Tel.

+39 0171614111 - Fax +39 0171614100

www.merlo.com - [email protected]

MAINTENANCE AND SERVICE MANUAL

VARIABLE REACH TRUCK

TRANSLATION OF THE ORIGINAL INSTRUCTIONS

PANORAMIC-02 (GB) VALID FROM SAV C422222

 INDEX

INTRODUCTION .......................................................................................................................................................... 1
MACHINE TECHNICAL INFORMATION ..................................................................................................................... 2
STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB ............................................................... 3
CONTROLS AND INSTRUMENTS .............................................................................................................................. 4
OPERATING INSTRUCTIONS..................................................................................................................................... 5
ORDINARY MAINTENANCE ....................................................................................................................................... 6
PERIODICAL SAFETY CONTROLS .......................................................................................................................... 7
ATTACHMENTS AND OPTIONAL EXTRA ................................................................................................................. 8
HYDRAULIC CIRCUITS' DIAGRAMS ......................................................................................................................... 9
ELECTRICAL SYSTEM ............................................................................................................................................. 10
PERKINS 3066/2300 WORKSHOP MANUAL AND USER MANUAL........................................................................ 11
 1 - INTRODUCTION
CONTENTS

VALIDITY OF THE MANUAL .......................................................................................................................................................... 2

GENERAL NOTES ......................................................................................................................................................................... 2

INTENDED USE OF THE MACHINE .............................................................................................................................................. 2

OPERATOR MANUAL .................................................................................................................................................................... 2

WORK ENVIRONMENT ................................................................................................................................................................. 3

FIRST COMMISSIONING OR RECOMMISSIONING AFTER A LONG SHUTDOWN.................................................................... 3

MACHINE GARAGING ................................................................................................................................................................... 4

TYRES ............................................................................................................................................................................................ 4

ORIGINAL MERLO SPARES ......................................................................................................................................................... 4

MACHINE SCRAPPING ................................................................................................................................................................. 4

WARRANTY ................................................................................................................................................................................... 5

ORDINARY MAINTENANCE OPERATIONS .................................................................................................................................. 5

INFORMATION FOR DRIVING THE MACHINE ON PUBLIC ROADS ........................................................................................... 5

SAFETY AND ACCIDENT PREVENTION MEASURES ................................................................................................................. 6

FIRE PREVENTION MEASURES .................................................................................................................................................. 7

"CE" COMPLIANCE........................................................................................................................................................................ 8

END OF SECTION ......................................................................................................................................................................... 9

1-1
 1 - INTRODUCTION

VALIDITY OF THE MANUAL

This manual is valid for the following MERLO machine models:

DEUTZ 74 kW (100CV) ENGINE

• P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10

KUBOTA 55.4 Kw (75CV) ENGINE

• P38.12 – P38.13 – P38.14 – P40.17

KUBOTA 74 Kw (100CV) ENGINE

• P38.13EE – P40.17EE – P60.10EE – P72.10EE

Pay attention to these sub-divisions when consulting the Operator's Manual.

GENERAL NOTES

This machine has been designed and manufactured according to MERLO specifications. In order to avoid accidents and
ensure the best performances over time, the machine must not be modified or altered in any way and all safety rules, as well as
the general operation instructions described in chapter "SAFETY PREVENTION MEASURES” of this instruction manual must
be respected.
Any change made to either the machine or its attachments by subjects other than Merlo S.p.A. shall forfeit the manufacturer's
liability and suspend warranty. Any civil or criminal consequences shall fall on the subject who has made the change.
All information, images and specifications contained in this manual are based on the updated product at the time of publication.
MERLO S.p.a. reserves the right to make all the necessary changes deemed necessary without prior notice.
Entrust the machine only to qualified and skilled staff whose characteristics are compliant with existing legal requirements. The
non observance of that indicated in this document may cause personal or material damage.
The handling of both the machine and loads must be carried out in an operating range free of people.

INTENDED USE OF THE MACHINE

This machine is designed and manufactured for agricultural and industrial applications. Any use in other sectors is to be
considered not compliant with its intended use.
Compliance and strict adherence to the Manufacturer's specifications for use, storage and maintenance are also fundamental
for the intended use of this machine.
This machine must only be used by qualified, skilled and authorized personnel. Operators must be familiar both with the
various components of this machine and with the safety procedures to be followed if the need arises.
Any arbitrary changes made to this machine without prior written authorization from the Manufacturer exempt Merlo S.p.A. from
any civil and/or criminal liability.

OPERATOR MANUAL

Before using your MERLO machine, it is necessary to carefully read the OPERATION AND MAINTENANCE MANUAL to fully
understand all the operation, maintenance and safety information it contains.

The operator's manual is an integral part of the machine, it shall be written in a language spoken or at least understood by the
operator and be held in the document holding pocket behind the driver's seat, so that it can be consulted at any time. Should
the manual be damaged or made illegible in any of its parts, please order a new copy from the Merlo Technical Assistance
service, by providing the identification code written in the bottom left-hand corner of the front page.
The stickers and leaflets found on the machine must always be present and accessible to the driver. Should these be
unreadable, damaged or missing, it is necessary to order them again from the Merlo Technical Assistance Service indicating
the superimposed code or referring to chapter "ADHESIVE CONTROL LABELS" of the machine operator manual.

If the machine is fitted with special applications supplied under specific customer request, which are not included in the official
list of accessories, the related instructions can be found in the last page of this manual.
Any device and/or label found on the machine and not described by the present manual are related to applications installed
under specific customer request; in this case the specific operating instructions shall be supplied separately.
The complete or partial reproduction of the Merlo operator manual is forbidden.

1-2
 1 - INTRODUCTION

SYMBOLS USED IN THE MANUAL

The operator manual contains some graphic symbols which help the user understand the importance of instructions and
highlight any specific precautions to be taken or general notes:

WARNING!
This symbol indicates important messages aimed at ensuring driver and vehicle safety. In such cases it is
necessary to carefully read the text following the symbol and strictly follow the instructions given.

NOTE!
This symbol indicates a closer description of an instruction and aims at highlighting a part of the text.

HEXAGONAL WRENCH
This symbol is used to identify the dimension of the wrench to be used for some operations described in the
manual.
The type of wrench is indicated only if different from the standard one.

OPERATOR MANUAL SYMBOL

This symbol is shown on some machine plates and warns the operator that the explanations contained in the
Operator manual shall be carefully read before using the control.

WORK ENVIRONMENT

The machines manufactured by Merlo S.p.a., are designed to be used within the following environmental temperature ranges:

- minimum temperature: - 20°C

- maximum temperature: + 40°C

Always take the atmospheric and climatic conditions of the workplace into account.
Special applications may be provided on request for particularly cold or hot environments.
A single fire extinguisher should be fitted on the machine when the workplace does not have external fire extinguishing
equipment and the risk of fires exists.
The machine is supplied with a leaflet stating the maximum permissible wind under normal operating conditions. Before using
the machine read the table showing the Beaufort scale to estimate wind strengths, so that you can check whether there are the
right conditions to ensure safety when working at a certain height. Please note that the maximum permissible value is 12.5 m/s
(level 6 on the "Beaufort scale").

CONFIGURATION FOR UNDERGROUND OPERATIONS

Merlo machines are fitted for outdoor use.

When using them in closed, underground environments or in places where a risk of explosion exists, special equipment can be
fitted on the machine. These shall be defined when ordering the machine and its attachments.

FIRST COMMISSIONING OR RECOMMISSIONING AFTER A LONG SHUTDOWN

Before operating the machine for the first time, or after a long shutdown, the following operations should be carried out:

- check that the machine is not damaged

- check that the mechanical parts of the machine are in prime condition and not rusted
- check both the engine coolant level and the coolant level for the service hydraulic system
- check the tire wear level
- check that the lights and the electrical equipment work correctly
- check for any oil leaks from the fittings or the pipes of the hydraulic system
- check both the battery electrolyte level and the battery charge
- check that all protection devices are in their correct positions
- thoroughly grease all the mobile parts of the machine

1-3
 1 - INTRODUCTION

MACHINE GARAGING

If the machine needs to be shut down for a prolonged period of time, it should be garaged in a place where it is not exposed to
atmospheric agents, and should be protected to avoid any damage. Before being garaged, the machine should be cleaned
down and all its mechanical parts properly lubricated to prevent rusting.
Check that the temperature of the garaging location is between 0°C and 50°C. For temperatures below 0°C and not more than -
29°C, the density of the antifreeze fluid in the cooling circuit of the engine must be checked. The main operations to be carried
out before garaging the machine for a prolonged period of time are listed below. Please follow these instructions:

- clean down the whole machine.

- perform a general visual inspection of the machine, so that you can identify any structural damage and/or deep abrasions
on painted surfaces.
- perform a general visual inspection of the machine, so that you can check whether all safety plates and stickers are in place
and in prime condition. Replace the damaged or illegible plates and/or stickers with new ones, to be ordered from the Merlo
Technical Assistance Service.
- lubricate and grease all mechanical parts, as well as all the pins exposed to the air.
- garage the machine in a sheltered place, and park it on a flat, compact surface.
- engage the parking brake
- take the engine start key out of the dashboard, lock the cab door and store the key in a safe place.

TYRES

Only use tyres approved by Merlo S.p.a.

If tyres are deteriorated or show excessive wear, they must be replaced with new tyres with the same characteristics. Fit tyres
suited to the operating surface conditions - several types of tyres exist (for agricultural or industrial use, sandy terrains etc.). If
needed, or in case of abnormal wear, contact your dealer. Do not fit polyurethane-filled or fluid-filled tyres if not explicitly
authorised by Merlo S.p.a.

WARNING! The list of tyres that are authorized and installed on your machine are shown in the paragraph
PERFORMANCE AND FEATURES of chapter TECHNICAL INFORMATION. In the event a type of tire needs to be
replaced with another model in the list of those authorized, contact the Merlo Technical Assistance Service, since tire
replacement may also require the replacement of the safety devices electronic management unit and load tables.

ORIGINAL MERLO SPARES

Maintenance operations on Merlo machines should be carried out only with original and approved spare parts. In this way, the
customer is legally covered and has the following advantages:

- guaranteed quality of spare parts

- guaranteed training of the technical staff
- support in preventive maintenance operations
- support in diagnosis operations

If NON original Merlo spare parts are used, the customer runs the following risks:

- from a technical point of view, this may damage or cause general operation problems to the machine
- from a legal point of view, the customer may be deemed directly liable in case of accidents
- from an economic point of view, any claims for repairs carried out in the warranty period (materials and labour) may be
rejected.

In this case Merlo S.p.A holds itself free from any liability, and the warranty terms on the machine shall no longer be applicable.
Finally, only Merlo S.p.A has all the technical and engineering know-how which ensures maximum expertise in the
maintenance if its machines.

MACHINE SCRAPPING

When the machine is scrapped, it shall be disposed of in proper dumps, in compliance with current legislation. Before
scrapping the machine, separate plastic or rubber parts, as well as electric or electronic parts, from other components. Recover
used oil and dispose of it in proper collection centres.
Parts which are solely made of plastic, aluminium or steel can be recycled if they are collected in proper collection centres.

WARNING! Used oil shall be properly recovered, and not released into the environment. Current legislation
classifies it as a hazardous substance, therefore it shall be disposed of in proper collection centres.

1-4
 1 - INTRODUCTION

WARRANTY

To benefit from the Manufacturer's warranty, the operator shall take all the precautions described in the Operator's Manual, with
particular reference to the following:

- comply with the operating limits defined by the Manufacturer

- never make any changes to the machine without prior written authorization from the Manufacturer
- always carry out all the maintenance operations prescribed by the Manufacturer
- always use Merlo original spare parts
- make sure that the personnel operating the vehicle have the necessary skills and are properly trained.

The Manufacturer's warranty shall not apply if the conditions above are not met, or are only partially met.
If spare parts which are not approved by the Manufacturer are used, any warranty shall be made void and the Manufacturer
shall be exempt from any liability for malfunctions or accidents.
The removal or modification of safety guards exonerates the Manufacturer from any liability for damage caused to property
and/or persons.

ORDINARY MAINTENANCE OPERATIONS

In order to ensure that the machine is used in maximum safety, reliability and efficiency conditions, it is key to regularly carry
out all ordinary maintenance operations following closely the instructions provided by the present operator manual.
Do not use the machine unless all maintenance operations and any necessary repair work have been executed.
Should the operator notice that the machine does not operate as it should or it does not meet all safety requirements, the
anomaly shall be immediately communicated to the person in charge.
Before carrying out any work on the machine, the engine must be stopped, the travel direction selector must be brought to its
central position and the gear selector must be in neutral gear.
Maintenance operations must be carried out by qualified and skilled staff. For any work on parts which fall outside the scope of
ordinary maintenance operations - as defined by the present operator manual - contact the Merlo Technical Support Service.
It is strictly forbidden and highly dangerous to modify any machine component by changing its original structure. it is further
forbidden to change the hydraulic and electric setup or modify the safety systems. Otherwise, Merlo S.p.A shall be relieved
from any civil or criminal liability.

INFORMATION FOR DRIVING THE MACHINE ON PUBLIC ROADS

For all information on how to drive the machine on public roads, always refer to the applicable laws of the country where the
machine is used.

1-5
 1 - INTRODUCTION

SAFETY AND ACCIDENT PREVENTION MEASURES

WARNING!
To prevent any conditions of risk, avoid accidents and injuries, minimize failures and improve the functionality and the
durability of your machine, always operate your machine correctly, obey the rules described in the following sections
of this paragraph, and take all the necessary precautions while working.

