relay switching contact “Stop light”; K 19
By actuating the brake pedal, S 18 closes as a result of the consequent pressure increase over
3-4 bar in the brake circuit. Three voltages 24 V are switched further by pressure switch “Stop Wiring
light” S 18. Diagram
• Through X 102 : 10 to rocker switch S 26.4
• to FWD-control system (PIN 8) Sheet 19
• Actuation of relay K 19 (Stop light)
After actuating the rocker switch S 26.4, the symbol area glows and a voltage 24 V is switched
further through X 102 : 11 to the gearbox control system EST 37 ( PIN 66 ).
GEARBOX NEUTRALISATION
Signal processing in EST 37

Wiring
If a voltage 24 V stands by at the gearbox control system EST 37 at PIN 66 / input ED9, the
Diagram
proportional valves Y1-Y6 are not supplied with current.
Now the gearbox is shifted into the “idling position”.
Sheet 16
This function is effective only with the 1st to 3rd gears forwards and with the 1st reverse gear.
Reversing light / Disconnection of reversing alarm (Option)
ACTIVATION OF REVERSING LIGHT:
The reversing signal is forwarded by the gear selector (B12, PIN R) to the gearbox control system
Wiring
EST-37, PIN 64.
Diagram
The gearbox control system EST-37 informs the console A 100 for each data set, through the
Sheet 16
CAN-Bus and connector XCAN, about the selected drive direction.
A 100 X4:10 switches 24V to the reversing light (E50) Wiring

Reversing light ON Diagram
At intervals A 100 forwards a voltage of 24V through X4 : 12 to relay K81.2, this changes its
switching condition Sheet 12
Wiring
and switches 24V from fuse F2, 10A and achieves the reversing signal horn (H81) Diagram
Reversing signal horn ON
Sheet 19
DISCONNECTION OF REVERSING ALARM:
Wiring
If on the console the push-button switch F3 is operated, the console A 100 prevents the relay
Diagram
K 81.2 from being activated through output X4 : 12.
Reversing signal horn OFF
Sheet 12
Parking brake
POWER SUPPLY
Ignition ON
Wiring
Diagram
This fuse protects the following circuits:
• Air conditioning system, dual hydraulic system control, solenoid valve, parking brake
Sheet 8
• Front position lights, with min. 15 A.
ACTUATION
A voltage 24 V coming from fuse F23 stands by at latching switch S 16. If the switch is in its
latching position and the warning lamp glows on the switch: Warning lamp H2 ON. In this position,
the solenoid valve Y 16 remains currentless and the parking brake is closed by the spring force.
Parking brake “ON” Wiring
Diagram
If switch S16 is released from its latching position, its switching contact closes the connection to
solenoid valve Y 16. This is triggered through Sheet 8
X 124 : 10 and X 33.10 : 23 with 24 V. After this, it changes its switching condition and lets the
hydraulic oil flow into the spring chamber of the brake cylinder and opens the brake.
Parking brake “RELEASED”
RESPONSE OF THE GEARBOX CONTROL SYSTEM

Power supply
The pressure switch S 16.1, fitted into the oil circuit of parking brake, monitors the prevailing
pressure level.
Wiring
At a pressure under 80 bar, S 16.1 is open! EST 37 now does not recognise any voltage at ED
Diagram
10 (PIN21). This means parking brake „ON“ and the gearbox remains in idling position.
At a pressure over 80 bar, S 16.1 is closed! Now at EST 37 ED 10 (PIN21) a voltage 24 V stands
Sheet 16
by. This means that the parking brake is released and the gearbox may shift the selected driving
functions.
Gear shifting Automatic / Manual
POWER SUPPLY
Ignition ON
Wiring
Diagram
This fuse protects the following circuits::
• Gear selector, revolution sender at gearbox output shaft, parking brake
Sheet 16
• Power supply EST37, ZF- diagnostic connector with min. 7,5 A.
ACTUATION
Wiring
A voltage 24 V coming from fuse F22 stands by at rocker switch S 87.8. Diagram
By actuating the switch, a voltage 24 V is forwarded to the gearbox control system through X 102 : 6:
Sheet 8
GEAR SHIFTING, MANUAL
Signal processing in EST 37 Wiring

