New Holland 6010 User manual

SERVICE MANUAL
6010 / 6510 / 7510
Tractor
Part number 47969433
1st edition English
November 2016
Replaces part number 47628612
© 2016 CNH Industrial (India) Pvt.Ltd. All Rights Reserved.

SERVICEMANUAL
6010
6510
7510
4796943328/11/2016
EN
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.102]Panandcovers....................................................................10.2
[10.106]Valvedriveandgears..............................................................10.3
[10.101]Cylinderheads.....................................................................10.4
[10.105]Connectingrodsandpistons.......................................................10.5
[10.103]Crankshaftandywheel............................................................10.6
[10.210]Liftpumpandlines.................................................................10.7
[10.206]Fuellters..........................................................................10.8
[10.218]Fuelinjectionsystem...............................................................10.9
[10.202]Aircleanersandlines............................................................10.10
[10.250]Turbochargerandlines...........................................................10.11
[10.400]Enginecoolingsystem...........................................................10.12
[10.414]Fananddrive....................................................................10.13
[10.310]Aftercooler........................................................................10.14
[10.304]Enginelubricationsystem........................................................10.15
[10.408]Oilcoolerandlines...............................................................10.16
Clutch.......................................................................................18
[18.110]Clutchandcomponents............................................................18.1
Transmission..............................................................................21
[21.114]Mechanicaltransmission...........................................................21.1
[21.112]Powershuttletransmission.........................................................21.2
[21.110]Masterclutchhousing..............................................................21.3
[21.134]Powershuttletransmissionexternalcontrols......................................21.4
[21.154]Powershuttletransmissioninternalcomponents..................................21.5
[21.120]Gearbox............................................................................21.6
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[21.126]Gearboxexternalcontrols..........................................................21.7
[21.145]Gearboxinternalcomponents......................................................21.8
[21.160]Creeper............................................................................21.9
[21.162]Reverser.........................................................................21.10
[21.168]Hi-Lounit.........................................................................21.11
[21.200]Dropbox..........................................................................21.12
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3
[25.400]Non-poweredfrontaxle............................................................25.4
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
[27.120]Planetaryandnaldrives..........................................................27.3
PowerT ake-Off(PTO).................................................................31
[31.114]Two-speedrearPowerTake-Off(PTO)............................................31.1
Brakesandcontrols....................................................................33
[33.120]Mechanicalservicebrakes.........................................................33.1
[33.202]Hydraulicservicebrakes...........................................................33.2
[33.110]Parkingbrakeorparkinglock......................................................33.3
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.104]Fixeddisplacementpump..........................................................35.2
[35.204]Remotecontrolvalves.............................................................35.3
[35.100]Mainliftsystem.....................................................................35.4
Steering.....................................................................................41
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[41.101]Steeringcontrol....................................................................41.1
[41.200]Hydrauliccontrolcomponents......................................................41.2
[41.216]Cylinders...........................................................................41.3
Wheels......................................................................................44
[44.511]Frontwheels........................................................................44.1
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.100]Harnessesandconnectors.........................................................55.2
[55.201]Enginestartingsystem.............................................................55.3
[55.301]Alternator...........................................................................55.4
[55.302]Battery..............................................................................55.5
[55.640]Electronicmodules.................................................................55.6
[55.404]Externallighting....................................................................55.7
[55.408]Warningindicators,alarms,andinstruments......................................55.8
Platform,cab,bodywork,anddecals.............................................90
[90.118]Protectionsandfootboards.........................................................90.1
[90.114]Operatorprotections...............................................................90.2
[90.120]Mechanically-adjustedoperatorseat...............................................90.3
[90.100]Enginehoodandpanels...........................................................90.4
[90.116]Fendersandguards................................................................90.5
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INTRODUCTION
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Contents
INTRODUCTION
Safetyrules.....................................................................................3
Safetyrules-Healthandsafety................................................................5
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INTRODUCTION
Safetyrules
PAYATTENTIONTOTHISSYMBOL
Thiswarningsymbolpointsoutimportantmessagesinvolvingpersonalsafety.Carefullyread
thesafetyrulescontainedhereinandfollowadvisedprecautionstoavoidpotentialhazardsand
safeguardyoursafetyandpersonalintegrity.Inthismanualyouwillndthissymboltogetherwiththe
followingkey-words:
WARNING–Itgiveswarningaboutimproperrepairoperationsandderivingpotentialconsequences
affectingtheservicetechnician’spersonalsafety.
DANGER–Itgivesspecicwarningaboutpotentialdangersforpersonalsafetyoftheoperator
orotherpersonsdirectlyorindirectlyinvolved.
