New Holland F156.6 and F156.6A Motor Graders Workshop Service Manual

Description

The New Holland F156.6 and F156.6A Motor Graders Workshop Service Manual (Print No. 604.13.572)

is the complete, factory-level technical reference engineered specifically for heavy equipment technicians, fleet service mechanics, and workshop specialists servicing these high-performance grading machines. Whether managing routine maintenance cycles or performing complete component tear-downs, this comprehensive New Holland F156.6 service manual provides exact assembly instructions, manufacturer specifications, step-by-step diagnostic routines, and dimensional standards required to maintain maximum machine productivity and operational reliability across both the tandem-drive F156.6 and the all-wheel-drive F156.6A variants.

Technical File Details

• Manual Type: Workshop Service Manual / Shop Repair Manual
• Machine Make: New Holland
• Equipment Model: F156.6 and F156.6A Motor Graders
• Document / Publication Number: Print No. 604.13.572 English
• Edition / Revision Date: Edition III – 2005
• Applicable Engine Model: IVECO F4BE0684H*D400 (Tier 2 Turbocharged Intercooled Diesel)
• Applicable Transmission: ZF Ergo Power 6WG160 Powershift Transmission with EST 37 A TCU
• Rear Axle Assembly: TG16 Tandem Axle with No-Spin Differential (Type 250S-133)
• Front Axle Assembly: GF16 Standard Front Axle / GF16A Hydrostatic All-Wheel Drive Front Axle
• Language: English
• File Format: Portable Document Format (PDF)

Complete Chapters and Systems Covered

• Section 0 – Safety Instructions: Fundamental safety guidelines, warning signs and indicator decaling (left and right side layouts), designated machine deployment, road travel requirements, refueling safety protocols, towing and recovery procedures, crane lifting instructions, high-pressure hydraulic safety, battery maintenance, wheel and tyre inflation precautions, and welding preparation routines.
• Section 1 – Technical Data: Comprehensive dimensional layouts (main, travel, and working dimensions with tyre-dependent variance tables), tyre inflating pressures and wheel nut torque values (550 Nm with spring washer, 650 Nm with flat washer), maximum gear travel speeds (forward 1st to 6th and reverse 1st to 3rd), complete IVECO engine parameters, ZF transmission mechanical gear ratios, hydraulic pump flows, cylinder strokes and pin diameters, lamellar braking surface areas, steering geometry, and factory lubricant classification charts.
• Section 2 – Engine (IVECO F4BE0684H*D400): Engine identification coding, general construction features, technical data tables, three-phase angle-controlled tightening torques, engine removal and chassis installation, separation and rejoining of engine-to-transmission assembly, crankcase structure, steel induction-hardened crankshaft, fracture-split connecting rods, ceramic-chrome coated piston rings, camshaft with internal oil galleries, overhead valve train mechanism, monolithic cylinder head overhaul, auxiliary Poly-V belt routing, forced-feed lubrication with plate heat exchanger, closed-circuit cooling circuit, Bosch PES 6A mechanic injection pump timing, Bosch 24V 4kW starter motor, Bosch NCBI 28V 35-70A alternator charging system, and 12-point comprehensive troubleshooting diagnostic trees.
• Section 3 – ZF Ergo Power Transmission (6WG160): Hydrodynamic torque converter with lock-up converter clutch (W 300), countershaft multi-disk powershift gearbox layout, hydraulic test port locations (system pressure, converter inlet/outlet, clutches KV, KR, K1, K2, K3, K4), main pressure regulation, subsequence slide valves, electro-hydraulic shift control valve block, ZF fine-mesh filter bypass monitoring (FDV), VTS-3 electronic speed range selector, TCU EST-37 electronic control architecture, laptop Testman diagnostic interfaces, automatic AEB shifting element calibration procedures, and complete hex fault code diagnostic tables (codes 11 through F6).
• Section 4 – Rear Axle (TG16 Tandem Drive): Axle structural identification, No-Spin mechanical differential (type 250S-133), 2.818 spiral bevel gear set backlash adjustment (0.2 to 0.3 mm) and pinion bearing preload (2 to 3 daN), 1.167 chain-driven tandem cases, 6.00 planetary hub reduction (19.731 overall reduction ratio), self-contained wet disc service brakes, maintenance schedules, oil drain and level verification, tandem axle chassis removal and installation with heavy rigging, and structural axle failure diagnostic analysis.
• Section 5 – Front Axle (GF16 / GF16A): Technical features of standard GF16 and driven GF16A axles, axle pivot mounting, wheel lean and steering geometry, kingpin and wheel hub disassembly/assembly, steering and wheel rake cylinder overhaul, complete F156.6A hydrostatic front-wheel drive (FWD) closed-loop system, Rexroth A4VG 71EP2 variable displacement pump (0–71 cm³/rev, 160 L/min, 420 bar working pressure), Poclain MS 11 radial piston dual-displacement wheel motors (1259 / 629 cm³), high-pressure lines, flow divider differential lock operation, 6/2-way freewheeling changeover valve, and full hydraulic schematic tracing.
• Section 6 – Attachment: Front leveling blade, middle moldboard assembly, drawbar circle and slewing ring drive, moldboard cutting angle adjustment, tip cylinder mechanics, moldboard side shift mechanism, and rear-mounted ripper/scarifier assemblies.
• Section 7 – Hydraulic System: Variable displacement axial piston load-sensing pump (Rexroth A10VO60DFR), hydraulic distribution blocks, pilot-operated control valves, priority demand valves, circuit relief pressure testing, and schematic diagrams.
• Section 8 – Brake System: Hydraulically operated oil-immersed lamellar multi-disc service brakes, dual tandem braking circuits, hydraulic brake booster charging valves, accumulator nitrogen pre-charge checks, and transmission-mounted mechanical disc parking brake.
• Section 9 – Steering System: Hydrostatic orbital steering valve (Rexroth Servostat LAGC160), priority flow divider, secondary emergency steering pump (16 cm³/rev, transmission-driven), steering cylinder overhaul, and wheel lean tie-rod linkages.
• Section 10 – Electrical System: Main power distribution, central console electronics, relay boards, lighting circuits, instrument cluster displays, wire harness routing, and CAN-bus communication lines linking TCU, engine, and cab controls.
• Section 11 – Operator’s Cab: ROPS/FOPS operator environment, steering console adjustments, HVAC heating and air conditioning (R134a refrigeration circuit), pedal assemblies, and hydraulic control lever linkages.