If a voltage 24 V stands by at the gearbox control system EST 37 at PIN 29 / input ED11, the 1st Diagram
to 6th gears forwards and the 1st to 3rd backwards can be only manually shifted. The automatic
driving mode is ineffective. Sheet 16
Cooling packet - Grid Heater - Filter Heaters (Option)
GRID HEATER (OPTION)
The grid heater requires the voltage 24 V three times as there are three heating periods.
1. before starting, 24V at GHC : 15

Inquiry on temperature through B116, should be pre-heated or not? (max. pre-heating phase
15 s)
Wiring
Signal through the Display (Z5)
Diagram
2. during the starting phase: S1 on position II (starting) then 24V at GHC : 50 (at every starting)
Sheet 9
3. after starting, 24V at GHC : D+
Inquiry on temperature through B116, should be reheated or not? (max. reheating phase 120 s)
No signal on Display, to avoid strong sootiness.
FILTER HEATERS CIRCUIT (OPTION)
The voltage is applied to the temperature sender B 116 with switched ignition through fuse F 16
10A.
The measured fuel temperature determines the switching condition of the sender. Wiring
Fuel temperature < 0 °C ➝ ON Diagram
Fuel temperature > 5 °C ➝ OFF
If the switching contact of temperature sender is close, relays K 20.3 and K 20.4 are activated. Sheet 9
Their switching contacts close and allow the heating resistances R 19 and R 20 to be supplied
with voltage. The circuits of filter heaters are protected separately by fuses F17 and F18.
SECTION 11
OPERATOR’S CAB
INDEX
11.1 CAB AND CONTROL PLATFORM REMOVAL-INSTALLATION ............................ 11-1

11.1.1 Cab removal ............................................................................................................ 11-1
11.1.2 Control platform removal ......................................................................................... 11-2
11.1.3 Control platform installation ..................................................................................... 11-4
11.1.4 Cab installation ........................................................................................................ 11-6
11.2 OPERATOR’S CAB COMPONENTS ...................................................................... 11-7
11.3 VENTILATION AND HEATING................................................................................ 11-9

11.3.1 Generalities.............................................................................................................. 11-9
11.3.2 Ventilation ................................................................................................................ 11-9
11.3.3 Heating .................................................................................................................... 11-9
11.4 AIR CONDITIONER (Option)................................................................................... 11-11

11.4.1 Switching on the air conditioner............................................................................... 11-11
11.4.2 Setting the air temperature ...................................................................................... 11-11
11.4.3 Switching off the air conditioner............................................................................... 11-11
11.4.4 Air conditioning components.................................................................................... 11-12
11.4.5 Safety instructions for inspection and servicing work .............................................. 11-14
11.4.6 Inspection and servicing work.................................................................................. 11-15
F156.6 / F156.6A OPERATOR’S CAB 11 - 1
11.1 CAB AND CONTROL PLATFORM REMOVAL-INSTALLATION

11.1.1 CAB REMOVAL
DANGER
Make sure that no bystanders are in the vicinity of loads to be lifted
1
- To remove the cab, proceed with the following operations:
- Disconnect all electric connections (1) located in the lower

right side of the cab;
2
- Remove the six nuts (2) securing the cab (three each side);
3
IMPORTANT – During the removal of the cab pay attention to
cables and pipes that have not been disconnected.
- Lift cab (3) with an adequate lifting devices and remove it.
3
11 - 2 OPERATOR’S CAB F156.6 / F156.6A
1
11.1.2 CONTROL PLATFORM REMOVAL
- Remove securing screws (4) and remove hydraulic pipes
guard (5);
4 4
2
IMPORTANT – Identify the pipes before disconnecting them, to
facilitate the reinstallation.
- Disconnect all oil pipes from the front control valves and lift
them to prevent the hindering the removal of the platform;
3
- Disconnect electric connections (6), rear side of the platform; XA
5 88 X3
3.1
XC XS 0
AN
X3 .1
3
X1
.4
6
XA X3
3.1
3 8.2
2 2X 1
2X B1
B1
X1
24 C4
X1
02
X2
3
X1
04 X3
3.2
X3 X3
2.1 10 8.8
X3 X1
2.4
18
29 X2
5
X3
8 2
9X
4 E1
Y8
OKs1-11-022
4
- Remove the seat (7);
OKs1-11-023
5
- Disconnect throttle cable (8) from the injection pump;
6
- Remove the two screws (9) securing the platform (one each
side);
7
IMPORTANT – During the removal of the platform pay attention
to cables and pipes that have not been disconnected.
- Lift the platform with appropriate lifting devices and remove it.
IMPORTANT – After removing the platform, recover the silent