TOPREVENTACCIDENTS
Mostaccidentsandpersonalinjuriestakingplaceinworkshopsareduefromnon-observanceofsomesimpleand
essentialprudentialruleandsafetyprecautions.Thepossibilitythatanaccidentmightoccurwithanytypeofmachines
shouldnotbedisregarded,nomatterhowwellthemachineinquestionwasdesignedandbuilt.
Awiseandcarefulservicetechnicianisthebestprecautionsagainstaccidents
Carefulobservanceofthisonlybasicprecautionwouldbeenoughtoavoidmanysevereaccidents.
NOTE:Nevercarryoutanycleaning,lubricationormaintenanceoperationswhentheengineisrunning.
SAFETYRULES
Generalities
•Carefullyfollowspeciedrepairandmaintenanceprocedures.
•Donotwearrings,wristwatches,jewels,unbuttonedorappingclothingsuchasties,tornclothes,scarves,open
jacketsorshirtswithopenzipswhichcouldgetcaughtinmovingparts.Useapprovedsafetyclothingsuchas
anti—slippingfootwear,gloves,safetygoggles,helmets,etc.
•Wearsafetyglasseswithsideguardswhencleaningpartsusingcompressedair.
•Damagedorfrayedwiresandchainsareunreliable.Donotusethemforliftingortowing.
•Wearsuitableprotectionsuchasapprovedeyeprotection,helmets,specialclothing,glovesandfootwearwhenever
welding.Allpersonsstandinginvicinityoftheweldingprocessshouldwearapprovedeyeprotection.NEVER
LOOKATTHEWELDINGARCIFYOUREYESARENOTSUITABLYPROTECTED.
•Nevercarryoutanyrepaironthemachineifsomeoneissittingontheoperator’sseat,excepttheyarequalied
operatorsassistingintheoperationtobecarriedout.
•Neveroperatethemachineoruseattachmentsfromaplaceotherthansittingattheoperator’sseatorattheside
ofthemachinewhenoperatingthefenderswitches.
•Nevercarryoutanyoperationonthemachinewhentheengineisrunning,exceptwhenspecicallyindicated.Stop
theengineandensurethatallpressureisrelievedfromhydrauliccircuitsbeforeremovingcaps,covers,valves,etc.
•Allrepairandmaintenanceoperationsshouldbecarriedoutwithgreatestcareandattention.
•Disconnectthebatteriesandlabelallcontrolstowarnthatthetractorisbeingserviced.Blockthemachineandall
equipmentwhichshouldberaised.
•Nevercheckorllfueltanksorbatteries,norusestartingliquidifyouaresmokingornearopenamesassuch
uidsareammable.
•Thefuelllinggunshouldalwaysremainincontactwithllerneck.Maintainthiscontactuntilthefuelstopsowing
intothetanktoavoidpossiblesparksduetostaticelectricitybuild-up.•T otransferafailedtractor,useatrailerof
alowloadingplatformtrolleyifavailable.
•T oloadandunloadthemachinefromthetransportationmeans,selectaatareaprovidingarmsupporttothe
trailerortruckwheels.Firmlytiethemachinetothetruckorthetrailerplatformandblockwheelsasrequiredby
thetransporter.
•Alwaysuseliftingequipmentofappropriatecapacitytoliftormoveheavycomponents.
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INTRODUCTION
•Chainsshouldalwaysbesafelyfastened.
•Ensurethatfasteningdeviceisstrongenoughtoholdtheloadforeseen.Nopersonsshouldstandnearthefastening
point.
•TheworkingareashouldbealwayskeptCLEANandDRY .Immediatelycleananyspillageofwateroroil.
•Neverusegasoline,dieseloilorotherammableliquidsascleaningagents.Usenonammablenon-toxicpropri-
etarysolvents.
•Donotpileupgreaseoroilsoakedrags,astheyconstituteagreatrehazard.Alwaysplacethemintoametal
container.
STARTUP
•Neverruntheengineinconnedspaceswhicharenotequippedwithadequateventilationforexhaustgasextrac-
tion.
•Neverbringyourbody,arms,legs,feet,hands,ngersnearfansorrotatingbelts.
ENGINE
•Alwaysloosentheradiatorcapveryslowlybeforeremovingittoallowpressureinthesystemtodissipate.Coolant
shouldbetoppeduponlywhentheengineisstopped.
•Donotllupfueltankwhentheengineisrunning.
•Neveradjustthefuelinjectionpumpwhenthetractorismoving.Neverlubricatethetractorwhentheengineis
running.
ELECTRICALSYSTEMS
•Ifitisnecessarytouseauxiliarybatteries,cablesmustbeconnectedatbothsidesasfollows:(+)to(+)and(-)to
(-).Avoidshort-circuitingtheterminals.GASRELEASEDFROMBATTERIESISHIGHLYFLAMMABLE.During
charging,leavethebatterycompartmentuncoveredtoimproveventilation.Avoidsparksoramesnearthebattery
area.Donotsmoke.