Merlo S.p.A. declines liability for any damage, accident or injury if the code of conduct described in the following sections of this
paragraph is not applied:

• SAFE USE CONDITIONS OF THE MACHINE

- the machine is not intended for use in sectors other than the one it was designed for; any use other than the one specified
by the manufacturer shall be considered improper.
- the machine shall be used by only one operator, sitting in the driver's cab.
- the machine should only be used by qualified, competent and authorized personnel. The operator shall read and
understand all the instructions provided in this operator's manual, be sufficiently trained on the correct use of the machine,
and hold a driving licence. Should the operator have any doubts on either the use of the machine or the interpretation of the
manual, they shall contact the Manufacturer.
- to drive the machine from one spot to another, the operator shall sit correctly in the driver's seat; if this is not the case, the
system will automatically lock the hydrostatic transmission.
- never operate the machine if you feel tired or sick, or if you are under the effect of alcohol, prescription drugs or illicit drugs.
- if you need to work either under poor visibility conditions or at night, always switch on the work headlights available on your
machine. As an alternative, you can install a proper external lighting system in the area you are working in.
- any arbitrary changes made to your machine shall exempt Merlo S.p.A. from any liability for any damages or injuries to the
operator, third parties or property.
- inspect your machine very carefully every time before use.
- if you stop your machine on sloping ground, place wheel chocks (if present) under its wheels.
- avoid operating the machine on a muddy, sandy or soft ground.
- never use the controls or the pipes on the machine as hand holds; these components are mobile and cannot offer a stable
grip.
- check tire inflation pressure at regular intervals, and make sure that it corresponds to the pressure value shown on the rim,
which has been determined based on the kind of soil the machine is supposed to be operated on.
- never use your machine to transport people or animals.
- never use your machine to lift people or animals.
- always refer to the load chart of your machine, which defines the maximum load capacity depending on the extension of the
telescopic boom.
- never leave your machine unattended while the engine is still running or when loads are hanging from the telescopic boom.
- before getting off the machine and before carrying out any maintenance operations, apply the parking brake, switch off the
engine and take the engine start key out of the dashboard.
- always fasten your seat belt while driving your machine from one spot to another on a site.

• PERSONAL PROTECTION SYSTEMS

- the personnel shall use both safety devices and personal protective
equipment during machine operation, servicing and maintenance. Machine
operators shall avoid wearing jewellery or loose clothes that may get caught
in machine parts or gears.
- if you usually work in particularly dusty or dry environments, you are
advised to inspect the filters of the cab ventilation system periodically and
to wear respiratory protection devices, such as dust masks or masks
equipped with filters.
- some personal protective equipment are shown here by way of example
only. Such devices should be used by telehandler operators while working
on and servicing their machines, as described in this chapter and in chapter
"ROUTINE MAINTENANCE":

- Head protection helmet (fig. 1)

- Safety shoes (fig. 2)
- Safety gloves (fig. 3)
- Safety overalls (fig. 4)
- Safety goggles (fig. 5)
- Safety face mask (fig. 6)
- Respiratory mask (fig. 7)
- Earmuffs (fig. 8)

- such devices shall be made available by either the employer or the foreman, based on their risk assessment.

1-6
 1 - INTRODUCTION

• MACHINE OPERATING AREA

- Before operating the machine, always check the workplace with extreme care, so as to prevent dangerous situations.
Check the lie of the land and the soil condition, so as to equip your machine with the necessary equipment for safe
operation.
- The operator shall make sure that no people or animals stand in or pass through the machine working area while the
machine is in operation.
- Avoid any accidental contact between the telescopic boom and high-voltage overhead lines; keep a minimum distance of at
least 5m.

• SAFETY PLATES AND STICKERS

- safety plates and stickers applied on your machine provide important information; obeying the rules written on them is
essential to your safety.
- make sure that the safety stickers and plates on your machine are in prime condition. Periodically clean all stickers and
plates with a cloth dampened with a mild soap and water solution. Should stickers and plates be damaged or illegible,
replace them with new original ones, to be ordered from Merlo Technical Support Service, and to be placed in the position
shown in the Operator's Manual.

• SAFETY DEVICES

- before operating your machine, make sure that all safety devices are in good condition and placed in their correct positions;
should guards and safety devices be faulty or damaged, stop working and file a replacement/repair claim.
- it is prohibited to either remove or tamper with safety devices.

• CLEANING YOUR MACHINE

- during machine operation the operator shall have enough visibility of the working areas which are considered dangerous;
therefore, rear-view mirrors shall always be kept clean and in good condition.
- remove any foreign matter (rubble, tools, various objects) from your machine, since they may damage it or injure the
operator.
- periodically inspect the wear level of hydraulic hoses; if they are worn, replace them.

FIRE PREVENTION MEASURES

Follow the instructions below:

- make sure that a fire extinguisher having a proper capacity is always available on board, and refill it periodically.
- inform machine operators about the measures to be taken in case of fire.
- note that all fuels and most lubricants and hydraulic fluids are flammable.
- never smoke or set anything aflame while refilling fluids, and never pour fuel.
- always switch off the engine before refuelling.
- never refuel in poorly ventilated rooms.
- before starting the engine make sure that there are no leaks or residual traces of fuel, lubricant, or other fluids which may
cause small fires.
- short-circuits may cause fires. Periodically check the condition of the battery terminals, of cables and of the electrical
equipment.
- never store flammable substances in places which are not suitable for that purpose; never prick or burn pressurized
receptacles or spray cans; never let materials soaked in flammable substances accumulate.
- be careful where you store rags or materials soaked in flammable substances.
- to minimize the risk of spontaneous ignition, periodically clean the machine with proper devices (either a high-pressure
water jet cleaner or compressed air).
- use appropriate fire extinguishers: carbon dioxide extinguishers, foam extinguishers, chemical fire extinguishers.
- avoid using water jets; only use this method to cool down surfaces exposed to fire.
- never use petrol, solvents or other flammable or toxic fluids to clean mechanical parts; use commercial, non-flammable,
non-toxic solvents instead.
- never perform welding operations near tanks, pipes, cans, cables, or flammable materials in general.
- if a weld needs to be made, protect flammable parts with proper shields.
- before making a weld always disconnect both battery terminals.

1-7
 1 - INTRODUCTION

"CE" COMPLIANCE

Your machine complies with the safety requirements of the European directives (2006/42/CE)
(2004/108/CE) for the protection and safety of people from potential hazards deriving from
machine operation.
To ensure the operator's safety, the cab is built in compliance with the following standards:

- ISO 3449 FALLING-OBJECT PROTECTIVE STRUCTURES (FOPS)

- ISO 3471 TIP-OVER PROTECTION STRUCTURES (ROPS)

As it complies with the above mentioned requirements of the Safety directive, your machine is
labelled with the "CE" marking.

• MACHINE-PRODUCED VIBRATIONS

Your machine has been designed and built in compliance with international ergonomic standards.
The vibrations sent by the machine to the upper limbs of the operator's body are irrelevant, as the machine operation does not
require a lengthy contact of upper limbs with vibrating parts. In any case, the value of such vibrations does not exceed 2.5
m/sec² Vibrations sent from the machine to the operator's body are less than 0.5 m/sec² (RMS).

• ELECTROMAGNETIC INTERFERENCE

This machine complies with Directive 2004/108/CE on electromagnetic interference which may arise between some electronic
device on the vehicle and further external devices.
Make sure that all extra electric devices fitted on the machine comply with the said standard and that they do not produce any
interference with the vehicle's on-board devices.
Also, make sure they are all labelled with the specific "CE" marking.

• NOISE

AIRBORNE NOISE

This machine complies with Directive 2000/14/CE (Legislative Decree n.262 dated 04 October 2002) concerning "acoustic
emissions in to the environment by machinery and attachments intended for operation outdoors".
The sound power level of your machine is determined on the basis of measurements carried out on an identical machine in
accordance with measurement methods of airborne noise generated by "fork lift trucks with cantilever loading and combustion
engines", whose validity applies at the time of publication of this manual.

The following table shows the sound power level (Lwa) measured:

TYPE OF MEASUREMENT SOUND POWER LEVEL

Guaranteed sound power level (Lwa) 106 dB(A)

During equipment operation, higher noise levels may be measured due to particular working conditions, the surrounding
environment and additional noise sources.

NOTE!
The guaranteed sound power level (Lwa) is also shown on a sticker applied on the inside of the cab window.

NOISE INSIDE THE CAB

Noise inside the cab heard by the operator is detected on the basis of the UNI 12053 standard detailing "sound pressure level
at the operator's position".
The sound pressure level of your machine is determined on the basis of on measurements performed on an identical machine
in accordance with the measurement methods described in the above-mentioned standards, whose validity applies at the time
of publication of this manual.

The following table shows the sound pressure level measured inside the cab (LpAZ):

TYPE OF MEASUREMENT SOUND PRESSURE LEVEL

Sound power level (LpAZ) 77 dB

1-8
 1 - INTRODUCTION

The value of uncertainty KpA is 2 dB.

The operating cycle used during measurement is as follows:

• LIFTING (a=0,18)
• MINIMUM (b=0,58)
• TRACTION (c=0,24)

References a, b, c are coefficients proportional to usage time.

During equipment operation, higher noise levels may be measured due to particular working conditions, the surrounding
environment and additional noise sources.

• CE CERTIFICATE OF CONFORMITY

END OF SECTION

1-9
 2 - MACHINE TECHNICAL INFORMATION
CONTENTS

CAB INTERIOR KEY WORD .......................................................................................................................................................... 7

(P) CONTROL PANEL KEY WORDS ........................................................................................................................................... 13

DESCRIPTION OF THE COMMAND PANEL (P1) ....................................................................................................................... 14

INSTRUMENT PANEL (C) DESCRIPTION .................................................................................................................................. 14

NOMENCLATURE FOR DYNAMIC LOAD CONTROL DISPLAY (D) ........................................................................................... 15

DIMENSIONS - P37.12 PLUS ...................................................................................................................................................... 16

DIMENSIONS - P38.12 PLUS – P38.12 ....................................................................................................................................... 16

DIMENSIONS - P38.13 PLUS – P38.13 – P38.13EE ................................................................................................................... 17

DIMENSIONS - P38.14 PLUS – P38.14 ....................................................................................................................................... 17

DIMENSIONS - P40.9 PLUS ........................................................................................................................................................ 18

DIMENSIONS – P40.17 PLUS – P40.17 – P40.17EE .................................................................................................................. 18

DIMENSIONS - P60.10 – P60.10EE ............................................................................................................................................ 19

DIMENSIONS - P72.10 – P72.10EE ............................................................................................................................................ 19

PERFORMANCE AND FEATURES ............................................................................................................................................. 20

LOAD CHART............................................................................................................................................................................... 22

SERIAL NUMBER OF THE MACHINE ......................................................................................................................................... 28

IDENTIFICATION AND TYPE APPROVAL PLATES .................................................................................................................... 28

TIGHTENING TORQUES FOR ISO METRIC THREADS ............................................................................................................. 30

END OF SECTION ....................................................................................................................................................................... 30

2-1
 2 - MACHINE TECHNICAL INFORMATION

NOMENCLATURE MACHINE EXTERIOR

Please, pay attention to the identification of the machine sides, because they will be re quoted in the manual.

REF. DESCRIPTION
A Front side
B Rear side
C Left-hand side

D Right-hand side

P37.12 PLUS - P40.9 PLUS

REF. DESCRIPTION REF. DESCRIPTION

1 Operator cab 9 Fork tilt jack

2 Engine compartment and battery compartment 10 Crossways tilt correction jacks
3 Front axle - brake callipers - wheel reducers 11 First boom
Rear axle - brake callipers - parking brake calliper -
4 12 Second boom
wheel reducers
5 Forks 13 Third boom ((only P37.12 PLUS)
6 Attachment carriage 14 Fuel tank
7 Protection on carriage 15 Hydraulic oil tank
8 Telescopic boom lifting jacks

2-2
 2 - MACHINE TECHNICAL INFORMATION

P38.12 PLUS - P38.13 PLUS – P38.12 – P38.13 – P38.13EE

REF. DESCRIPTION REF. DESCRIPTION

1 Operator cab 9 Fork tilt jack

2 Engine compartment and battery compartment 10 Crossways angle correction jacks
3 Front axle - brake callipers - wheel reducers 11 First boom
Rear axle - brake callipers - parking brake calliper -
4 12 Second boom
wheel reducers
5 Forks 13 Third boom
6 Attachment carriage 14 Fuel tank
7 Protection on carriage 15 Hydraulic oil tank
8 Telescopic boom lifting jacks 16 Stabilisers

2-3
 2 - MACHINE TECHNICAL INFORMATION

P38.14 PLUS – P38.14

REF. DESCRIPTION REF. DESCRIPTION

1 Operator cab 9 Fork tilt jack

2 Engine compartment and battery compartment 10 Crossways angle correction jacks
3 Front axle - brake callipers - wheel reducers 11 First boom
Rear axle - brake callipers - parking brake calliper -
4 12 Second boom
wheel reducers
5 Forks 13 Third boom
6 Attachment carriage 14 Fuel tank
7 Protection on carriage 15 Hydraulic oil tank
8 Telescopic boom lifting jacks 16 Stabilisers

2-4
 2 - MACHINE TECHNICAL INFORMATION

P40.17 PLUS – P40.17 – P40.17EE

REF. DESCRIPTION REF. DESCRIPTION

1 Operator cab 10 Telescopic boom lifting jack

2 Engine and battery compartment 11 Fork tilt jack
3 Electronic control unit compartment 12 Crossways angle correction jacks
4 Rear axle - brake callipers - wheel reducers 13 First boom
Front axle - brake callipers - parking brake calliper -
5 14 Second boom
wheel reducers
6 Forks 15 Third boom
7 Attachment carriage 16 Fourth boom
8 Protection on carriage 17 Fuel tank
9 Telescopic boom lifting jack 18 Hydraulic oil tank