blocks.
11.1.3 CONTROL PLATFORM INSTALLATION
DANGER
Make sure that no bystanders are in the vicinity of loads to be lifted
1
- Lift platform with appropriate lifting devices and place and
rest it on the frame;
2
- Install the silent blocks correctly, insert screws (9) securing
the platform and tighten nuts (10);
IMPORTANT – When reinstalling the platform, pay attention 9

that the silent blocks are correctly installed.
10
3
- Install the seat (7).
OKs1-11-023
4
- Connect electric connections (6), rear side of the platform; XA
5 88 X3
3.1
XC XS 0
AN
X3 .1
3
X1
.4
6
XA X3
3.1
3 8.2
2 2X 1
2X B1
B1
X1
24 C4
X1
02
X2
3
X1
04 X3
3.2
X3 X3
2.1 10 8.8
X3 X1
2.4
18
29 X2
5
X3
8 2
9X
4 E1
Y8
OKs1-11-022
5
- Connect throttle cable (8) on the injection pump;
6
IMPORTANT – Comply with the marks made during the disas-
sembly.
- Connect all oil pipes to the front control valves;
7
- Install hydraulic pipes guard (5) and secure it with its screws
(4);
4
11.1.4 CAB INSTALLATION
DANGER
8
- Lift the cab (3) with appropriate lifting devices and place and
rest it on the platform.
3
IMPORTANT – During the reinstallation of the cab, pay attention
to the correct installation of the front seal.
9
- Install correctly the silent blocks, insert the cab securing
screws and tighten nuts (2);
IMPORTANT – When reinstalling the cab, pay attention that the

silent blocks are correctly installed.
10
- Connect electric connections (1) relative to he cab located on
the right lower side.
11.2 OPERATOR’S CAB COMPONENTS
168
11 303
300 169
105
353
301 112
168
169
351
352 165
350
10
354
OKs1-11-014
10. Cab door left-hand 301. Pane

11. Cab door right-hand 302. Pane
105. Windscreen wiper 303. Pane
112. Front windscreen washer pump and reservoir 350. Front working headlight
165. Rear roller blind 351. Rear working headlight
168. Window strip 352. Rear windscreen wiper
169. Profile 353. Rear windscreen washer pump and reservoir
300. Pane 354. Front roller blind
NOTES:
11.3 VENTILATION AND HEATING
11.3.1 GENERALITIES
The driver’s cab is ventilated by 2 sliding windows
(optional), 2 front hinged windows and an electric
blower. It is heated by an engine-water heating
system.
As the coolant flows through the heat exchanger of

the cab, the heating performance is dependent on
the engine temperature. The full heating perform-
ance is not available until the engine has reached
running temperature.
OKs1-11-001
11.3.2 VENTILATION
• With the engine stationary, turn key-switch (73) to
position 1.
11.3.3 HEATING
The heating performance can be continuously regu-
lated by means of the draw-button (99).
Max. heating = draw-button pulled up com
Heating off = draw-button pushed in completely
Run the heating at least once a week

for about 5 minutes at max. perform-
ance to mix the water in the heat ex- OKs1-11-002
changer of the heating system and in

the engine.
• The blower for heating and ventilation is switched

on with key (32).
Depending on the quantity of air required, switch the

blower with key (32) to stages 1 - 3.
LED OFF = blower OFF
Depress key (32) once - LED 1 on = blower stage 1
(low).
Depress key (32) twice - LED 2 on = blower stage 2
(moderate).
Depress key (32) three times - LED 3 on = blower
stage 3 (high).
Continue depressing key (32) until all LEDs are off OKs1-11-003
= blower off.
The fan can be operated in the following modes:
Fresh air - draw-button (100) pulled up
completely
Recirculated air - draw-button (100) pushed in
completely
Fresh / recirculated - mixture depending on inter-
air mediate position of draw-
button (100).
Inlet openings
The inlet opening for fresh air is located externally in
the upper cab area.
OKs1-11-004
The inlet openings for recirculated air are located in
the cab behind the driver’s seat.
The inlet openings for fresh and recirculated air must

always be unobstructed.
OKs1-11-005
Outlet nozzles
The air is blown through outlet nozzles into the
driver’s cab. All nozzles can berotated and closed.
OKs1-11-006
OKs1-11-007
11.4 AIR CONDITIONER (Option)
11.4.1 SWITCHING ON THE AIR