•Donotchargebatteriesinconnedspaces.
•Alwaysdisconnectthebatteriesbeforeperforminganytypeofserviceontheelectricalsystem.
HYDRAULICSYSTEMS
•Someuidcomingoutfromaverysmallportcanbealmostinvisibleandbestrongenoughtopenetrateskin.
Forthisreason,NEVERUSEYOURHANDSTOCHECKFORLEAKS,butuseapieceofcardboardorapiece
ofwoodforthispurpose.Ifanyuidisinjectedintotheskin,seekmedicalaidimmediately.Lackofimmediate
medicalattentionmayresultinseriousinfectionsordermatitis.
•Alwaystakesystempressurereadingsusingtheappropriategauges.
WHEELSANDTIRES
•Checkthatthetyresarecorrectlyinatedatthepressurespeciedbythemanufacturer.Periodicallycheckfor
possibledamagetotherimsandtyres.
•Checkthepressureonlywhenthetractorisunloadedandtyresarecoldtoavoidwrongreadingduetoover-pres-
sure.
•Nevercut,norweldarimwiththeinatedtireassembled.
•Nevercut,norweldarimwiththeinatedtireassembled.
•Deatethetirebeforeremovinganyobjectcaughtintothetiretread.
•Neverinatetyresusingammablegasesastheymayoriginateexplosionsandcauseinjuriestobystanders.
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INTRODUCTION
Safetyrules-Healthandsafety
Healthandsafetyprecautions
Manyoftheproceduresassociatedwithvehiclemaintenanceandrepairinvolvephysicalhazardsorotherrisksto
health.Thissectionlists,alphabetically,someofthesehazardousoperationsandthematerialsandequipmentas-
sociatedwiththem.
Theprecautionsnecessarytoavoidthesehazardsareidentied.Thelistisnotexhaustiveandalloperationsand
proceduresandthehandlingofmaterials,shouldbecarriedoutwithhealthandsafetyinmind.
Acidandalkalis
seeBatteryacids,e.g.causticsoda,sulfuricacid.
Usedinbatteriesandcleaningmaterials
Irritantandcorrosivetotheskin,eyes,noseandthroat.Causesburns.
Avoidsplashestotheskin,eyesandclothing.Wearsuitableprotectiveglovesandgoggles.Candestroyordinary
protectiveclothing.Donotbreathemists.
Ensureaccesstowaterandsoapisreadilyavailableforsplashingaccidents.
Adhesiveandsealers
seeFireHighlyFlammable,Flammable,combustible.
Generallyshouldbestoredin“NoSmoking”areas;cleanlinessandtidinessinuseshouldbeobserved,e.g.
disposablepapercoveringbenches;shouldbedispensedfromapplicatorswherepossible;containers,including
secondarycontainers,shouldbelabeled.
SolventbasedAdhesive/Sealers
SeeSolvents.Followmanufacturer’sinstructions.
WaterbaseAdhesive/Sealers
Thosebasedonpolymeremulsionsandrubberlatticesmaycontainsmallamountsofvolatiletoxicandharmful
chemicals.Skinandeyecontactshouldbeavoidedandadequateventilationprovidedduringuse.Follow
manufacturer’sinstructions
ResinbasedAdhesives/Sealers
e.g.epoxiedandformaldehyderesinbased.
Mixingshouldonlybecarriedoutinwellventilatedareasasharmfulortoxicvolatilechemicalsmaybereleased.
Skincontactwithuncuredresinsandhardenerscanresultinirritation;dermatitisandabsorptionoftoxicofharmful
chemicalsthroughtheskin.Splashescandamagetheeyes
Provideadequateventilationandavoidskinandeyecontact.Followmanufacturers’instructions.
Anaerobic,CyanoacrylateandotherAcrylicAdhesives
Manyareirritant,sensitizingorharmfultotheskin.Someareeyeirritants.
Skinandeyecontactshouldbeavoidedandthemanufacturers’instructionsfollowed.
Cyanaocrylateadhesives(super-glues)mustnotcontacttheskinoreyes.Ifskinoreyetissueisbondedcover
withacleanmoistpadandgetmedicalattention.Donotattempttopulltissueapart.Useinwellventilatedareas
asvaporscancauseirritationofthenoseandeyes.
Fortwo-packsystemsseeResinbasedadhesives/sealers.
Isocyanate(Polyurethane)Adhesives/Sealers
—seeResinbasedAdhesives.
Individualssufferingfromasthmaorrespiratoryallergiesshouldnotworkwithornearthesematerialsassensitivity
reactionscanoccur.