2-5
 2 - MACHINE TECHNICAL INFORMATION

P60.10 - P72.10 – P60.10EE – P72.10EE

REF. DESCRIPTION REF. DESCRIPTION

1 Operator cab 8 Telescopic boom lifting jacks

2 Engine compartment and battery compartment 9 Fork tilt jack
3 Front axle - brake callipers - wheel reducers 10 Crossways angle correction jacks
Rear axle - brake callipers - parking brake calliper -
4 11 First boom
wheel reducers
5 Forks 12 Second boom
6 Attachment carriage 13 Fuel tank
7 Protection on carriage 14 Hydraulic oil tank

2-6
 2 - MACHINE TECHNICAL INFORMATION

CAB INTERIOR KEY WORD

(only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10)

2-7
 2 - MACHINE TECHNICAL INFORMATION

REF. DESCRIPTION

1 Telescopic boom control joystick

7 Rear windscreen-wiper switch
12 Pressure gauge for hydraulic system oil or hydrostatic transmission system
13 Spirit level
14 Accelerator pedal
15 Brake pedal
17 Steering wheel trim lock lever
18 Air vent
19 Gear control
20 Drive direction selector
21 Load chart and safety instruction holder
22 Steering wheel
24 Parking lights switch/ low beam lights / Direction indicators / head lights / Horn
26 Lever for the selection of the air suction from inside/outside the cab
27 Driving speed adjustment pedal
28 Small emergency pump for releasing parking brake
29 Steering mode selection lever
34 Front windscreen wiper and screen-washer switch
86 Hand accelerator
Stabiliser command switches
135
(only for models P38.12 PLUS – P38.13 PLUS – P38.14 PLUS – P40.17 PLUS)
C Instrument panel
D Attachments dynamic control display
P – P1 Control panels

2-8
 2 - MACHINE TECHNICAL INFORMATION

(only for models P60.10EE – P72.10EE)

2-9
 2 - MACHINE TECHNICAL INFORMATION

REF. DESCRIPTION

1 Telescopic boom control joystick

7 Rear windscreen-wiper switch
12 Pressure gauge for hydraulic system oil or hydrostatic transmission system
13 Spirit level
14 Accelerator pedal
15 Brake pedal
17 Steering wheel trim lock lever
18 Air vent
19 Gear control
20 Drive direction selector
21 Load chart and safety instruction holder
22 Steering wheel
24 Parking lights switch/ low beam lights / Direction indicators / head lights / Horn
26 Lever for the selection of the air suction from inside/outside the cab
27 Driving speed adjustment pedal
28 Small emergency pump for releasing parking brake
29 Steering mode selection lever
34 Front windscreen wiper and screen-washer switch
86 Hand accelerator
C Instrument panel
P – P1 Control panels

2 - 10
 2 - MACHINE TECHNICAL INFORMATION

(only for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE)

2 - 11
 2 - MACHINE TECHNICAL INFORMATION

REF. DESCRIPTION

1 Telescopic boom movements command lever

2 Telescopic boom and chassis movements command lever
7 Rear windscreen-wiper switch
12 Pressure gauge for hydraulic system oil or hydrostatic transmission system
13 Spirit level
14 Accelerator pedal
15 Brake pedal
17 Steering wheel trim lock lever
18 Air vent
19 Gear control
20 Drive direction selector
21 Load chart and safety instruction holder
22 Steering wheel
24 Parking lights switch/ low beam lights / Direction indicators / head lights / Horn
26 Lever for the selection of the air suction from inside/outside the cab
27 Driving speed adjustment pedal
28 Small emergency pump for releasing parking brake
29 Steering mode selection lever
34 Front windscreen wiper and screen-washer switch
86 Hand accelerator
135 Stabiliser command switches
C Instrument panel
P – P1 Control panels

2 - 12
 2 - MACHINE TECHNICAL INFORMATION

(P) CONTROL PANEL KEY WORDS

REF. DESCRIPTION

4 Emergency stop push-button

5 Anti-overturn disabling red warning lamp
6 Operating mode selector switch
8 Starter key
9 Emergency lights
11 Portable lamp socket
37 Parking brake selector
43 Lifting equipment load limiting device
61 Side-tilt corrector control
The selector type of equipment installed on the machine
204 (only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS –
P60.10 – P72.10)

2 - 13
 2 - MACHINE TECHNICAL INFORMATION

DESCRIPTION OF THE COMMAND PANEL (P1)

REF. DESCRIPTION

33 Roof flashing light switch

35 Heating cock
36 Fan switch for cab heating
226 Adjustment buttons for instrument panel settings (C)

INSTRUMENT PANEL (C) DESCRIPTION

REF. DESCRIPTION

58 Coolant thermometer
59 Fuel level indicator
60 Speedometer
61 Tachometer
62 Hour counter / clock LCD display
S Control lights

2 - 14
 2 - MACHINE TECHNICAL INFORMATION

NOMENCLATURE FOR DYNAMIC LOAD CONTROL DISPLAY (D)

(only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10)

REF. DESCRIPTION

210 Light bar indicating percentage machine stability

S1 Machine operating function display
P1 – P2 – P3
Section / setup buttons
P4 – P5

2 - 15
 2 - MACHINE TECHNICAL INFORMATION

DIMENSIONS - P37.12 PLUS

DIMENSIONS - P38.12 PLUS – P38.12

2 - 16
 2 - MACHINE TECHNICAL INFORMATION

DIMENSIONS - P38.13 PLUS – P38.13 – P38.13EE

DIMENSIONS - P38.14 PLUS – P38.14

2 - 17
 2 - MACHINE TECHNICAL INFORMATION

DIMENSIONS - P40.9 PLUS

DIMENSIONS – P40.17 PLUS – P40.17 – P40.17EE

2 - 18
 2 - MACHINE TECHNICAL INFORMATION

DIMENSIONS - P60.10 – P60.10EE

DIMENSIONS - P72.10 – P72.10EE

2 - 19
 2 - MACHINE TECHNICAL INFORMATION

PERFORMANCE AND FEATURES

The present tables contain data indicating the machine's standard configuration.
MERLO S.p.a. reserves the right to make changes to its range of machines without prior notice, even with regards the data
declared.

WEIGHT (kg)

MEASUREMENT CONDITIONS

• Machine in standard configuration, without accessories or options

• Machine equipped with standard tyres
• Standard forks installed on the carriage
• Operator NOT in the cab
• Diesel fuel tank empty
P38.13 PLUS
P37.12 PLUS 8400 (kg) P38.13 8650 (kg) P40.9 PLUS 7900 (kg)
P38.13EE
P40.17 PLUS
P38.12 PLUS P38.14 PLUS
8550 (kg) 9050 (kg) P40.17 10350 (kg)
P38.12 P38.14
P40.17EE

P60.10 P72.10
9800 (kg) 10650 (kg)
P60.10EE P72.10EE

PERFORMANCE
Maximum capacity Maximum reach Speed (Km/h)
Machine Lift height (mm)
(kg) (mm) 1st gear - 2nd gear
P37.12 PLUS 3700 11560 7650 14 - 40
P38.12 PLUS 3800 11560 7650 14 - 40
P38.13 PLUS 3800 12560 8650 14 - 40
P38.14 PLUS 3800 13630 9125 14 - 40
P40.9 PLUS 4000 9070 5200 14 - 40
P40.17 PLUS 4000 16700 12500 16 - 40
P60.10 6000 9550 5500 14 - 40
P72.10 7200 9550 5500 14 - 40
P38.12 3800 11560 7650 9 - 33
P38.13 3800 12560 8650 9 - 33
P38.14 3800 13630 9125 9 - 33
P40.17 4000 16700 12500 9 - 33
P38.13EE 3800 12560 8650 11 - 40
P40.17EE 4000 16700 12500 11 - 40
P60.10EE 6000 9550 5500 11 - 40
P72.10EE 7200 9550 5500 11 - 40

CAB
Compliance with ISO 3449 (FOPS) and ISO 3471 (ROPS) standards

STEERING
Four-wheel steering with automatic resynchronization
3 steering modes : normal, all wheel, crab

2 - 20
 2 - MACHINE TECHNICAL INFORMATION

TRANSMISSION
Hydrostatic with electronic control

ENGINE
P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10
DEUTZ TCD 3.6 Turbo – Intercooler – water cooled
Power: 74 kW – (100CV) at 2600 rpm
Reduced emissions IIIB Stage / Tier IV Interim

ENGINE
P38.12 – P38.13 – P38.14 – P40.17
KUBOTA V3307-DI-T Turbo Intercooler with direct injection - water cooled
Power: 55.4 kW – (75CV) at 2600 rpm
Reduced emissions EURO3 phase IIIA/Tier 3

ENGINE
P38.13EE – P40.17EE – P60.10EE – P72.10EE
KUBOTA V3800-DI-T Turbo Diesel– water cooled
Power: 74 kW (100CV) at 2600 rpm
Reduced emissions EURO3 phase IIIA/Tier 3

HYDRAULIC SYSTEM
Hydraulic system with Load-Sensing pump

ELECTRICAL SYSTEM
12 V
100 Ah battery

SYSTEM CAPACITIES (litres or dm³)

Hydraulic system:
105 litres
140 litres (P40.17 PLUS – P40.17 – P40.17EE)
diesel: 150
Hydrostatic oil: 12
Engine oil: 8
Coolant: 12

TYRES

To find out about tyres available for your machine, refer to the information in the DIAGRAMS FILE at the
end of the manual.

Observe also to the inflation pressures indicated for each type of tyre.

2 - 21
 2 - MACHINE TECHNICAL INFORMATION

LOAD CHART

WARNING! Always observe the load chart.

This paragraph provides instructions to consult the load charts correctly.

To see all attachments, the installation of which in combination with the machine has been approved by Merlo, refer to the file
of diagrams shown at the back of this manual.
DO NOT use any attachment if the corresponding load chart (diagrams file inside the cab and at the back of this
manual) valid for the machine/attachment combination is not present.
The centre of gravity of the load being transported is calculated at 500 mm from the fork heel.

• MACHINE WITHOUT STABILISERS

LIFTING A LOAD USE CONDITIONS TRANSPORTING A LOAD

2 - 22
 2 - MACHINE TECHNICAL INFORMATION

• MACHINE WITH STABILISERS

LIFTING A LOAD USE CONDITIONS TRANSPORTING A LOAD

2 - 23
 2 - MACHINE TECHNICAL INFORMATION

LIFTING A LOAD

2 - 24
 2 - MACHINE TECHNICAL INFORMATION

1. Metric grid
2. Lifting angle of the telescopic boom
3. Working area (in reference to section B)
4. Additional information

Use on rough and unprepared Filling the bucket with the boom extended is The transportation of people in the
terrain is prohibited prohibited handler is prohibited

Keep the forks symmetrically

Keep the load symmetrically centred Secure the oscillating load
centred

5. Indications of machine at a standstill

a. on stabilisers
b. on tyres

WARNING! The load charts for the machine on tyres refers to a machine that is standing still, with its wheels
aligned to the chassis and positioned on a sufficiently even and solid ground.

6. Maximum gradients that can be exceeded in static lifting conditions of a load

7. Distance of the load's centre of gravity from the heel of the forks
8. Extension indication of the telescopic boom
9. Working area valid for the machine model indicated

2 - 25
 2 - MACHINE TECHNICAL INFORMATION

USE CONDITIONS

WARNING!
Check all the points listed in section B of the diagram in use before using the machine.

11. Authorised tyres

WARNING! The list of tyres that are authorized and installed on your machine are shown in the paragraph
PERFORMANCE AND FEATURES of chapter TECHNICAL SPECIFICATIONS.
In the event a type of tire needs to be replaced with another model in the list of those authorized, contact the Merlo
Technical Assistance Service, since tire replacement may also require the replacement of the safety devices
electronic management unit and load tables.

12. Inflation pressure

13. Maximum wind speed
14. Indication to always refer to the information in the Operator's Manual
15. Reference sales code of the attachment used

2 - 26
 2 - MACHINE TECHNICAL INFORMATION

TRANSPORTING A LOAD

16. Indication of the machine moving at a speed less than 3 km/h

17. Load transportation in slow gear
18. Load transportation with partial throttle

WARNING!
Sudden acceleration can cause instability of the machine.

19. Position of load transportation

a. Maximum transportable capacity

b. Load transport height from the ground
c. Telescopic boom completely retracted
d. Carriage rotation: - carriage rotated completely backwards (example on the left)
- carriage perpendicular to the ground (example on the right)
e. Maximum transportation angle of a suspended load

20. Maximum gradients that can be exceeded when transporting a load

21. Direction of travel of the machine

2 - 27
 2 - MACHINE TECHNICAL INFORMATION

SERIAL NUMBER OF THE MACHINE

CHASSIS NUMBER

The chassis number of your machine is printed on the front right side of the
chassis, and coated with a layer of black paint. When requesting assistance or
spare parts, please provide Merlo Technical Support Service with both the
chassis number and the Sav number of your machine.
This code is made up of 17 characters, divided into 3 sectors, and shows the
manufacturing data of your machine.
An example of a chassis number stamped on a chassis is given below:

• chassis identification code: ZF1A28L01C1190883

ZF1: code that identifies MERLO S.p.A.

A28L01: specific model code
C1190883: code that identifies the manufacturing decade (C= 2010-2019), the manufacturing year (1=2011), the
manufacturing progressive number (1908), and the engine code (83)

IDENTIFICATION AND TYPE APPROVAL PLATES

• MACHINE IDENTIFICATION PLATE

The machine identification plate is placed in the rear left part of the cab and
provides the operator with the following data:

- Model
- SAV number
- Maximum capacity
- Weight
- Chassis number
- Manufacturing year

• MACHINE IDENTIFICATION PLATE (SWISS MARKET)

The machine identification plate is placed in the rear left part of the cab and
provides the operator with the following data:

- Model
- Total permissible mass
- Chassis number
- Maximum permissible load per axle (front and rear)
- Maximum load
- Manufacturing year
- SAV number

• MACHINE IDENTIFICATION PLATE (GERMAN MARKET)

The machine's identification plate is applied in the engine compartment and

provides the operator with the following information:

- German homologation certificate (ABE)

- Total weight of the machine
- Chassis number
- Weight on front and rear axle
- Capacity of the machine
- Manufacturing year
- ABE version
- ABE homologation number
- SAV number of the machine
- Total unladen mass of the machine

2 - 28
 2 - MACHINE TECHNICAL INFORMATION

• ENGINE IDENTIFICATION PLATE

The engine identification plate is applied in the upper part of the engine, and provides you with engine data and specifications.