CONDITIONER
• Starting the engine (see: "Operation and Mainte-
nance Instruction Manual").
• Switch on toggle switch (91) by pressing the switch
surface showing a symbol. The control lamp below
the symbol lights up.
The air conditioner is activated. It is switched on
with the blower switch (32).
If more air is required, the air conditioner can be
switched with the button (32) to stages 2 and 3.
OKs1-11-008
11.4.2 SETTING THE AIR TEMPERATURE

• The temperature of the air blown out by the air
conditioner can be set with the Heating drawbutton
(99). Meanings:
- Draw-button pressed in (min) = cooled air flows
out,
- Draw-button pulled out (max) = heated air flows
out.
Between these two extremes, the required tem-
perature can be set continuously.
For an increased cooling or heating perform-
ance, the blower can be switched to stages 2
and 3. OKs1-11-003
To obtain a good cooling performance, make sure:

- the fresh air intake at the back of the cab is not
covered up or contaminated,
- the filter mat and the lamellas of the evaporator
are clean, and
- the door and the windows of the cab are closed.
Important – Further information (e.g. on adjusting

the air outflow) is given under "Ventilation and
heating".
11.4.3 SWITCHING OFF THE AIR OKs1-11-009
CONDITIONER
• Switch off toggle switch (91) by pressing the switch
surface with no symbol.
Air outlets
The integrated air conditioner has additional outlets
that can be rotated and closed as required.
11.4.4 AIR CONDITIONING COMPONENTS
E19S1
9
4
9K 3
E1 19K K2
E E19
1
4 3
5
6
7
OKs1-11-015
1. Compressor 6. Condensation outlet

2. Condensator 7. Expansion valve
3. Evaporator 8. Switch
4. Heat exchanger 9. Relays
5. Blower
XM
82
OKs1-11-016
1. Fan 2. Round nozzle
11.4.5 SAFETY INSTRUCTIONS FOR

INSPECTION AND SERVICING
WORK
The present section describes in- WORK ON THE REFRIGERANT

spection and servicing work that can CIRCUIT (QUALIFIED PERSONNEL):
be performed by the machine oper- The refrigerating agent (R 134a) used
ator. in this system is known as a safety
refrigerant. This means that it is non-
Any other work on the air conditioner combustible, non-explosive, non-
requires special knowledge and spe- toxic, non-irritating, odourless and
cial tools and may therefore be per- tasteless. Nevertheless, the fol-
formed by qualified and specially lowing points must be observed:
trained personnel only.
Entrust the work in these cases to a Av oid an y conta ct with li quid
specialized workshop for air condi- coolant. Parts of the skin that have
tioners. been in contact with refrigerant must
be treated like chilblains.
Observe the following instructions
Wear safety goggles to protect your
for your personal safety:
eyes. In the event of refrigerant
Never stick your hand or other ob-
coming into contact with your eyes
jects into the air conditioner.
seek medical advice immediately.
Shut off the engine and let it cool
down before performing any serv- When carrying out repairs on the air
icing work. conditioner, the system must be
Disconnect the fan from the power emptied. Never allow refrigerant to
supply to avoid injury when the fan escape into the environment. For
starts up inadvertently. sucking off refrigerant use only ap-
Some air conditioner components proved suction units.
(e.g. heat exchanger and the resistor
on the fan) can still be very hot after It is strictly forbidden to carry out
shut-off and may cause severe welding work on parts of the closed
burns. Wait until these components system or in the immediate vicinity
have cooled down before working on thereof. Heat leads to strong over-
them when the machine is open. pressure and may
cause damage or even an explosion
of the s ys t em ind epe nde nt of
whether the system is filled with re-
frigerant or empty.
When filled, refrigerant bottles must

not be handled roughly and not ex-
posed for prolonged periods to di-
rect sunlight or to other sources of
heat. The temperature to which a
filled refrigerant bottle is exposed
must not exceed 45°C.
It is essential to keep the refrigerant

system free from chlorine and
chloric substances as well as from
oils or greases. Evacuation and
filling units for R134a should not be
used for other substances.
11.4.6 INSPECTION AND SERVICING

WORK
Read and observe: “Safety instructions for Inspection
and servicing work”.
Location of components in the machine
IN THE CAB:
In the cab, the heater / air conditioner is installed
below the driver’s seat, where the components:
- blower (1);
- heat exchanger (2);
OKs1-11-010
- evaporator (3);
- condensation outlet (5) are assembled.
They are accessible after removal of the top cover.