Anysprayingshouldpreferablybecarriedoutinexhaustventilatedboothsremovingvapors’andspraydroplets
formthebreathingzone.Individual’sworkingwithsprayapplicationsshouldwearsuppliedairrespirators
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INTRODUCTION
Antifreeze
-seeFire,Solventse.g.Isopropanol,EthyleneGlycol,Menthol.
HighlyFlammable,Flammable,Combustible.Usedinvehiclecoolingsystems,brakeairpressuresystems,
screenwashsolutions.
Vaporsgivenofffromcoolantantifreeze(glycol)ariseonlywhenheated.
Antifreezemaybeabsorbedthroughskinintoxicorharmfulquantities.Antifreezeifswallowedisfatalandmedical
attentionmustbefoundimmediately.
Arcwelding
seeWelding
Batteryacids
seeAcidsandAlkalis.
Gasesreleasedduringchargingareexplosive.Neverusenakedamesorallowsparksnearchargingorrecently
chargedbatteries.
Brakeandclutchuids(PolyalkyleneGlycols)
-seeFireCombustible.
Splashestotheskinandeyesareslightlyirritating.Avoidskinandeyecontactasfaraspossible.Inhalationof
vaporshazardsdonotariseatambienttemperaturesbecauseoftheverylowvaporpressure
Brazing
Seewelding
Chemicalmaterials-General
-seeLegalAspects
Chemicalmaterialssuchassolvents,sealers,adhesives,paints,resinfoams,batteryacids,antifreeze,brake
uids,oilsandgreaseshouldalwaysbeusedwithcautionandstoredandhandledwithcare.Theymaybetoxic,
harmful,corrosiveirritantorhighlyinammableandgiverisetohazardousfumesanddusts.
Theeffectsofexcessiveexposuretochemicalsmaybeimmediateordelayed;brieyexperiencedorpermanent;
cumulative;supercial;lifethreateningormayreducelifeexpectancy.
Do’s
Doremovechemicalmaterialsfromtheskinandclothingassoonaspracticableaftersoiling.Changeheavily
soiledclothingandhaveitcleaned.
Docarefullyreadandobservehazardandprecautionwarninggivenonmaterialcontainers(labels)andinany
accompanyingleaets,posterorotherinstructions.Materialhealthandsafetydatasheetscanbeobtained
frommanufacturers’.
Doorganiseworkpracticesandprotectiveclothingtoavoidsolingoftheskinandeyes;breathing
Vapors/aerosols/dusts/fumesinadequatecontainerlabelling;reandexplosionhazards.
Dowashbeforejobbreaks;beforeeating,smoking,drinkingorusingtoiletfacilitieswhenhandlingchemical
materials.
Dokeepworkareasclean,unclutteredandfreeofspills.
Dostoreaccordingtonationalandlocalregulations.
Dokeepchemicalmaterialsoutofreachofchildren.
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INTRODUCTION
Donot’s
Donotmixchemicalmaterialsexceptunderthemanufacturers’instructions;somechemicalscanformothertoxic
orharmfulchemicals;giveofftoxicorharmfulfumes;beexplosivewhenmixedtogether.
Donotspraychemicalmaterials,particularthosebasedonsolvents,inconnedspacese.g.whenpeopleare
insideavehicle.
Donotapplyheatorametochemicalmaterialsexceptunderthemanufacturers’instructions.Somearehighly
inammableandsomemayreleasetoxicorharmfulfumes.
Donotleavecontainersopen.Fumesgivenoffcanbuilduptotoxic,harmfulorexplosiveconcentrations.Some
fumesareheavierthanairandwillaccumulateinconnedareas,pitsetc.
Donottransferchemicalmaterialstounlabeledcontainers.
Donotcleanhandsorclothingwithchemicalmaterials.Chemicals,particularlysolventsandfuelswilldrytheskin
andmaycauseirritationwithdermatitis.Somecanbeabsorbedthroughtheskinintoxicorharmfulquantities.
Donotuseemptiedcontainersforothermaterials,exceptwhentheyhavebeencleanedundersupervised
conditions.
Donotsnifforsmellchemicalmaterials.Briefexposuretohighconcentrationsoffumescanbetoxicorharmful.
Clutchuids
seeBrakeandClutchFluids.
Clutchliningsandpads
seeBrakeandClutchLiningsandPads.
Corrosionprotectionmaterials
seeSolvents,Fire.
Highlyammable,ammable.
Thesematerialsarevariedandthemanufactures’instructionsshouldbefollowed.Theymaycontainsolvents,
resins,petroleumproductsetc.skinandeyecontactshouldbeavoided.Theyshouldonlybesprayedinconditions
ofadequateventilationandnotinconnedspaces.