Together, these twelve detailed sections supply workshop technicians with the genuine technical roadmap required to diagnose anomalies, conduct complete mechanical overhauls, verify hydraulic flow and relief pressures, and properly execute complex electronic calibrations on all major systems of the New Holland grader.

IVECO F4BE0684H Engine Architecture & Overhaul Procedures

The heart of both grader models is the robust IVECO F4BE0684H*D400 6-cylinder, direct-injection, 5.9-liter (5883 cm³) turbocharged diesel engine equipped with charge air intercooling. Delivering a rated power of 129 kW (175 HP) at 2100 rpm and peak torque of 680 Nm at 1400 rpm, the engine utilizes a monolithic cast-iron crankcase with integrated cylinder liners (102.01 to 102.03 mm diameter) and an underslung stiffening bedplate. Technicians will find complete rebuild tolerances throughout the New Holland F156.6A workshop manual, covering piston-to-cylinder clearance (0.215 to 0.253 mm), gudgeon pin fit, ring gap tolerances for all three ring lands (including trapezoidal ceramic-chrome coated compression rings), and journal diameter standards for the seven induction-hardened main bearings (82.99 to 83.01 mm).

Specialized repair procedures detail connecting rod overhaul utilizing advanced fracture-split manufacturing technology, requiring strict pairing of rod bodies and caps. Complete multi-phase tightening sequences are provided for the cylinder head (utilizing angle-tightening through 90-degree and 180-degree increments), main bearing bed caps, connecting rod caps, and the engine flywheel. Fuel system coverage encompasses the mechanical Bosch PES 6A in-line injection pump, start-of-delivery timing (3.1 mm stroke at 0° ± 30′), DSLA 145 injector calibration at 245 bar injection pressure, and the 12-stage engine troubleshooting chart covering overheating, abnormal exhaust smoke color, power loss, and fuel delivery irregularities.