Except for cleaning, the heat exchanger, the evapo-
rator and the blower do not require any servicing.
OUT THE CAB:

The condenser unit is mounted at the driver’s cab
and comprises the following components:
- condenser (6);
- coolant tank (7);
- dryer (8);
OKs1-11-011
- blower (9);
- filter mat (10)
IN THE ENGINE COMPARTMENT:

The following components are installed in the engine
compartment:
- compressor (11);
- heating valve (12).
Work to be carried out every month

(Machine operator)
The visual checks should be carried even in those
cases where the air conditioner is not used. OKs1-11-012
The air conditioner should moreover be activated
once every month for 10 - 15 minutes to prevent
drying out and embrittlement of the shaft seal in the
compressor with the risk of refrigerant leaking out of
the unit. This measure also ensures regular lubrica-
tion of the compressor components.
OKs1-11-013
Blower in heater / air conditioner
Malfunction Cause Remedial action
Blower not working Fuse defective or loose Check fuse contact, if necessary, plug in correctly.
Replace defective fuse. Reappearance of the defect
after a short time indicates a short-circuit
Check blower for blocking or other defects and

rectify
Connector loose Check that connector at the bottom of the unit is

firmly in place. Plug in properly, if necessary
Check connections at blower switch
Open the unit and check electrical connections

inside
Connecting cable damaged Replace cable, observing correct cable run and
or ripped off connection
Wrong electrical Check connecting cables and, if necessary,

connections reconnect properly
Blower switch defective Replace by OEM part
Blower assembly blocked Eliminate cause of blockage, e.g. by removing

foreign object from rotor. If necessary, install new
blower
Blower motor defective Replace blower
Blower cannot be stopped Blower switch internally Replace blower switch

short-circuited
Blower performance Wrong nominal supply Nominal voltage of conditioner and of vehicle
reduced voltage system must be identical. Replace blower
Contacts dirty Clean connector contacts. Work carefully to avoid

short-circuits
Insufficient cross-section of Lay cables with the recommended cross-sections

electrical cables
Heat exchanger very dirty Clean carefully to avoid any damage to the
exchanger resulting in consequential leaks
Blower ducts obstructed Check air ducts and outlets for obstructions and
remove any foreign objects
Insufficient cooling performance
Compressor not working Open circuit in compressor Check power supply to the clutch
solenoid
Thermostat defective Replace thermostat
V-belt loose or broken Adjust belt tension, replace belt
Belt pulley not turning Check compressor and replace, if necessary

although magnetic clutch is
engaged
Compressor clutch slipping Repair clutch or replace compressor
Evaporator flooded Expansion valve jammed or Replace expansion valve

stuck in open position
Evaporator frozen up Thermostat sensor in wrong Install sensor in another place

position
Evaporator clogged up Cooling fins dirty Clean evaporator
Loss of refrigerant Refrigerant line defective Check all lines for defects caused by external
influences or chafing
Leaks in the system Evacuate the system, refill, check for leaks and
repair
Air filter Air filter clogged up Clean air filter or replace
Heating is on Bowden cable wrongly Adjust Bowden cable (see: "Heating valve,
centered or defective adjustment of Bowden cable") or replace
Insufficient heating performance
Heating not working Cooling agent still cold Wait until the engine has reached its operating
temperature
Water valve closed Open the valve (see "Heating" section in Operator’s
Manual)
Water lines kinked or Eliminate the causes

crushed
Pressure of water pump No coolant flowing through heat exchanger. Install

insufficient an auxiliary or more powerful main pump.
Heating working with Heat exchanger or filter Clean carefully to avoid any damage resulting in
reduced performance strongly contaminated consequential leaks
Amount of water flowing Water lines crushed or kinked. Change position of

through heat exchanger hoses. Insufficient pressure of water pump
insufficient (remedial action see above)
Air in heat exchanger The radiator is self-venting when the pump pressure
is high enough. Install an auxiliary or more powerful
water pump
Conditioning unit under- Consider installing an additional heating or a more

dimensioned powerful conditioning unit
Heating cannot be stopped Bowden cable controlling Readjust the Bowden cable
the water valve wrongly
adjusted
Valve not installed correctly Check valve mounting position with respect to flow
in flow and/or reflow line and reflow direction and correct if necessary
Control element, i.e. Check control / Bowden cable and replace if