Should you need information, support, or original spare parts, please provide the engine Manufacturer with the data shown on
the engine identification plate.

• TYPE APPROVAL PLATE FOR DRIVING ON PUBLIC ROADS

The machine type approval plate for driving on public roads is located in the front
part of the cab and provides the operator with the following data:

A- Type of machine
B - Modification
C - Manufacturing year
D - Identification no.
E - Type approval no.
F - Maximum permissible load
G - Maximum load on front axle
H - Maximum load on rear axle
I - Towable weight with assisted braking (hydraulic)
L - Towable weight with assisted braking (pneumatic)
M - Towable weight with overrun braking

• TYPE APPROVAL PLATE DNT01A

The type approval plate for the DNT01A cab is applied inside the cab itself and
indicates:

- ISO 3449 standards - Falling Object Protective Structures (FOPS)

- ISO 3471 standards - (ROPS)

2 - 29
 2 - MACHINE TECHNICAL INFORMATION

TIGHTENING TORQUES FOR ISO METRIC THREADS

The tightening torque "Ma" of either a screw or a nut is the moment of a force required to put the screw under a certain initial
tension. The tightening torque value is used to adjust the dynamometric wrench, as well as to prevent the screw from breaking
due to fatigue. The following table shows the tightening torques "Ma" related to the external diameters of screws having metric
threads. These are just indicative values, because the exact values depend on both the friction and the machining conditions of
the screw supporting surfaces.

NOTE!
This table refers to a slowly applied tightening and with dynamometric cables.

TYPE OF BOLT
SIZE OF BOLT 8.8 10.9 12.9
Nm Kgm Nm Kgm Nm Kgm
M3 x 0.5 1.8 0.18 2.6 0.27 3 0.31
M4 x 0.7 3.1 0.32 4.5 0.46 5.3 0.54
M5 x 0.8 6.1 0.62 8.9 0.91 10.4 1.06
M6 x 1 10.4 1.06 15.3 1.56 17.9 1.82
M7 x 1 17.2 1.75 25 2.55 30 3.06
M8 x 1.25 25 2.55 37 3.77 44 4.49
M10 x 1.5 50 5.10 73 7.44 86 8.77
COARSE M12 x 1.75 86 8.77 127 12.95 148 15.09
PITCH M14 x 2 137 13.97 201 20.49 235 23.96
M16 x 2 214 21.81 314 32.01 368 37.51
M18 x 2.5 306 31.19 435 44.34 509 51.89
M20 x 2.5 432 44.04 615 62.69 719 73.29
M22 x 2.5 592 60.35 843 85.93 987 100.61
M24 x 3 744 75.84 1060 108.05 1240 126.4
M27 x 3 1100 112.13 1570 160.04 1840 187.56
M30 x 3.5 1500 152.91 2130 217.13 2500 254.84
M8 x 1 27 2.75 40 4.08 47 4.79
M10 x 1.25 53 5.4 78 7.95 91 9.28
M12 x 1.25 95 9.68 139 14.17 163 16.62
M14 x 1.5 150 15.29 220 22.43 257 26.2
M16 x 1.5 229 23.34 336 34.25 393 40.06
PICHT
M18 x 1.5 345 35.17 491 50.05 575 58.61
FINE
M20 x 1.5 482 49.13 687 70.03 804 81.96
M22 x 1.5 654 66.67 932 95.01 1090 111.11
M24 x 2 814 82.98 1160 118.25 1360 138.63
M27 x 2 1200 122.32 1700 173.29 1990 202.85
M30 x 2 1670 170.23 2370 241.59 2780 283.38
Nm = Newton-meter / lbft = pound - foot kgm = kilogram - meter

END OF SECTION

2 - 30
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB
CONTENTS

GENERAL REMARKS .................................................................................................................................................................... 2

INSIDE CAB STICKERS................................................................................................................................................................. 2

OUTSIDE CAB STICKERS ............................................................................................................................................................. 7

END OF SECTION ....................................................................................................................................................................... 14

3-1
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

GENERAL REMARKS

All the stickers and the leaflets described in this chapter shall always be available on your machine; for this reason, make sure
that they are undamaged, and clean them periodically with a cloth dampened with a mild soap and water solution.
Should they be damaged or illegible, replace them with new original ones, to be ordered from Merlo Technical Support Service,
and to be placed in the positions shown in the Operator's Manual.
Most of the symbols used are based on the International ISO 3287 and ISO 6405 standards. In any case, to avoid any
misinterpretation, do not use the controls before having looked up the pertaining information contained in section "CONTROLS
AND INSTRUMENTS".

INSIDE CAB STICKERS

(only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10)

3-2
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

(only for models P60.10EE – P72.10EE)

3-3
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

(only for models P38.13 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE)

3-4
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

• CONTROL PANEL STICKERS (P)

(only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10)

3-5
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

(only for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE – P60.10EE – P72.10EE)

3-6
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

OUTSIDE CAB STICKERS

• P40.17 PLUS – P40.17 – P40.17EE

3-7
3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

3-8
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

• P38.12 PLUS – P38.13 PLUS – P38.12 – P38.13 – P38.13EE – P38.14 – P38.14PLUS

3-9
3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

3 - 10
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

• P37.12 PLUS – P40.9 PLUS

3 - 11
3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

3 - 12
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

• P60.10 – P72.10 – P60.10EE – P72.10EE

3 - 13
 3 - STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB

END OF SECTION

3 - 14
 4 - COMMANDS AND INSTRUMENTS
CONTENTS

GENERAL OVERVIEW OF THE CAB ............................................................................................................................................ 2

STANDARD SEAT .......................................................................................................................................................................... 5

INSTRUMENT PANEL (C) DESCRIPTION .................................................................................................................................... 6

CONTROL PANEL (P) DESCRIPTION ........................................................................................................................................ 11

DESCRIPTION OF THE COMMAND PANEL (P1) ....................................................................................................................... 15

HYDROSTATIC TRANSMISSION LOCK (90) ............................................................................................................................. 16

DYNAMIC LOAD CONTROL SYSTEM (M-CDC) ......................................................................................................................... 16

FRONT ANTI-TIP-OVER CONTROL ............................................................................................................................................ 27

JOYSTICK (1) ............................................................................................................................................................................... 27

MAIN DISTRIBUTOR LEVER (1-2) .............................................................................................................................................. 28

HYDRAULIC OR HYDROSTATIC SYSTEM PRESSURE GAUGE (12) ....................................................................................... 29

PEDALS (14-15-27) ...................................................................................................................................................................... 29

LEVER FOR THE ADJUSTMENT OF THE STEERING WHEEL (17) .......................................................................................... 29

HAND ACCELERATOR (86) ........................................................................................................................................................ 29

GEARBOX (19) ............................................................................................................................................................................. 30

DIRECTION SELECTOR (20) ...................................................................................................................................................... 30

LIGHTS AND HORN ON/OFF LEVER (24) .................................................................................................................................. 31

• SELECTING STEERING MODE (29) ......................................................................................................................................... 32

WINDSCREEN WIPERS AND WINDSCREEN WASHER (34), (7) ............................................................................................. 32

STABILISER COMMAND SWITCHES (135) ................................................................................................................................ 33

END OF SECTION ....................................................................................................................................................................... 33

4-1
 4 - COMMANDS AND INSTRUMENTS

GENERAL OVERVIEW OF THE CAB

• OPENING THE DOOR

To open the driving cab door, release the lock by rotating the key "X" (supplied) clockwise, then act on handle "A" as indicated
in the figure (1).

• ACCESSING THE CAB

In order to access the cab correctly, please follow these instructions:

- open the cab door

- look towards the machine and grasp handles "A" and "B", located on the two sides of the cab (fig.2)
- use the steps to access the cab

ATTENTION! Use the fitted supports only when accessing the cab (handles "A" and "B", non-slip steps). Do
not grasp any control (steering wheel, switches, instrument panel) to access the driver’s cab. Always keep the steps
and handles to access the cab clean and in perfect operating condition.

• CLOSING THE DOOR

Before using the machine, close the cab door by grasping the handrail "D" and pulling firmly inwards (fig.3).

ATTENTION! The lower part of the driver’s cab must always be closed, both during transfers with the machine
and when working.

• OPENING THE CAB DOOR FROM THE INSIDE

To open the cab door from the inside, simply pull lever "E" (fig.4) in the direction shown by the arrow.

• DESCENDING FROM THE DRIVER’S CAB

Use the appropriate supports (handles "A" and "B") to exit the cab.
Always perform these operations facing the machine.

• CLOSING THE CAB DOOR

Always close the door after descending from the driver’s cab. In the event of a prolonged stoppage or at the end of each
working day, it is recommended to close the cab door and lock it with the provided key, so as to prevent any unauthorised
tampering. To close the cab door, rotate the key "X" (supplied) anticlockwise.

• FIRE EXTINGUISHER INSTALLATION IN THE CAB

WARNING!
The person in charge (owner, responsible of the building site, etc.) must check whether it is necessary to mount a fire
extinguisher inside the cabin.

4-2
 4 - COMMANDS AND INSTRUMENTS

• OPENING THE UPPER PART OF

THE DOOR

To open the upper part of the door,

proceed as follows:

- rotate handle "A" upwards

(direction indicated by the arrow)
(fig.5)
- completely open the upper part of
the door and hook it to the
appropriate external device "B"
(fig.6)

WARNING! Please
remember that the lower part of the door must be closed both during transfers with the machine and when working.

• CLOSING THE UPPER PART OF THE DOOR

To close the upper part of the door, proceed as follows:

- from the inside of the cab, release stop "B" by acting on its tongue "C" (fig.7)
- from the outside of the cab, release stop "B1" by acting on its tongue "C1" (fig.8)
- completely close the upper part of the door and lock it into position by rotating handle "A" downwards (in the direction
shown by the arrow) (fig.9)

WARNING! Before starting operating with the machine, the operator must ensure that the upper part of the
door cannot accidentally open.

• LEAVING THE CAB IN THE EVENT OF AN EMERGENCY

If it is not possible to leave the

vehicle using the cab door, it is
necessary to use the emergency exit:

FRONT WINDOW (A)

- Remove the fixing pivot "P" by

pulling in the direction indicated
- Fling the front window "A" open
and exit the cab with the utmost
care.

REAR WINDOW (B)

- Remove the fixing pivot "P" by

pulling in the direction indicated
- Fling the rear window "B" open and exit the cab with the utmost care.

4-3
 4 - COMMANDS AND INSTRUMENTS

• WINDSCREEN OPENING

- turn the lever "A" through 45°

- open the windscreen slightly
- move the lever "A" in the horizontal position
- push the windscreen forward up to the automatic stop position.

• WINDSCREEN CLOSING

- turn the lever "A" through 45°

- close the windscreen slightly
- move the lever "A" in the horizontal position
- close the windscreen by pulling it backwards up the rest position.

• REAR WINDOW OPENING

Rotate the lever (A) to the left, then open the window pushing it forward to the
desired position.

• REAR WINDOW CLOSING

Rotate the lever (A) to the right to the automatic stop position.

• CAB LIGHT

The cab courtesy light "P" is located in the right upper part of the roof lining.

The light has 3 positions:

a) left position: light off

b) central position: light off
c) right position: courtesy light on

The cab courtesy light can be switched on even when the instrument panel is
switched off.

CAB VENTILATION

The cab ventilation is granted by the outlets present on the dashboard and under the seat.
Press to lift fins, then adjust the outlet in the desired position.

4-4
 4 - COMMANDS AND INSTRUMENTS

STANDARD SEAT

The instructions for the proper use of the driver's seat, described in this
paragraph, refer to the standard model mounted on your machine. If your
machine is equipped with a seat different from the standard one, please refer
to the relevant instructions in the "OPTIONAL EXTRAS" chapter.

SEAT SHIFT (1)

Lift lever "M", slide the seat forwards or backwards to obtain the required
position and release the lever.

HEIGHT ADJUSTMENT (2)

Sit on the seat and use knob "I" to adjust to the required height; turn the
knob to direction "+" to raise the seat or in direction "-" to lower it.

SUSPENSION ADJUSTMENT (3)

To adjust the seat suspension use handle "A" located at the front side of the
seat frame. Sit on the seat and turn the handle until just the right degree of
suspension is achieved for one's weight. (direction "R" to tighten the
suspension, direction "S" to slacken the suspension)

BACK ADJUSTMENT (4)

Sit with your back firmly against the seat back.
Lift lever "L" upwards to position the back to the required angle.

DOCUMENT HOLDER POCKET (5)

Located behind the seat for holding the machine documentation and small
objects.

ATTENTION! It is forbidden and it is extremely dangerous to

adjust the driver's seat while the vehicle is moving. Position the
driver's seat so that the driver can easily reach the vehicle controls.
Always keep the "INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE" in the document holder pocket
(5).

SAFETY BELT

Seat correctly in the driving seat and check that the safety belt is not kinked. Fasten correctly the safety belt as shown in the
picture.

ADJUSTMENT LOCKING RELEASE

ATTENTION! Before operating the machine always fasten the seat belt and close the lower part of the door
whether machine is stationary or moving.
Adjust the safety belt so that it lays on your hips and not on your stomach.