Cutting
seeWelding
De-waxing
seeSolventsandFuels(Kerosene).
Dusts
Powder,dustsorcloudsmaybeirritant,harmfulortoxic.Avoidbreathingdustsfrompowderychemicalmaterialsor
thosearisingfromdryabrasionoperations.Wearrespiratoryprotectionifventilationisinadequate.
Electricshock
Electricshockscanresultfromtheuseofthefaultyelectricalequipmentorfromthemisuseofequipmentevenin
goodcondition.
Ensurethatelectricalequipmentismaintainedingoodconditionandfrequentlytested.
Ensurethatexes,cables,plugsandsocketsarenotfrayed,kinked,cut,crackedorotherwisedamaged.
Ensurethatelectricequipmentisprotectedbythecorrectratedfuse.
Nevermisuseelectricalequipmentandneveruseequipmentwhichisinanywayfaulty.Theresultscouldbefatal.
Usereducedvoltageequipmentwherepossibleinpreferencetoelectricalequipment.
Incasesofelectrocution:-
•switchoffelectricitybeforeapproachingvictim
•ifthisisnotpossible,pushordragvictimfromsourceofelectricityusingdrynon—conductivematerial
•Commenceresuscitationiftrainedtodoso.
•SUMMONMEDICALASSISTANCE
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INTRODUCTION
Exhaustfumes
Thesecontainasphyxiating,harmfulandtoxicchemicalsandparticlessuchascarbonoxides,nitrogenoxides,alde-
hydes,leadandaromatichydrocarbons.Enginesshouldonlyberununderconditionsofadequateextractionor
generalventilatorandnotinconnedspaces.
Gasoline(petrol)engine
Theremaynotbeadequatewarningpropertiesofodororirritationbeforeimmediateanddelayedtoxicorharmful
effectsarise.
Dieselengine
Soot,discomfortandirritationusuallygiveadequatewarningofhazardousfumeconcentrations.
Fibreinsulation
seeDucts
Usedinnoiseandsoundinsulation.
Thebrousnatureofsurfacesandcutedgescancauseskinirritation.Thisisusuallyaphysicalandnotachemical
effect.
Precautionsshouldbetakentoavoidexcessiveskincontactthroughcarefulorganizationofworkpracticesandthe
useofgloves.
Fire
seeWelding,Foams,andLegalAspects.
Manyofthematerialsfoundonorassociatedwiththerepairofvehiclesarehighlyinammable.Somegiveofftoxic
orharmfulfumesifburnt.
Observestrictresafetywhenstoringandhandlingammablematerialsorsolvents,particularlynearelectricalequip-
mentorweldingprocesses.
Ensurebeforeusingelectricalorweldingequipmentbutthatthereisnorehazardpresent.
Havesuitablereextinguisheravailablewhenusingweldingorheatingequipment.
Firstaid
Apartfrommeetinganylegalrequirementsitsdesirableforsomeoneintheworkshoptobetrainedinrstaidproce-
dures.
Splashesintheeyeshouldbeushedwithcleanwaterforatleasttenminutes.
Soiledskinshouldbewashedwithsoapandwater.
Inhalationaffectedindividualsshouldberemovedtofreshairimmediately.
Ifswallowedorifeffectspersistconsultadoctorwithinformation(label)onmaterialused.
Donotinducevomiting(unlessindicatedbymanufacturer)
Foams
seeFire.
Usedinsoundandnoiseinsulation.Curedfoamsusedinseatandtrimcushioning.
Followmanufacturers’instructions.
Unreactedcomponentsareirritatingandmaybeharmfultotheskinandeyes.Wearglovesandgoggles.
Individualswithchronicrespiratorydiseases,asthma,bronchialmedicalproblemsorhistoriesofallergicdiseases
shouldnotworkwithornearuncuredmaterials.
Thecomponents,vapors,spraymistscancausedirectirritation,sensitivityreactionsandmaybetoxicorharmful.
Vaporsandspraymistsmustnotbebreathed.Thesematerialsmustbeappliedwithadequateventilationandrespi-
ratoryprotection.Donotremoverespiratorimmediatelyafterspraying,waituntilvapor/mistshavecleared.
Burningoftheuncuredcomponentsandthecuredfoamscangeneratetoxicandharmfulfumes.
Smoking,openamesortheuseofelectricalequipmentduringfoamingoperationsanduntilvapors/mistshave
clearedshouldnotbeallowed.Anyheatcuttingofcuredfoamsorpartiallycured-foamsshouldbeconductedwith
extractionventilation(seeBodySection44LegalandSafetyAspects).
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INTRODUCTION
Fuels
seeFire,LegalAspects,Chemicals-General,Solvents.
Usedasfuelsandcleaningagents.
Gasoline(petrol)
Highlyammable.