ZF Ergo Power 6WG160 Transmission & AEB Shifting Calibration

Detailed coverage of the ZF Ergo Power 6WG160 powershift transmission provides the technician with comprehensive diagnostic and service data for the hydrodynamic torque converter (model W 300 with infinitely variable torque multiplication up to 3.0:1) and the 6-speed forward, 3-speed reverse countershaft gearbox. The electro-hydraulic shift control unit houses six proportional solenoid valves (P1 through P6) regulating clutches K1, K2, K3, K4, KV (forward), and KR (reverse). Clear hydraulic flow diagrams illustrate main line system pressure (16 to 18 bar), pilot reducing pressure (9 bar), converter back-pressure (4.3 bar), and converter safety relief (11 bar).

The manual provides complete operational guidelines for the ZF EST-37 electronic control unit, detailing the Autonomous Calibration of Shifting Elements (AEB cycle). Technicians learn how to initiate the AEB procedure via diagnostic connection XA5 using either an AEB Starter tool (ZF P/N 0501 211 778) or laptop Testman software. This automated routine recalibrates clutch filling parameters, compensating for disc wear and thermal tolerances to maintain smooth gear transitions. An extensive fault-code directory outlines exact root causes, TCU failsafe responses, and step-by-step troubleshooting repair actions for codes ranging from wiring open/short circuits to clutch slippage and speed sensor deviations.

Tandem Rear Drive Axle & All-Wheel Drive Front Hydrostatics

Drive axle servicing is thoroughly documented across specialized sections. The TG16 tandem rear axle combines a central 2.818 spiral bevel gear set with a heavy-duty No-Spin mechanical differential (type 250S-133), distributing torque evenly while allowing automatic ratcheting during turns. Heavy-duty roller chain cases with an internal ratio of 1.167 power the planetary final drives (6.00:1 reduction) for a cumulative axle reduction of 19.731:1. The manual guides mechanics through pinion shim selection, bearing preload checks (2 to 3 daN), gear tooth contact pattern interpretation, and the inspection of the four integrated oil-immersed lamellar brake packs.

For the all-wheel-drive F156.6A grader, this manual provides unique coverage of the hydrostatic front-wheel drive system. Operating in a closed hydraulic loop powered by an engine-mounted Rexroth A4VG 71EP2 axial piston pump (delivering up to 160 L/min at 420 bar working pressure), propulsion is transmitted to two Poclain MS 11 radial-piston wheel motors. The workshop text details front-wheel speed synchronization with rear tandems, flow divider differential lock operation, hydraulic freewheel mode at speeds over 2 km/h via 6/2-way valving, and dual-displacement motor chamber switching (halving displacement to 629 cm³ for high-speed operation in 4th and 5th gears).

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Practical Maintenance, Hydraulic Testing & Diagnostic Utility

This F156.6 grader repair manual includes complete physical fluid specifications, listing exact capacities and viscosities for every compartment—from the 185-liter (F156.6) and 200-liter (F156.6A) hydraulic reservoirs to the 27-liter transmission initial fill, 275-liter diesel fuel tank, and tandem chain cases. Comprehensive dimensional tables cover all factory tyre combinations (17.5-25 EM, 13.00-24 TG, and 14.00-24 TG), detailing machine height, blade reach, bank-sloping angles, and ground clearances.

Every major implement cylinder—including dual moldboard lift cylinders, circle reverse motor and slewing cylinder, blade power-shift cylinder, blade pitch tip cylinder, frame articulation cylinders, and front wheel lean rake cylinders—is fully cataloged with piston diameters, rod sizes, extended/retracted lengths, stroke data, and pin journal tolerances. Hydraulic schematics clearly mark test ports, high-pressure relief valves, and pilot distribution paths, allowing service personnel to isolate weak pumps, leaking spool valves, or internal cylinder packing failures rapidly.

Professional Capability & Instant Digital Delivery

Performing repair, overhaul, and diagnostic operations with the New Holland F156.6 and F156.6A Motor Graders Workshop Service Manual ensures your machinery operates to exacting factory standards. Relying on verified engineering data eliminates guesswork, prevents costly component failures during high-load grading applications, and ensures all torque-critical fasteners, hydraulic relief pressures, and electronic control units are calibrated according to genuine manufacturer requirements.

Delivered as an instant digital PDF download immediately upon checkout, this manual provides immediate technical access without waiting for physical delivery or risking damage to scarce paper manuals. The digital document is fully compatible with Windows, macOS, iOS, and Android devices, enabling you to inspect high-resolution schematics directly on a field tablet at the job site or print targeted service pages for your workshop bench. Equip your service department with the essential technical manual for the New Holland F156.6 and F156.6A motor graders today.