4-5
 4 - COMMANDS AND INSTRUMENTS

INSTRUMENT PANEL (C) DESCRIPTION

The instrument panel on your machine shows the following information:

- ANALOGUE TACHOMETER (61)

The analogue tachometer is used to:

- check the engine usage speed

- adjust the engine speed when using the manual lever (86) (see the relevant paragraph)
- allow specialised personnel to perform maintenance operations

- ANALOGUE TACHOMETER (60)

The analogue tachometer is used to check the drive speed on roads.

WARNING!
Always respect current regulations when driving on public roads in the country where your machine is used.

- INDICATOR SHOWING THE TEMPERATURE OF THE ENGINE COOLANT (58)

When using the machine, check the temperature of the engine coolant at regular intervals. If the temperature reaches the
upper limit (indicated by a red line and the yellow indicator light ON), you must switch off the engine immediately and wait for it
to cool down.

Check the level of the motor coolant too, as explained in the "ROUTINE MAINTENANCE" chapter.

- FUEL LEVEL INDICATOR (59)

This instrument indicates the level of fuel in the tank. When topping up the level, only use the fuel indicated in Standard EN590.
For further information, refer to "FUEL AND LUBRICANTS".

- INDICATOR LIGHTS ON THE INSTRUMENT PANEL

The instrument panel contains indicator lights of various colours, that inform the operator:

- when a command is switched ON (green or blue light ON)

- when a device requiring special usage attention has been activated (yellow light ON)
- when an alarm has been activated (red light ON and buzzer sounding continuously)

4-6
 4 - COMMANDS AND INSTRUMENTS

REF. DESCRIPTION
Battery recharging
44
The alternator cannot recharge the battery correctly while the engine is running
Engine oil pressure
Insufficient oil pressure in the engine.
45 This indicator light switches on when the engine is running at more than 1000 rpm and the engine oil pressure is
low. In these conditions, stop the engine immediately and top up the oil level. Start the engine again and make sure
the indicator light switches off. If the problem persists, contact Merlo Technical Assistance service.
Brake oil level
46
Insufficient brake oil. Stop the machine and check the reason for the fault. Top up the level with specific oil.
Clogged engine air filter
47 The engine's air intake filter is clogged.
Clean the filter or if necessary replace it
Hydrostatic transmission oil level
48 Insufficient level of oil in the hydrostatic transmission.
Stop the machine and check the reason for the fault. Top up the level with specific oil.
Hydrostatic transmission oil temperature
49
High temperature of the hydrostatic transmission oil. Stop the machine and check the reason for the fault.
Low-beam lights
50
Low-beam headlights ON. Comply with the current regulations in the country of use.
High-beam lights
51
High-beam headlights ON. Comply with the current regulations in the country of use.
Direction indicators
52
Direction indicators for turning lights, switched on with intermittent signal
Indicator light for glowplug pre-heating
53
Pre-heating of the glowplugs for cold engine start-up
Front anti-tip-over check
54
Activation of the front anti-tip-over check, with resulting deactivation of the commands
Crab steering
55
Crab steering engaged; pay special attention during movements
Chassis side-shift
56
Shift system not in central position
Parking brake
Activation of the parking brake with the direction selector in neutral position. If the fault signal persists even after
57
you have disengaged the brake, this means the system pressure has fallen below the minimum value (about 18
bar).
Engine fault
87
Contact Merlo Technical Assistance Service to define the cause of the problem
Differential locking
88
The differential lock is engaged (available upon request).
Engine coolant temperature
93 Engine coolant temperature too high. Turn off the engine and wait for it to cool down. Check the coolant level in the
expansion small tank.
Tail lights
96
Tail lights on. Comply with the current regulations in the country of use.
Rear power take-off
103
(not active on this model)
Fuel reserve indicator light
108
Low fuel level in the tank. Top it up
Coolant level
132 The level of the engine coolant is low. Stop the machine and top up the level in the engine cooling system, using
the coolant indicated in the engine manual. Once topped up, check the system for any leaks
Water in the diesel oil
133 Drain the water from the diesel pre-filter as indicated in the chapter “ORDINARY MAINTENANCE” in the section
“EVERY 50 HOURS”.
Fault with the direction indicators for agricultural trailers
205
(available as an option)
Breaking of the extension cable of the telescopic boom
206
(only for models P40.9 PLUS – P60.10 – P72.10 – P60.10EE – P72.10EE)
Merlo Service signal
207
(not active on this model)
Malfunctioning of the steering hydraulic system
Lowering of the pressure in the machine's steering system, with subsequent difficulty in steering wheel
208
manoeuvres. If this indicator light comes on while you are driving on a public road, stop immediately and contact the
Merlo Technical Assistance Service.

4-7
 4 - COMMANDS AND INSTRUMENTS

- LCD DISPLAY (62)

When the engine is off, the display (62) is disabled. To set some functions of the LCD display it is necessary to use the (OK)
and (C) keys on the control panel (P1). The LCD display provides the operator with the following information:

• gear selected (Ref.1)

The gear currently engaged is displayed in the middle of the LCD display (62). Gear selection is carried out using the gear
selector switch (19) beside the steering wheel. For further information see the section "GEAR SELECTOR" in this chapter.

• date and time (Ref.2)

The current time and date is displayed in the top part of the LCD display. To manually set this data, follow the instructions
below:

- press the button (C) for about 3 seconds; the time indicator will start to flash. Release the button (C) and then press the
button (OK) to adjust the time and date. By briefly pressing the button (OK) the data decreases, while keeping it pressed the
data quickly increases until the button is released. To switch to adjusting other information (minutes, day, month, year) press
the button (C) and carry out the same adjustment operations.

• partial and total hour counter (Ref.3)

The lower part of the LCD display (62) shows the information of the partial hour counter / total hour counter (separated by a
central indicator light in the shape of an hourglass) or the information of the trip odometer /total kilometres odometer (separated
by an indicator light showing the lettering "km"). To switch from one adjustment to another just press the button (C).
The partial hour counter shows the number of hours the machine has been used since the last reset. The maximum value that
can be displayed is 999.99 hours and then it starts again from 0.0. To reset the partial hour counter press the (OK) button for 3
seconds.

The total hour counter shows the total machine usage hours (the hour counter starts working when the engine is switched on).
The maximum value that can be displayed is 999999 hours, after which it will restart from 0.

• partial and total kilometre odometer (Ref.4)

The lower part of the LCD display (62) shows the information of the trip odometer / total kilometres odometer (separated by an
indicator light showing the lettering "km") or the information of the partial hour counter / total hour counter (separated by an
indicator light in the shape of an hourglass). To switch from one adjustment to another just press the button (C).
The trip odometer indicates the number of kilometres travelled with the machine since the last reset. The maximum value that
can be displayed is 999.99 hours and then it will restart from 0.0. To reset the trip odometer press the button (OK) for 3
seconds.

The total kilometres odometer indicates the total kilometres travelled with the machine (the odometer starts to operate after the
engine is started). The maximum value that can be displayed is 999999 hours, after which it will restart from 0.

• direction of the gear selected (Ref.5)

The system represents, in a graphic format, the direction of the gear selected (forwards or backwards) and displays it in the
display (62) in the following way:

A) forward gear selected

B) reverse gear selected

The selection of the gear direction takes place using the specific control lever (20). For further information see the section
DIRECTION SELECTOR in this chapter.

4-8
 4 - COMMANDS AND INSTRUMENTS

• indication of operating faults

Any faults with the machine are signalled to the operator by the lighting up of the
relative indicator lights in the specific fields (A) of the LCD display (62).

Some faults also light up, at the same time, the corresponding indicator light at
the top of the instrument panel. In this case, follow the instructions in the table of
the section "INDICATOR LIGHTS ON THE INSTRUMENT PANEL".

The following table shows all the possible faults that can be signalled:

INDICATOR IGNITION AUDIBLE

FAULT DESCRIPTION
LIGHT MODE ALARM
Engine fault
Steady No
Function corresponding to warning light (87)
Communication error between control unit and engine
Steady No
(not active on this model)
Engine coolant level
Flashing Intermittent
Function corresponding to warning light (132)
Engine coolant temperature
Steady No
Function corresponding to warning light (93)
Intercooler system air temperature
Steady No
(not active on this model)
Hydrostatic transmission oil temperature
Steady No
Function corresponding to warning light (49)
Hydrostatic transmission oil level
Steady No
Function corresponding to warning light (48)
Brake oil level
Steady No
Function corresponding to warning light (46)
Parking brake alarm
With the engine running and the parking brake applied, the Flashing Intermittent
forward/reverse drive is selected.
Front overturn prevention system control
Steady No
Function corresponding to warning light (54)
Break in ropes
Steady No
Function corresponding to warning light (206)
Centring rear axle wheels (on request)
The wheels of the rear axle are not centred with the axis of the
machine. In this condition, do not drive on public roads. (for additional Flashing Intermittent
information, refer to the section “OPTIONAL ATTACHMENTS AND
ACCESSORIES”.
Starting the engine or drive direction command inhibited
Starting the engine or drive direction command (forward / reverse) are
Steady Intermittent
inhibited because no operator is sitting on the seat.
Sit correctly to restore operating conditions.

4-9
 4 - COMMANDS AND INSTRUMENTS

• display of info messages

In the event the operator is carrying out an unauthorised manoeuvre, the system
indicates this by displaying one or more info message icons in the middle of the
display (62) (see photo on the side). When the info message icons appear, the
buzzer goes off at the same time, and emits a continuous tone.

The following table shows the info message icons available for your machine, the
ways the icons come on and the operations to carry out to resolve the problem.

FAULT DESCRIPTION ICONS DISPLAYED PROBLEM SOLVING

It is impossible to start the engine using the

Set the direction selector in the central position
direction selector in the forwards or reverse
(neutral) and then start the diesel engine.
position. Steady / Flashing
Request for scheduled machine maintenance.
Request for scheduled maintenance. Refer to the information provided in the
Steady / Flashing Operator Manual
Deactivate the parking brake and then place
It is impossible to move the machine with the
the direction selector in the forwards or reverse
parking brake engaged.
Steady / Flashing position in order to move the machine.
It is impossible to change gear if the direction To change gear, firstly place the direction
selector is in the forwards or reverse position. selector in the central position (neutral) and
then engage the required gear
It is impossible to select the driving direction
(forwards or reverse) if the operator is not To drive the machine, the operator must sit
sitting correctly on the driving seat correctly in the driver's seat (indicator light 90
Flashing OFF);
Forward or reverse driving direction selected
with the engine OFF and the starter key in Shift the drive direction selector to the central
position “R” (instrumental panel comes on) position (neutral).

Release the emergency button by rotating it in

Emergency button pressed.
the direction of the arrow
Flashing
Electrical plug of the attachment not connected Connect the plug from the attachment correctly
to the socket on the machine's boom to the electrical outlet on the telescopic boom
of the machine
Incorrect position of the 3-position blue
command source selector (available together Steady / Steady Select the appropriate command source for the
with a platform or radio remote control) attachments installed
Electrical plug of the attachment not connected Connect the plug from the attachment correctly
to the socket on the machine's boom to the electrical outlet on the telescopic boom
of the machine
Incorrect position of the 2-position key
command source selector (available together Steady / Steady Select the appropriate command source for the
with a platform or radio remote control) tool installed

Radio control signal insufficient (available with Radio field interference or too distant from
purchase of a remote control unit) machine
Steady

Control joystick fault (available with purchase

Contact Merlo Technical Assistance Service
of single-lever joystick)
Flashing
Machine lock following activation of satellite
anti-theft device (available with purchase of Switch off the satellite anti-theft device
optional SATELLITE ANTI-THEFT DEVICE) Flashing / Steady

NOTE! To switch off an info-message icon, it is also possible to press the (OK) button on the control panel
(P1); in this case, the window is disabled but the problem persists.

4 - 10
 4 - COMMANDS AND INSTRUMENTS

CONTROL PANEL (P) DESCRIPTION

• EMERGENCY PUSH BUTTON (4)

These can be used to stop the diesel engine with subsequent disconnection of
the controls.
Before starting the engine again, the button has to be reset rotating it in direction
of the arrow.

• OPERATING MODE SELECTOR SWITCH (6)

When your machine is delivered to you, the key (6) can be found in the
document pocket behind the seat. When using the key, observe the following
instructions scrupulously:

A) Movement engagement.

Material or personnel hoisting use. The machine can be used as a lifting

equipment (e.g. using forks, fly jib...) and the key must be removed from its
location.

B) Running on the road.

Isolation of all hydraulic controls except steering. This prevents accidental control operation whilst driving the machine on
the road.
When this operating mode is selected, the system switches off the display (D) in the cab.

C) Emergency movements (command with spring return to position B)

Position "C" of the selector (6) allows you to make all the movements to bring the machine back into acceptable driving
conditions in the event of a fault on one of the safety devices.
When emergency movements are being performed, the red indicator light (5) on the "P" command panel flashes while the
buzzer is deactivated.
The safety bypass function can be activated in any machine configuration or operating condition

ATTENTION! The correct and safe use of the key described in this paragraph is ultimately the responsibility of
the person in charge of the operation (owner, foreman, etc.). Never leave the key inserted, to avoid any improper use
during normal operation. The key can only be taken out when the selector (6) is in position "A".

4 - 11
 4 - COMMANDS AND INSTRUMENTS

• IGNITION KEY (8)

0 = engine off
R = dash board lights on
H = spark plug heating

For models with DEUTZ ENGINE, the management of the glow plugs is
automatically managed by the electronic control unit

For models with KUBOTA ENGINE, the management of the glow plugs is
controlled manually by the operator with the key (8) in position "H" for about 15
seconds.

HS = engine start

• EMERGENCY LIGHTS (9)

HAZARD WARNING LIGHT SWITCH

Push the switch to operate the 4 emergency lights (it can be used also with the
ignition key in position 0).