Swallowingcanresultinmouthandthroatirritationandabsorptionfromthestomachcanresultindrowsinessand
unconsciousness.Smallamountscanbefataltochildren.Aspirationofliquidintothelungs,e.g.throughvomiting,
isaveryserioushazard.
Gasolinedriestheskinandcancauseirritationanddermatitisonprolongedorrepeatedcontact.Liquidintheeye
causesseveresmarting.
Motorgasolinemaycontainappreciablequantitiesofbenzene,whichistoxicuponinhalationandtheconcentrations
ofgasolinevaporsmustbekept.verylow.Highconcentrationswillcauseeye,noseandthroatirritation,nausea,
headache,depressionandsymptomsofdrunkenness.Veryhighconcentrationswillresultinrapidlossofconscious-
ness.
Ensurethereisadequateventilationwhenhandlingandusinggasoline.Greatcaremustbetakentoavoidtheserious
consequencesofinhalationintheeventofvaporbuilduparisingfromspillagesinconnedspaces.
Specialprecautionsapplytocleaningandmaintenanceoperationsongasolinestoragetanks.Gasolineshouldnot
beusedasacleaningagent.Itmustnotbesiphonedbymouth.
Kerosene(Parafn)
Usedalsoasheatingfuel,solventandcleaningagent.
Flammable.
Irritationofthemouthandthroatmayresultfromswallowing.Themainhazardfromswallowingarisesifliquidaspi-
rationintothelungsoccurs.Liquidcontactdriestheskinandcancauseirritationordermatitis.Splashesintheeye
maybeslightlyirritating.
Innormalcircumstancesthelowvolatilitydoesnotgiverisetoharmfulvapors.Exposuretomistsandvaporsfrom
keroseneatelevatedtemperaturesshouldbeavoided(mistsmayariseinde-waxing).Avoidskinandeyecontact
andensurethereisadequateventilation.
Gas-oil(dieselfuel)
seeFuels(Kerosene).Combustible.
Grossorprolongedskincontactwithhighboilinggasoilsmayalsocauseseriousskindisordersincludingskincancer.
Gascylinders
seeFire.
Gasessuchasoxygen,acetylene,carbondioxide,argonandpropanearenormallystoredincylindersatpressuresof
upto2000Ib/sq.in.(13,790kn/m2)andgreatcareshouldbetakeninhandlingthesecylinderstoavoidmechanical
damagetothemortothevalvegearattached.Thecontentsofeachcylindershouldbeclearlyidentiedbyappropriate
markings.
Cylindersshouldbestoredinwellventilatedenclosures,andprotectedfromiceandsnow,ordirectsunlight.Fuel
gases(e.g.acetyleneandpropane)shouldnotbestoredincloseproximitytooxygencylinders.
Careshouldbeexercisedtopreventleaksfromgascylindersandlines,andtoavoidsourcesofignition.Onlytrained
personnelshouldundertakeworkinvolvinggascylinders
Gases
seeGasCylinders
Gasshieldedwelding
-seeWelding.
Gaswelding
-seeWelding.
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INTRODUCTION
Generalworkshoptoolsandequipment
Itisessentialthatalltoolsandequipmentaremaintainedingoodconditionandthecorrectsafetyequipmentused
whererequired.
Neverusetoolsorequipmentforanypurposeotherthanthatforwhichtheyweredesigned.
Neveroverloadequipmentsuchashoists,jacks,axleandchassisstandsorliftingslings.Damagecausedbyover-
loadingisnotalwaysimmediatelyapparentandmayresultinafatalfailurehenexttimethattheequipmentisused.
Donotusedamagedordefectivetoolsorequipment,particularlyhighspeedequipmentsuchasgrindingwheels.A
damagedgrindingwheelcandisintegratewithoutwarningandcauseseriousinjury.
Wearsuitableeyeprotectionwhenusinggrinding,chiselingorsandblastingequipment
Wearasuitablebreathingmaskwhenusingsandblastingequipment,workingwithasbestosbasedmaterialsorusing
sprayingequipment
Glues
seeAdhesivesandSealers.
Highpressureair,lubricationandoiltest
Equipment
seeLubricantsandGreases.
AlwayskeephighpressureequipmentingoodConditionandregularlymaintained,particularlyatjointsandunions.
Neverdirectahighpressurenozzleattheskinastheuidmaypenetratetotheunderlyingtissueetc.andcause
seriousinjury.
Legalaspects
Manylawsandregulationsmakerequirementsrelatingtohealthandsafetyintheuseofmaterialsandequipmentin
workshops.
Workshopsshouldbefamiliar,indetail,withassociatedlawsandregulations.Consultlocalfactoryinspectorsifin
anydoubt.