Bowden cable defective necessary
Air distribution flaps Adjustment no longer Check Bowden cables

uncontrollable possible due to kinking of
Bowden cables
Flap hinges sluggish Check flap and lubricate, if necessary
Flap deformed Check flap
Flap blocked by foreign Check flap and remove foreign object if necessary
object
Conditioner very noisy
Conditioner very noisy V-belt loose or excessively Retension V-belt or replace

worn
Clutch noisy Repair clutch
Compressor supporting Repair bracket, replace compressor

bracket loose or worn-out
parts inside the compressor
Blower motor excessively Replace blower

worn
System overfilled Evacuate refrigerant until the high pressure reading

is normal again
Not enough refrigerant in Check for leaks, refill the system

the system
NOTES:

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THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Most accidents, whether they occur in industry, on the

SAFETY INSTRUCTIONS .................................................................................. SECTION 0

TECHNICAL DATA ............................................................................................. SECTION 1

ENGINE .............................................................................................................. SECTION 2

REAR AXLE ........................................................................................................ SECTION 4

FRONT AXLE...................................................................................................... SECTION 5

HYDRAULIC SYSTEM........................................................................................ SECTION 7

BRAKE SYSTEM ................................................................................................ SECTION 8

STEERING SYSTEM .......................................................................................... SECTION 9

ELECTRICAL SYSTEM .................................................................................... SECTION 10

OPERATOR’S CAB .......................................................................................... SECTION 11

F156.6 / F156.6A INTRODUCTION IN - 1

IN - 2 INTRODUCTION F156.6 / F156.6A

FUNDAMENTAL SAFETY INSTRUCTIONS ..................................................................................... 0-1

WARNING AND INSTRUCTION SIGNS ........................................................................................... 0-8

INSPECTION AND SERVICING........................................................................................................ 0-23

F156.6 / F156.6A SAFETY INSTRUCTIONS 0-1

FUNDAMENTAL SAFETY INSTRUCTIONS

0-2 SAFETY INSTRUCTIONS F156.6 / F156.6A

Use protective equipment wherever required by the

F156.6 / F156.6A SAFETY INSTRUCTIONS 0-3

SELECTION AND QUALIFICATION OF

Do not allow persons to be trained or instructed or

0-4 SAFETY INSTRUCTIONS F156.6 / F156.6A

SAFETY INSTRUCTIONS GOVERNING

F156.6 / F156.6A SAFETY INSTRUCTIONS 0-5

SPECIAL WORK IN CONJUNCTION

For carrying out overhead assembly work always use

0-6 SAFETY INSTRUCTIONS F156.6 / F156.6A

WARNING OF SPECIAL DANGERS

Electric energy Hydraulic and pneumatic equipment

Observe the regulations in force at the respective

Carry out welding, flame-cutting and grinding work

Before carrying out welding, flame-cutting and

F156.6 / F156.6A SAFETY INSTRUCTIONS 0-7

TRANSPORTING AND TOWING

0-8 SAFETY INSTRUCTIONS F156.6 / F156.6A

WARNING AND INSTRUCTION SIGNS

F156.6 / F156.6A SAFETY INSTRUCTIONS 0-9

Always observe the warning and in-

Keep signs clean and legible.

Replace signs immediately if they

New warning and instruction signs

0 - 10 SAFETY INSTRUCTIONS F156.6 / F156.6A

F156.6 / F156.6A SAFETY INSTRUCTIONS 0 - 11

Always observe the warning and in-

Keep signs clean and legible.

Replace signs immediately if they

New warning and instruction signs

0 - 12 SAFETY INSTRUCTIONS F156.6 / F156.6A

F156.6 / F156.6A SAFETY INSTRUCTIONS 0 - 13

Never operate the machine before SAFETY BELT

Pay special attention to: Check safety belt attached to driver’s

PERSONAL PROTECTIVE WEAR Before starting work or travelling

0 - 14 SAFETY INSTRUCTIONS F156.6 / F156.6A

ENTERING AND LEAVING MARSHALLERS

F156.6 / F156.6A SAFETY INSTRUCTIONS 0 - 15

EXPLOSION HAZARD FILLING IN FUEL

0 - 16 SAFETY INSTRUCTIONS F156.6 / F156.6A

REFUELLING SYSTEM (Option)

HEALTH AND ENVIRONMENT

SECURING THE MACHINE