• SOCKET FOR PORTABLE LIGHT (11)

The indicated socket (11) can be used to feed a portable light equipped with a
normal electric cigarette lighter connection. Use a 12 V and max. 40 W lamp.

• PARKING BRAKE (37)

With engine running:

- Turn the (37) selector switch towards right to engage parking brake (the
selector switch lights)
- Turn the (37) selector switch towards left to release parking brake (the
selector switch stops lightening)

Whenever the engine stops, the parking brake remains engaged independently
from the selected condition.
The emergency pump (28) must be used only to release the parking brake
before towing the vehicle.

WARNING!
The machine is fitted with a system which activates the intermittent sound
alarm when, while the parking brake (37) is applied, the drive direction
selector (20) is activated.

4 - 12
 4 - COMMANDS AND INSTRUMENTS

LOAD LIMITER FOR LIFTING ATTACHMENTS (43)

(valid for models P37.12PLUS - P38.12PLUS - P38.13PLUS - P38.14PLUS - P40.9PLUS - P40.17PLUS - P60.10 - P72.10)

Lifting attachments (fitted with a hook) having a lower maximum capacity than the
capacity of the machine are fitted with a load limiting system designed to protect
the attachment when performing lifts/hoists with the machine boom.

Below are listed several types of attachments fitted with a load limiter:

- fly jib with hook, fly jib with winch (max. capacity 600kg or 1500kg)
- winch on LIFT BOX platform
- lifting boom, telescopic lifting boom
- etc, etc…

• PREPARING THE MACHINE FOR USE WITH THE LOAD LIMITER

- hook up the attachment to the machine platform

- connect any hydraulic hoses (Fig.1)
- connect the electrical connection from the attachment to socket "A" on the head
of the boom (Fig.2) (see paragraph "QUICK-COUPLING ATTACHMENTS" in
the "ATTACHMENTS" Section)

The machine is ready for operation.

• ACTIVATING THE LOAD LIMITER

The load limiting device is set off when the load lifted exceeds the maximum load
capacity of the attachment. In this case, the system blocks all machine controls and
activates the following indicators:

- indicator light in button (43) on the control panel (Fig. 3)

- green-yellow-red indicators on the graphic LED bar (210) (Fig. 4)
- red indicator (219) of the dynamic load chart (Fig. 4)

In this case, the operator must perform the movements that do not worsen the overload on the attachment, as they are required
to restore safe working conditions (indicator light 43) OFF and green indicators (210-219 ).. To do so, proceed as follows:

- press and hold down the button (43)

- use the joystick (1) in the cab to perform movements that do not worsen the overload on the attachment, until safe working
conditions are restored

If, during these manoeuvres, the operator performs a movement that worsens the overload on the attachment, the system
blocks machine controls again, indicators (210 and 219) are red and after 5 seconds the indicator light in button (43) also
comes ON again. To reset controls and restore the machine to safe working conditions, repeat the operations described above.
The system envisages a maximum of 3 attempts to reset safe operating conditions. If, after the third attempt, an overload
situation affecting the attachment occurs again, the system will block the machine controls and activate:

- Indicator light (54) on instrument panel (C) (Fig.5)

- green-yellow-red indicators on the graphic LED bar (210) (Fig. 4)
- red indicator (219) of the dynamic load chart (Fig. 4)

In this condition, turn the operating mode selector switch key (6) to position "C" (emergency movements), then slowly and
carefully make the necessary movements to make the load transportable (for further information, refer to the "WORKING
MODE SELECTOR" and "FRONT OVERTURN PREVENTION CONTROL" paragraphs in the "CONTROLS AND
INSTRUMENTS"). (Fig.6)

4 - 13
 4 - COMMANDS AND INSTRUMENTS

LOAD LIMITER FOR LIFTING ATTACHMENTS (43)

(valid for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE – P60.10EE – P72.10EE)

Lifting attachments (fitted with a hook) having a lower maximum capacity than
the capacity of the machine are fitted with a load limiting system designed to
protect the attachment when performing lifts/hoists with the machine boom.
Below are listed several types of attachments fitted with a load limiter:

- fly jib with hook, fly jib with winch (max. capacity 600kg or 1500kg)
- winch on LIFT BOX platform
- lifting boom, telescopic lifting boom
- etc, etc…

• PREPARING THE MACHINE FOR USE WITH THE LOAD LIMITER

- hook up the attachment to the machine platform

- connect any hydraulic hoses (Fig.1)
- connect the electrical connection from the attachment to socket "A" on the
head of the boom (Fig.2) (see paragraph "QUICK-COUPLING
ATTACHMENTS" in the "ATTACHMENTS" Section)

The machine is ready for operation.

• ACTIVATING THE LOAD LIMITER

The load limiting device is set off when the load lifted exceeds the maximum load
capacity of the attachment. In this case, the system blocks all machine controls
and activates the following indicators:

- indicator light in button (43) on the control panel (Fig. 3)

- the acoustic alarm in the cab

In this case, the operator must perform the movements not aggravating the overload of the attachment needed to restore the
safe operating conditions, in the following manner:

- press and hold down the button (43)

- use the joystick (1) in the cab to perform movements that do not worsen the overload on the attachment, until safe working
conditions are restored

In the event that, during these manoeuvres, the operator performs a movement aggravating the overload of the attachment, the
system blocks the controls of the machine again and the lamp inside the button (43) lights again after 5 seconds. To reset
controls and restore the machine to safe working conditions, repeat the operations described above.
The system envisages a maximum of 3 attempts to reset safe operating conditions. If, after the third attempt, an overload
situation affecting the attachment occurs again, the system will block the machine controls and activate:

- Indicator light (54) on instrument panel (C) (Fig.4)

- the acoustic alarm in the cab

In this condition, turn the operating mode selector switch key (6) to position "C" (emergency movements), then slowly and
carefully make the necessary movements to make the load transportable (for further information, refer to the "WORKING
MODE SELECTOR" and "FRONT OVERTURN PREVENTION CONTROL" paragraphs in the "CONTROLS AND
INSTRUMENTS"). (Fig.5)

4 - 14
 4 - COMMANDS AND INSTRUMENTS

• CROSSWAYS TILT CORRECTOR COMMAND (61)

ROCKER SWITCH (61)

A = clockwise chassis levelling

B = anticlockwise chassis levelling

WARNING!
Make sure that machine is correctly levelled before attempting any lifting
operations.
Load handling on uneven surfaces is permitted by using frame levelling
device to level the machine chassis to the proper position. Check correct
levelling using the spirit level in the cab.
If the machine boom is raised beyond the safety limit, operating the
crossways tilt corrector is prevented by a specific device.

DESCRIPTION OF THE COMMAND PANEL (P1)

• HEATING (35)

COCK (REF. 35)

A = maximum temperature
C = minimum temperature

CAB FAN SWITCH (REF. 36)

0 fan OFF
1 fan activated at first speed
2 fan activated at second speed

WARNING! Do not leave any objects behind the seat as they could
obstruct the ventilation system air inlet.

SELECTION OF THE AIR SUCTION FROM INSIDE/OUTSIDE THE CAB

To select the air suction mode, use the relevant reference control "R" located
behind the seat, as follows:

- lever in position "A" (air intake grill "C" not visible): air suction from the
outside of the cab
- lever in position "B" (air intake grill "C" visible): air suction from the inside of the cab (recirculation)

4 - 15
 4 - COMMANDS AND INSTRUMENTS

• FLASHLIGHT ON ROOF (33)

Press the switch (33) to activate the rotary flashlight on the cab roof.

For the use of the flashlight, respect the regulations for road use given in
"COMMAND STICKERS - LEAFLETS IN THE CAB".

HYDROSTATIC TRANSMISSION LOCK (90)

If the operator decides to leave the driving can with the engine ON and the parking
brake not engaged, the machine automatically set a safe mode by locking the
hydrostatic transmission.

In order to resume using the hydrostatic transmission for machine forward / reverse
manoeuvres, the operator must sit correctly on the seat in the cab.
If the operator decides to leave the driving can with the engine ON and the
direction selector (20) in position "F" or "R", the hydrostatic transmission is reset by
placing the selector switch (20) in neutral position "N" and then in the position for
the required direction.
If the operator forgets to engage the parking brake before leaving the machine, a
flashing yellow signal (90) warns this non-conforming use situation.

NOTE! Correct and safe use of the machine requires the following steps before leaving the driving cab:
• place the gear selector (19) in the neutral position "N"
- place the direction selector (20) in neutral position "N"
• engage the parking brake (37)
- switch off the machine's diesel engine
- leave the driving cab and close the cab door
The automatic lock of the hydrostatic transmission described in this paragraph must be considered as an exceptional
case and not a routine procedure.

DYNAMIC LOAD CONTROL SYSTEM (M-CDC)

(only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10)

• INTRODUCTION

The dynamic load control system constantly checks the longitudinal stability of your
machine in relation to the load lifted on the carriage, the position of the telescopic
boom and the attachments installed in order always to ensure maximum machine
operating safety for the operator.

The following paragraphs provide all the instructions for correct operation of the
dynamic load control system installed on your machine. Inasmuch, pay very close
attention to this information before using the machine.

• DISPLAY NOMENCLATURE (D)

When the instrument panel is switched on (starter key (8) in position "R") (FIg.1), the
system displays a screen for 3 seconds with the MERLO logo (Fig.2) and then
automatically opens the main screen.

4 - 16
 4 - COMMANDS AND INSTRUMENTS

The main screen displays the following information:

REF. DESCRIPTION

211 Percentage longitudinal stability limit

212 Maximum liftable load, in the point where the telescopic boom is located, in relation to the attachment
213 Graphics bar indicating the load effectively lifted in relation to the attachment mounted
214 Height of load from ground (in metres)
215 Distance of load from external limit of tyres (or stabilisers, if present) (in metres)
216 Telescopic boom lifting angle (in degrees)
219 Colour indicator (green – yellow – red) of the position of the lifted load on the carriage
Machine load chart in relation to the attachment mounted (auto-identification) or the position of selector switch
220
(204) (manual identification)
221 Indication when operating the machine on tyres
222 Image of attachment mounted and auto-identified by the system
224 Weighing information: operating mode, lifting angle set, total weight
225 In MAN WEIGHING mode: Manual weighing – In AUTO WEIGHING mode: No command

4 - 17
 4 - COMMANDS AND INSTRUMENTS

• ACTIVATING THE COMMAND SELECTION GRAPHIC BAR

The display (D) of the load control system is equipped with a disappearing
graphics bar which shows the functions of command buttons P1 - P2 - P3 - P4 -
P5. Activation of this graphic bar is regulated by weighing mode selection:

1) In "AUTO WEIGHING" mode (see paragraph WEIGHING SCREEN), on

pressing one of the 5 selection buttons (P1 - P2 - P3 - P4 - P5), the system
activates the graphic bar in the lower part of the display (D) which shows the
functions which can be performed. At this stage, the operator has 5 seconds of
time to press the button for the function intended to be performed. If no selection
button is pressed within 5 seconds, the system de-activates the graphic bar.

2) In "MAN WEIGHING" mode (see paragraph WEIGHING SCREEN), on pressing one of the 4 selection buttons (P1 - P2 - P3
- P4), the system activates the graphic bar in the lower part of the display (D) which shows the functions which can be
performed. At this stage, the operator has 5 seconds of time to press the button for the function intended to be performed. If no
selection button is pressed within 5 seconds, the system de-activates the graphic bar.
Pressing button P5 does not activate the graphic bar but weights the lifted load (see paragraph MANUAL WEIGHING (E)

The functions offered by the selection buttons are:

(P1): press button (P1) to activate the display set-up menu (D) where day/night brightness and speaker volume can be
adjusted.
(P2): press button (P2) to activate the telecamera installed on the machine (optional on request). Every time button (P2) is
pressed, the system cycles through all telecameras that may be mounted on the machine (check whether your machine is
fitted with optional telecameras)
(P3): this button has no machine function
(P4): press button (P4) to activate display (D) day/night brightness modes
(P5): press button (P5) to activate the weighing screen (for additional information, refer to the instructions in paragraph
"WEIGHING SCREEN").

• DISPLAY SET-UP (BUTTON P1)

To adjust the brightness of the display (D) (in day and night modes) and speaker
volume, perform the following operations:

- activate the menu graphic bar

- press button (P1); the brightness and volume adjustment screen opens
- press button (P2) to select the graphic bar for the setting to be modified (in
sequence: day brightness (A), night brightness (B) , volume (C)
- press buttons (P3) and (P4) to set the required brightness and volume values
la adjustment from min. 0 to max. 100)

To leave the display set-up screen (D), press button (P1).

• TELECAMERA SELECTION (BUTTON P2)

To see images from the telecameras installed on the machine on the display
screen (D) (optional on request), perform the following operations:

- activate the menu graphic bar

- press button (P2); the system activates display on CHANNEL 1. Press button
(P2) again to go to CHANNEL 2.
- press button (P1) to return to the main screen

4 - 18
 4 - COMMANDS AND INSTRUMENTS

• DISPLAY DAY/NIGHT BRIGHTNESS MODE SELECTION (BUTTON P4)

To set day or night display (D) brightness mode, perform the following operations:

- activate the menu graphic bar

- press button (P4) to switch between day and night brightness mode for the display (D). The system signals the operator that
the setting has been made by showing window "1" (day mode) or "2" (night mode) in the middle of the display (D).