Lubricantsandgreases
Avoidallprolongedandrepeatedcontactwithmineraloils,especiallyusedoils.Usedoilscontaminatedduringservice
(e.g.routineservicechangesumpoils)aremoreirritatingandmorelikelytocauseseriouseffectsincludingskin
cancerintheeventofgrossandprolongedskincontact.Washskinthoroughlyafterworkinvolvingoil.Proprietary
handcleanersmaybeofvalueprovidedtheycanberemovedfromtheskinwithwater.Donotusepetrol,parafnor
othersolventstoremoveoilfromtheskin.
Lubricantsandgreasesmaybeslightlyirritatingtotheeyes.
Repeatedorprolongedskincontactshouldbeavoidedbywearingprotectiveclothingifnecessary.Particularcare
shouldbetakenwithusedoilsandgreasescontaininglead.Donotallowworkclothingtobecontaminatedwithoil.
Drycleanorlaundersuchclothingatregularintervals.Discardoilsoakedshoes.
Donotemployusedengineoilsaslubricantsorforanyapplicationwhereappreciableskincontactislikelytooccur.
Usedoilsmayonlybedisposedofinaccordancewithlocalregulations.
Therearepublicationsdescribingtheproblemsandadvisingonprecautionarymeasures.
Noiseinsulationmaterials
SeeFoams,FibreInsulation.
Paints
seeSolventsandChemicalMaterials-General.
HighlyFlammable,Flammable.
ONEPACK.
Cancontainharmfulortoxicpigments,driersandothercomponentsaswellassolvents.Sprayingshouldonlybe
carriedoutwithadequateventilation.
4796943328/11/2016
10

INTRODUCTION
TWOPACK.
Canalsocontainharmfulandtoxicunreactedresinsandresinhardeningagents.Themanufacturer’sinstructions
shouldbefollowedandthesectionofpage5onresinbasedadhesives,isocyanatecontainingAdhesivesandFoams
shouldbeconsulted.
Sprayingshouldpreferablybecarriedoutinexhaustedventilatedboothsremovingvaporandspraymistsfromthe
breathingzone.Individualsworkinginboothsshouldwearrespiratoryprotection.Thosedoingsmallscalerepairwork
intheopenshopshouldwearsuppliedairrespirators.
PAINTTHINNERS-seeSolvents.
PETROL-seeFuels(Gasoline).
PressurisedEquipment-seeHighPressureAir,LubricationandOilTestEquipment.
ResistanceWelding
seeWelding
Sealers
seeAdhesivesandSealers.
Solder
seeWelding.
Soldersaremixturesofmetalssuchthatthemeltingpointofthemixtureisbelowthatoftheconstituentmetals(nor-
mallyleadandtin).Solderapplicationdoesnotnormallygiverisetotoxicleadfumes,providedagas/airameis
used.Oxy-acetyleneamesshouldnotbeused,astheyaremuchhotterandwillcauseleadfumestobeevolved.
Somefumesmaybeproducedbytheapplicationofanyametosurfacescoatedwithgreaseetc.andinhalationof
theseshouldbeavoided.
Removalofexcesssoldershouldbeundertakenwithcare,toensurethatneleaddustisnotproduced,Whichcan
givetoxiceffectsifinhaled.Respiratoryprotectionmaybenecessary.
Solderspillageandlingshouldbecollectedandremovedpromptlytopreventgeneralaircontaminationbylead.
Highstandardsofpersonalhygienearenecessaryinordertoavoidindigestionofleadorinhalationofsolderdust
fromclothing.
Solvent
seeChemicalMaterials-General
Fuels(Kerosene),Fire.
e.g.Acetone,whitespirit,toluene,xylene,trichlorethane.
Usedincleaningmaterials,de-waxing,paints,plastics,resins,thinnersetc.
HighlyInammable,Flammable.
Skincontactwilldecreasetheskinandmayresultin.-irritationanddematitisfollowingrepeatedorprolongedcontact.
Somecanbeabsorbedthroughtheskinintoxicorharmfulquantities.
Splashesintheeyemaycausesevereirritationandcouldleadtolossofvision.
Briefexposuretohighconcentrationsofvaporsormistswillcauseeyeandthroatirritation,drowsiness,dizziness,
headachesandintheworstcircumstances,unconsciousness.
Repeatedorprolongedexposurestoexcessivebutlowerconcentrationsofvaporsormists,forwhichtheremight
notbeadequatewarningindications,cancausemoreserioustoxicorharmfuleffects.Aspirationintothelungs(e.g.
throughvomiting)isthemostseriousconsequenceofswallowing.
Avoidsplashestotheskin,eyesandclothing.Wearprotectivegloves,gogglesandclothingifnecessary.
Ensuregoodventilationwheninuse,avoidbreathingfumes,vaporsandspraymistsandkeepcontainerstightly
sealed.Donotuseinconnedspaces.
Whenthesprayingmaterialcontainssolvents,e.g.paints,adhesives,coatings,useextractionventilationorpersonal
respiratoryprotectionintheabsenceofadequategeneralventilation.
Donotapplyheatorameexceptunderspecicanddetailedmanufacturersinstructions.
SoundInsulation
seeFibreInsulation,Foams.
4796943328/11/2016
11

INTRODUCTION
SpotWelding
-seeWelding.
Suspendedloads
Thereisalwaysadangerwhenloadsareliftedorsuspended.Neverworkunderanunsupportedsuspendedorraised
load,e.g.jackedupvehicle,suspendedengine,etc.
Alwaysensurethatliftingequipmentsuchasjacks,hoists,axlestands,slings,etc.areadequateandsuitableforthe
job,ingoodconditionandregularlymaintained.
Neverimproviseliftingtackle.
Underseal
seeCorrosionProtection
Welding
seeFire,ElectricShock,GasCylinders.WeldingprocessesincludeResistanceWelding(SpotWelding),ArcWelding
andGasWelding.
Resistancewelding
Thisprocessmaycauseparticlesofmoltenmetaltobeemittedathighvelocityandtheeyesandskinmustbepro-
tected.
Arcwelding
Thisprocessemitsahighlevelofultravioletradiationwhichmaycauseeyeandskinburnstothewelderandtoother
personsnearby.Gasshieldedweldingprocessesareparticularlyhazardousinthisrespect.Personalprotectionmust
beworn,andscreensusedtoshieldotherpeople.
Metalspatterwillalsooccurandappropriateeyeandskinprotectionisnecessary.
Theheatoftheweldingarcwillproducefumesandgasesfromthemetalsbeingweldedandfromanyappliedcoatings
orcontaminationonthesurfacesbeingworkedon.Thesegasesandfumesmaybetoxicandinhalationshould
alwaysbeavoided.Theuseofextractionventilationtoremovethefumesfromtheworkingareamaybenecessary,
particularlyincaseswherethegeneralventilationispoor,orwhereconsiderableweldingworkisanticipated.In
extremecaseswhereadequateventilationcannotbeprovided,suppliedairrespiratorsmaybenecessary.
Gaswelding
Oxy-acetylenetorchesmaybeusedforweldingandcuttingandspecialcaremustbetakentopreventleakageof
thesegases,withconsequentriskofreandexplosion.
Theprocesswillproducemetalspatterandeyeandskinprotectionisnecessary.
Theameisbrightandeyeprotectionshouldbeused,buttheultra-violetemissionismuchlessthanthatfromarc
weldingandlighterltersmaybeused.
Theprocessitselfproducesfewtoxicfumes,butsuchfumesandgasesmaybeproducedfromcoatingsonthework,
particularlyduringcuttingawayofdamagedbodypartsandinhalationofthefumesshouldbeavoided.
Inbrazing,toxicfumesmaybeevolvedfromthemetalsinthebrazingrod,andaseverehazardmayariseifbrazing
rodscontainingcadmiumareused.Inthiseventparticularcaremustbetakentoavoidinhalationoffumesandexpert
advicemayberequired.
Specialprecautionmustbetakenbeforeanyweldingorcuttingtakesplaceonvesselwhichhavecontainedcom-
bustiblematerials,e.g.boilingorsteamingoutoffueltanks.
Whitespirit
Seesolvents
4796943328/11/2016
12

SERVICEMANUAL
Engine
6010
6510
7510
4796943328/11/2016
10

Contents
Engine-10
[10.001]Engineandcrankcase...............................................................10.1
[10.102]Panandcovers......................................................................10.2
[10.106]Valvedriveandgears................................................................10.3
[10.101]Cylinderheads.......................................................................10.4
[10.105]Connectingrodsandpistons.........................................................10.5
[10.103]Crankshaftandywheel..............................................................10.6
[10.210]Liftpumpandlines...................................................................10.7
[10.206]Fuellters............................................................................10.8
[10.218]Fuelinjectionsystem.................................................................10.9
[10.202]Aircleanersandlines..............................................................10.10
[10.250]Turbochargerandlines.............................................................10.11
[10.400]Enginecoolingsystem.............................................................10.12
[10.414]Fananddrive......................................................................10.13
[10.310]Aftercooler..........................................................................10.14
[10.304]Enginelubricationsystem..........................................................10.15
[10.408]Oilcoolerandlines.................................................................10.16
4796943328/11/2016
10

Engine-10
Engineandcrankcase-001
6010
6510
7510
4796943328/11/2016
10.1[10.001]/1