• WEIGHING SCREEN (BUTTON P5)

From the main screen, activate the menu's graphic bar and then press button (P5) to access the weighing screen. This screen
indicates the following information:

4 - 19
 4 - COMMANDS AND INSTRUMENTS

REF. DESCRIPTION
A Net weight lifted by the attachment mounted on the carriage (in tonnes)
B Table summarising the last 20 weighing operations stored indicating total lifted weight
C Cancel all stored weighing operations. The total weight is reset.
D Attachment tare
E Manual weighing
F Selecting the weighing mode: automatic or manual
G Modifying the weights stored in table “B”
P1 Weighing screen exit button and return to main screen
P2 Weighing menu scroll button
P3 Confirm button for menu item selected
P4 Automatic weighing angle decrease button
P5 Automatic weighing angle increase button

1) INDICATIONS FOR WEIGHING A LOAD

To perform the most precise weighing operations possible, proceed as follows:

1) the machine must be placed on firm, level ground

2) the machine must be at a standstill with the wheels aligned with the chassis
3) the telescopic boom must be completely withdrawn and in a horizontal position
4) the carriage must be in a vertical position
5) the MANUAL WEIGHING mode is recommended

Under these conditions, the indicative load readout tolerance is about ±5% of maximum rated load.
The weight of the lifted load is merely indicative for the operator and has no fiscal and/or certified weighing value.

The various functions of the weighing system are described below in this paragraph.

2) RESET (C)

The reset command is used to cancel all weighing operations stored in table "B".
When all partial weights are cancelled, the total weight is also cancelled.

The reset command is performed from the weighing screen using the button
(P2), selecting "RESET" and then confirming by pressing the button (P3).
The total weighing value is also given in the main screen in field (224). The
RESET command also resets the value of field (224).

Press button (P1) to return to the main screen

3) TARE (D)

This command is used to calculate the tare of the weighing system. In this way, it
will then be possible to display in field (A) only the weight of the load lifted, net of
the weight of the attachment.

The tare command is performed from the weighing screen using the button (P2),
selecting "TARE" and then confirming by pressing the button (P3). At this stage,
the weight detected (in tonnes) is indicated next to the wording TARE.

Press button (P1) to return to the main screen

4 - 20
 4 - COMMANDS AND INSTRUMENTS
4) MANUAL WEIGHING (E)

Use this command to weigh the load lifted by the attachment manually. The data
measured by the system is displayed in Table "B" starting from box n. 1 through
to box n. 20. When there are more than 20 weighing operations, all values scroll
upwards and more recent figures will always be displayed at the bottom of the
table. The total shown at the bottom of Table "B" is always the sum of all
weighing operations, including those that are off-screen.

The manual weighing command is performed from the weighing screen using the
button (P2), selecting "WEIGHING" and then confirming by pressing the button
(P3). Audible confirmation is given that the weight has been read and the system
stores the result in Table "B".
To obtain the sum of all weighing operations performed, refer to the figure next to
the wording "TOT" at the bottom of the table; this total increases up to a
maximum of 9999,99 t. (Fig.1)

Press button (P1) to return to the main screen

It is also possible to perform a manual weighing operation even from the main
screen by pressing the OK button (P5); audible confirmation is given that the
weight has been read and the system stores the result. The main screen also
has the total for weighing operations performed and the value is given
underneath the load graph in field (224). Manual readout of weight from the main
screen can only be performed if "MAN WEIGHING" was previously selected in
the weighing screen. (Fig.2)

5) WEIGHING MODE (F)

This command is used to set the weighing readout mode:

1) MANUAL
2) AUTOMATIC

If manual weighing is set, the symbol "X" and the item "MAN WEIGHING"
appears; if automatic mode is set, the symbol "Y" and the item "AUTO
WEIGHING” appears. To perform manual weighing, refer to the instructions
provided in the previous item (MANUAL WEIGHING "E").while for automatic
weighing refer to the following instructions.

Move around the weighing screen using button (P2) and select the item "AUTO
WEIGHING"; then press button (P3) to confirm. It is now possible to set a lifting
angle for the telescopic boom beyond which the system automatically performs a
weighing operation. This angle must be set using buttons (P4, decrease) and
(P5, increase) and must be between 0° and 70°. Having set these functions,
press button (P1) and return to the MAIN MENU since automatic weighing does
not work in the WEIGHING MENU. (Fig.3)

In order to confirm that the system has been set correctly in automatic mode, the
main screen displays in field (224) the symbol "Y" and the value (in degrees) of
the angle chosen.
In this condition, every time the telescopic boom is lifted beyond this angle, the
system automatically weighs the load (with audible signal) and stores the value
in Table "B". The sum of weighing operations is always given in the main screen, under the load chart next to the wording
"TOT". (Fig.4)

To perform a new automatic weighing operation, lower the telescopic boom by 5° less than the value of the angle set
beforehand; if this is not the case, when the telescopic boom is lifted again, the system will not perform an automatic weighing
operation.

4 - 21
 4 - COMMANDS AND INSTRUMENTS

6) MODIFYING WEIGHTS (G)

If one or more weights stored in Table "B" have to be modified or cancelled, this
can be done using the modification function on the WEIGHING SCREEN. To do
this, move around the weighing screen using button (P2) and select the item
"EDIT DATA"; then press button (P3) to confirm. At this stage, the manual
weighing and eraser symbols respectively under buttons (P4) and (P5).
To select the weighing to be modified, press button (P2) until the desired
weighing operation is highlighted (flashing) and then press button (P4) to repeat
a manual weighing or button (P5) to cancel the weighing. (Fig.5). Press the
button (P3) to confirm the selection.
Press button (P1) to return to the main screen

• SELECTOR SWITCH FOR TYPE OF ATTACHMENT MOUNTED ON THE

CARRIAGE

The machine is fitted with a selector switch (204) with 4 stable positions allowing
the operator to set (manually or automatically) the type of attachment mounted
on the carriage in order to define the appropriate capacity chart for the machine
+ attachment set-up.

The 4 positions of the selector switch (204) for the type of attachment installed
on the carriage are (Fig.1):

a) AUTO: auto-identification of the attachment installed

b) 0.5/0.6: attachments with a centre of gravity of the lifted load at 0.5 / 0.6
metres from the carriage
c) 1.5: attachments with a centre of gravity of the lifted load at 1.5 metres from
the carriage
d) 4: attachments with a centre of gravity of the lifted load at 4 metres from the
carriage

A graphic depiction of the selector switch (204) is also provided on the display
(D) in the cab in field (222) (Fig.2) and is displayed when:

- there is no attachment mounted on the carriage.

- the attachment mounted on the carriage is not identified.
- there is a fault or problem with the auto-identification system for an attachment
mounted on the carriage

When an attachment is installed and identified on the carriage and the system is
functioning correctly, the graphic depiction of the selector switch (204) in field
(220) shows the symbol of the attachment installed (see below in this paragraph)

For a better understanding of the functional modes of the selector switch (204), refer to the following instructions:

4 - 22
 4 - COMMANDS AND INSTRUMENTS

• AUTO-IDENTIFICATION OF AN ATTACHMENT (selector switch (204)

positioned on AUTO)

When an attachment fitted with an auto-identification sensor is installed on the

carriage, the selector switch (204) must be placed in the "AUTO" position; in this
case, the system automatically calculates the work chart for the machine +
attachment combination to define the correct index of stability, maximum
capacity and the safe working area. At this stage, field (222) displays the graphic
icon of the attachment detected (in this instance a loader) (Fig.3).

When, on the other hand, the carriage has an attachment with an auto-
identification sensor but the selector (204) is not turned to the "AUTO" position,
the following are activated:

- the red indicator of the led graphic bar (210)

- the red indicator (219) of the load position on the dynamic diagram
- the indicator light (54) on the instrument panel (C)
- the buzzer in the cab

In this case, the system immediately locks the machine's controls and centre of
the display (D) displays the window "X" with the instruction to turn the selector
(204) to the "AUTO" position (Fig. 4);

WARNING!
The equipment self-identification system is deactivated if the operating
mode selector switch (6) is on "B" position (moving on a road). In this case
turn the selector (6) to position "A" (movements enabled).

If the auto-identification system works correctly but there is no graphic depiction

of the attachment installed on the carriage, the machine signals this status with
the symbol in field (222) of the display (D) in the cab (Fig.5).

For a better understanding of the attachment auto-identification and manual

selection system, a table is provided with all the icons used in field (222) of
display (D) and their description.

• MANUAL ATTACHMENT SELECTION (selector switch (204) positioned on

0.5/0.6 or 1.5 or 4)

When an attachment is mounted on the machine's carriage that is not fitted with
an auto-identification sensor or when the system has an operating problem or
fault, the type of equipment must be defined manually using the selector switch
(204) as follows (FIg.6):

- place the selector switch (204) in position "A" (0.5/0.6) when fitting an
attachment with a centre of gravity at 0.5 - 0.6 metres in front of the carriage
- place the selector switch (204) in position "B" (1.5) when fitting an attachment
with a centre of gravity within 1.5 metres in front of the carriage
- place the selector switch (204) in position "C" (4) when fitting an attachment
with a centre of gravity within 4 metres in front of the carriage

In this way, the machine is set up to receive the selected attachment in relation
to its type, defining the work chart and calculating the correct index of stability,
maximum capacity and the safe working area. Field (222) shows the icon of the
position of the selector switch (204) (Fig.7)

If the selector switch (204) is set to AUTO and an attachment is mounted on the
machine's carriage that is not fitted with an auto-identification sensor or when the
system has an operating problem or fault, the system automatically activates the
work chart in position "C" (load centre of gravity at 4 metres from the locator on
the carriage).

SYMBOL SHOWN IN
DESCRIPTION
FIELD (222)

4 - 23
 4 - COMMANDS AND INSTRUMENTS

The attachment installed on your machine was correctly identified by the system, but the
corresponding image is not available in the database.

Make sure that selector (204) is turned to the AUTO position

The attachment installed on your machine is either not equipped with a self-identification
sensor, or it was not automatically identified by the system due to a system failure or
malfunctioning. Manual selection of the type of attachment installed with selector (204) was
necessary.
When selector switch (204) is in the AUTO position, mode “C” of the load chart is active,
referring to attachments whose centre of gravity is 4 metres ahead of the carriage.
The attachment installed on your machine is either not equipped with a self-identification
sensor, or it was not automatically identified by the system due to a system failure or
malfunctioning. Manual selection of the type of attachment installed with selector (204) was
necessary.
When selector switch (204) is in the 0.5/0.6 position, mode “A” of the load chart is active,
referring to attachments whose centre of gravity is between 0.5 and 0.6 metres ahead of the
carriage.
The attachment installed on your machine is either not equipped with a self-identification
sensor, or it was not automatically identified by the system due to a system failure or
malfunctioning. Manual selection of the type of attachment installed with selector (204) was
necessary.
When selector switch (204) is in the 1.5 position, mode “B” of the load chart is active, referring
to attachments whose centre of gravity is no more than 1.5 metres ahead of the carriage.
The attachment installed on your machine is either not equipped with a self-identification
sensor, or it was not automatically identified by the system due to a system failure or
malfunctioning. Manual selection of the type of attachment installed with selector (204) was
necessary.
When selector switch (204) is in position 4, mode “C” of the load chart is active, referring to
attachments whose centre of gravity is no more than 4 metres ahead of the carriage.
Attachments whose centre of load gravity is 0.5/0.6 metres from the machine carriage (position “A” of selector 204)
The TRAVELLING LIFT ON CARRIAGE - SIDE-SWINGING CARRIAGE /
CARRIAGE WITH FLOATING FORKS - FEM CARRIAGE / EXTRA-LARGE FORK CARRIAGE
attachment, installed on the machine, was correctly identified by the system.

The BRICK HANDLER attachment installed on the machine was correctly identified by the
system.

The CHOPPER attachment installed on the machine was correctly identified by the system.

The HAY BALE HANDLER WITH GRABS / 2/3 FOLDING-SPIKE FORK FOR HAY BALES /
HAY BALE FORK WITH SLIDING PROTECTION attachment, installed on the machine, was
correctly identified by the system.

The MANURE FORK WITH GRABS attachment installed on the machine was correctly
identified by the system.

The CARRIAGE-MOUNTED HOOK attachment installed on the machine was correctly

identified by the system.

The 4 IN 1 BUCKET attachment installed on the machine was correctly identified by the
system.

The MULTI-PURPOSE LOADER WITH CLAW attachment installed on the machine was
correctly identified by the system.

The DOUBLE LOG GRABS attachment installed on the machine was correctly identified by the
system.

4 - 24
 4 - COMMANDS AND INSTRUMENTS

The BULK LOADER / REHANDLING BUCKET / DIGGING BUCKET attachment, installed on

the machine, was correctly identified by the system.

The CARRIAGE-MOUNTED WINCH attachment installed on the machine was correctly

identified by the system.

The PUSHING BLADE attachment installed on the machine was correctly identified by the
system.

Attachments whose centre of load gravity is 1.5 metres from the machine carriage (position “B” of selector switch 204)

The WHEEL JOYSTICK attachment installed on the machine was correctly identified by the
system.

The MIXING BUCKET attachment installed on the machine was correctly identified by the
system.

The ROUND-BALE HANDLER attachment installed on the machine was correctly identified by
the system.

The FRONT CLAMPS attachment installed on the machine was correctly identified by the
system.

The LOWERED LIFTING BOOM / TELESCOPIC LIFTING BOOM attachment, installed on the
machine, was correctly identified by the system.

The FLY JIB / FLY JIB WITH WINCH attachment, installed on the machine, was correctly
identified by the system.

Attachments whose centre of load gravity is 4 metres from the machine carriage (position “C” of selector 204)
The MINI TOWER JIB attachment installed on the machine was correctly identified by the
system.

The TUNNEL RIB HANDLER attachment installed on the machine was correctly identified by
the system.

Attachments that cannot be used with the dynamic load control system in the event of malfunctioning, faults or absence of
the self-recognition sensor.

The SLEWING HOIST attachment installed on the machine was correctly identified by the
system.

The COUNTER-CARRIAGE MOUNTED HOIST attachment installed on the machine was

correctly identified by the system.

The FIXED PLATFORM / TRILATERAL PLATFORM / TRILATERAL EXTENSIBLE PLATFORM

attachment, installed on the machine, was correctly identified by the system.

The PANEL HANDLING PLATFORM attachment installed on the machine was correctly
identified by the system.

The SPACE 11 attachment installed on the machine was correctly identified by the system.

4 - 25
 4 - COMMANDS AND INSTRUMENTS

• FRONT ANTI-TIP-OVER CONTROL

The front anti-tip-over control device steps in when the machine is close to its longitudinal stability limit, and locks all
aggravating movements.
During handling operations, the system automatically detects and processes the position of the lifted load and the machine's
stability percentage. These values are shown on the display D) in the cab in 3 different ways:

- icon of the lifting position (indicator (219) green - yellow - red)

- led icon of the machine's stability condition indicator (210) (green - yellow - red)
- percentage icon (211) of the longitudinal stability limit

The number displayed at point (211) refers to 3 stability conditions:

• 0%-90% (Fig.1)

- machine stable and no movement block

- indicator (219) is green
- graphic bar (210) has green LEDs on

• 90%-100% (Fig.2)

- close to the longitudinal stability limit and no movement block

- indicator (219) on load chart is yellow
- graphic bar (210) has yellow LEDs on
- buzzer sounds intermittently in cabin. The sound becomes more frequent as it reaches 100% (red zone)

• over 100% (Fig.3)

- longitudinal stability limit reached with consequent block of movements that may worsen the condition
- instrument panel warning light (54) comes ON
- indicator (219) on load chart is red
- graphic bar (210) has red LED on
- buzzer in the cab sounds continuously

To restore safe machine operating conditions (indicator (219) and led graphic
bar (210) - green), the telescopic boom must be retracted.
If either it's not possible to retract the telescopic boom or this manoeuvre is not
sufficient to restore safe operating conditions for your machine, turn operating
mode selector (6) to the "C" position and hold it in that position. Then proceed
slowly and very cautiously with non-aggravating manoeuvres until safe operating
conditions are restored (both warning light 54 and audible alarm in the cab are
off; indicator light (219) and graphic bar (210) - green).

WARNING!
Before working with the machine, test the warning and overload systems.
With the boom just above the ground, pick up a load and extend the boom
to the point of overbalance. In the event of malfunction do not use the
machine until the fault has been repaired.

4 - 26
 4 - COMMANDS AND INSTRUMENTS

FRONT ANTI-TIP-OVER CONTROL

(only for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE – P60.10EE – P72.10EE)

The front anti-tip-over control device steps in when the machine is close to its
longitudinal stability limit, and locks all aggravating movements.

To restore the safe operating condition of the machine, the retraction manoeuvre
of the boom must be performed until the safety conditions are restored (indicator
light 54 on the instrument panel off and buzzer off)

If either it's not possible to retract the telescopic boom or this manoeuvre is not
sufficient to restore safe operating conditions for your machine, turn operating
mode selector (6) to the "C" position and hold it in that position. Then proceed
slowly and very cautiously with non-aggravating manoeuvres until safe operating
conditions are restored (both warning light 54 and audible alarm in the cab are
off)

WARNING! Before working with the machine, test the warning and
overload systems. With the boom just above the ground, pick up a load
and extend the boom to the point of overbalance. In the event of
malfunction do not use the machine until the fault has been repaired.

JOYSTICK (1)

(only for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.9PLUS – P40.17PLUS – P60.10 – P72.10
– P60.10EE – P72.10EE)

These machines are fitted with an electro-mechanical single-lever joystick for performing 5 hydraulic functions:

• Position A: lift telescopic boom

• Position B: lower telescopic boom

• Position C: rotate carriage downwards

• Position D: rotate carriage upwards

• Position E: extend telescopic boom

• Position F: retract telescopic boom

• Position G: release attachments installed on carriage

• Position H: • command for attachments installed on carriage

• Button L: shift machine to right

• Button M: shift machine to left

The movement speed required is proportional to the angle given to the joystick (the
larger the angle of the joystick the higher the movement speed), the rotation of the
control thumb-wheels (the larger the rotation of the thumb-wheels the higher the
movement speed) and diesel engine rpm (the higher the diesel engine rpm the higher the movement speed).
Depending on load conditions, it is possible to combine machine movements.
Movements stop automatically when the joystick, control thumb-wheel or button are released.

To enable the operation of the joystick it is necessary to press and keep pressed the red button (U) located on the rear.

To move the machine, press and hold down the dedicated button. The movement execution speed is set with a proportional
ramp and reaches maximum speed within about 4 seconds of pressing the control. To make small movements, press the
control switches briefly.

WARNING! Before operating the machine, please mark off the area where the machine needs to be operated, in
order to keep both people and vehicles away from it.
Should you need to operate the machine near overhead lines, the person in charge of safety shall require the
minimum safety distance from such lines to the manager of said lines, as well as from the authorities in charge of
safety and health in the workplace; in this way all necessary precautions shall be taken and potential accidents shall
be prevented.
For further information please refer to paragraph "INSTRUCTIONS FOR A CORRECT USE OF THE MACHINE NEAR
OVERHEAD LINES" in chapter "OPERATING INSTRUCTIONS".

4 - 27
 4 - COMMANDS AND INSTRUMENTS

MAIN DISTRIBUTOR LEVER (1-2)

(only for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE)

These machines are equipped with two control levers with which it is possible to perform the following movements:

1) LIFTING/LOWER OF THE TELESCOPIC BOOM

2) UPWARD/DOWNWARD ROTATION OF THE FORKS
3) EXTENSION/RETRACTION OF THE TELESCOPIC BOOM
4) LEFT/RIGHT SIDE SHIFT
5) COMMAND FOR ATTACHMENTS INSTALLED ON THE CARRIAGE

The speed of the movement to be made is proportional to:

- the inclination given to the control lever (the greater the movement of the lever, the greater the speed of the movement)
- the rpm of the diesel engine (the higher the rpm of the engine, the greater the speed of movement).

The movement stops automatically when the lever used is released. Depending
on load conditions, it is possible to combine movements.

This machine is equipped with a side-shift that works directly on the base
chassis.
When the chassis of the machine is not in a central position, the system will
signal it with the lighting of the indicator light (56) on the instrument panel (C)
(see Chapter NOMENCLATURE).
Before driving on a public road, the chassis of the machine must be positioned
centrally (indicator light 56 off).

• CONTROL LEVERS ENABLING BUTTONS (U1) AND (U2)

U1 = Press and hold the button (U1) to enable the controls of the lever (1)
U2 = Press and hold the button (U2) to enable the controls of the lever (2)

• LEVER (1) IN POSITION:

A= boom lifting
B= boom descent

C= tilting of forks downward

D= tilting of forks upward

E= right side-shift
F= left side-shift

• LEVER (2) IN POSITION:

G = retraction of the telescopic boom

H = extension of the telescopic boom
L= attachments release/attachments command
M = attachments command

To move the machine, press and hold down the dedicated button. The movement
execution speed is set with a proportional ramp and reaches maximum speed
within about 4 seconds of pressing the control. To make small movements, press
the control switches briefly.

WARNING! Before operating the machine, please mark off the area
where the machine needs to be operated, in order to keep both people and vehicles away from it.
Should you need to operate the machine near overhead lines, the person in charge of safety shall require the
minimum safety distance from such lines to the manager of said lines, as well as from the authorities in charge of
safety and health in the workplace; in this way all necessary precautions shall be taken and potential accidents shall
be prevented. For further information please refer to paragraph "INSTRUCTIONS FOR A CORRECT USE OF THE
MACHINE NEAR OVERHEAD LINES" in chapter "OPERATING INSTRUCTIONS".

4 - 28
 4 - COMMANDS AND INSTRUMENTS

HYDRAULIC OR HYDROSTATIC SYSTEM PRESSURE GAUGE (12)

WARNING!! During normal operating conditions of the machine, the

instrument must be left disconnected.
In case of loss of pressure in the hydraulic system, please refer to the
instructions in the paragraph "HYDRAULIC SYSTEM OIL PRESSURE" in the
chapter "SECURITY PERIODICAL INSPECTIONS".
In case of anomalies in the hydrostatic transmission system, please refer
directly to the Merlo Service Centre for further information.

PEDALS (14-15-27)

ACCELERATOR PEDAL (14) operate the pedal to increase or decrease the

diesel engine rpm.

SERVICE BRAKE PEDAL (15) the disc brakes on both vehicle axles are
activated by means of this pedal. Service brakes are seldom used thanks to the
braking efficiency of the hydrostatic transmission. We suggest using the services
brakes from time to time to keep them efficient and to the avoid pads sticking.

INCHING PEDAL (27) depress the pedal to slow the vehicle down independently
of the diesel engine rpm and in any working condition, it can be used
continuously without causing damage or wear to the transmission. It is
particularly useful to approach a load or when using the machine as a loader.
When going down slopes, it is advisable to use the pedal (27), in order to reduce
vehicle speed without relying only on the braking system. The following should
also be kept in mind:

- Select suitable gear according to the slope and the transported load.
- In extreme conditions, it is advisable to put the load in front of the machine in order to ensure stability.

LEVER FOR THE ADJUSTMENT OF THE STEERING WHEEL (17)

Turn the steering wheel locking lever (17) to position B. Pull the steering wheel to
the required position and lock by returning the locking lever to position A.

ATTENTION!
Never adjust the steering wheel angle whilst the machine is in motion.

HAND ACCELERATOR (86)

Lever (86) allows manual diesel engine rpm adjustment.

It is always possible to use the pedal to reach maximum revs; on releasing the
pedal, the engine returns to the preset rpm value.

WARNING!!
It is forbidden to use this command while driving on road.

4 - 29
 4 - COMMANDS AND INSTRUMENTS

GEARBOX (19)

The machine gearbox has two forward gears and two reverse gears which can
be selected through selector switch (19), located on the steering column.

Press button (P1) to downshift

Press button (P2) to upshift
Press and hold button (P1) for more than 5 seconds to select the neutral gear.

The gears available are (in order):

• neutral (idle)
• 1st gear
• 2nd gear

The machine speed changes to:

- 0 Km/h up to 14 Km/h (16 Km/h for P40.17 PLUS) in first gear

- 0km/h - 40km/h in second gear

For the proper use of the gear-shift (19), follow the instructions below:

- start the machine engine; the system will automatically engage the fast gear
(P2)
- if necessary, engage the required gear
- bring the direction selector (20) to position "F" (forwards) or "R" (backwards),
depending on the movement you need to make
- accelerate smoothly without brusque steering movements

To change gear, follow these instructions:

- stop the machine with the diesel engine running

- press button (P1) or (P2) to engage the required gear

The gear used will be shown on the LCD display (62).

WARNING!! Gears can only be changed with machine at a standstill.

When reverse gear is selected, the reverse alarm system will be activated automatically and an intermittent audible
warning signal will sound. When the machine is moving, the drive direction can only be reversed if the 1st gear is
engaged. When the machine is moving, never reverse the drive direction if the 2nd gear is engaged.

DIRECTION SELECTOR (20)

In order to select the machine direction of travel, use lever (20) located by the
steering column as described below:

pull the lever (20) towards you, then move it:

- towards "F" to select the machine forward gear

- towards "R" to select the machine reverse gear

Moving lever (20) into "N" position engages the neutral gear. No movement is
generated when operating the accelerator pedal in this condition.
The driving direction can only be inverted when the machine is moving in first
gear.

WARNING!
Do not invert the driving direction with the machine in 2nd gear.
With the direction selector (20) in position "F" or "R" it is impossible to start up the engine. In this case it is necessary
to move the machine direction of travel selector (20) into position "N" and then start the diesel engine.
When reverse drive is selected, the reverse alarm system will be activated automatically and an intermittent audible
warning signal will sound.

4 - 30
 4 - COMMANDS AND INSTRUMENTS

LIGHTS AND HORN ON/OFF LEVER (24)

Lever (24), located beside the steering wheel, allows you to switch the lights on
your machine on/off, and to operate the horn. To carry out these operations, the
ignition key (8) needs to be in position "R".
Should the ignition key (8) be in position "0", the operation of lever (24) is
disabled.

SWITCHING OFF THE LIGHTS (Fig.M)

To switch off all the lights on your machine, turn the switch of control lever (24) to
position "0"

TAIL LIGHTS (Fig.N)

To switch on the tail lights, turn the switch of control lever (24) to position "1"

LOW-BEAM HEADLIGHTS (Fig.P)

To switch on the low-beam lights, turn the switch of control lever (24) to position "2"

TURN INDICATORS (Fig.R)

To switch on the right turn indicators, shift lever (24) to position "C"
To switch on the left turn indicators, shift lever (24) to position "D"

HIGH-BEAM HEADLIGHTS (Fig.S)

To switch on the high-beam lights, shift lever (24) to position "A"

To flash the high-beam lights, shift lever (24) to position "B"

HORN (Fig.T)

To operate the horn, press button "B" placed at one end of lever (24)

4 - 31
 4 - COMMANDS AND INSTRUMENTS

• SELECTING STEERING MODE (29)

The machine relies on a system which allows the operator to choose among 3 steering modes:

A) Four wheel coordinated steering

Use this mode to obtain a narrower steering angle.

B) Front axle steering mode

Use this mode when travelling on public roads.

C) Crab steering
Use this mode to move the machine laterally without losing the longitudinal alignment.

The selection of a different steering mode must be made when the machine is standing still and all wheels are aligned with the
chassis. The correction of a possible misalignment between the front and the rear wheel can be achieved by bringing the
steering wheel to its end stop for a few seconds on one side, then repeat on the other side.

WARNING! Such correction can only be carried out when in "four-wheel" or "crab" mode, even if the
misalignment occurred while using the front axle steering mode.

WINDSCREEN WIPERS AND WINDSCREEN WASHER (34), (7)

FRONT WINDSCREEN WIPER & WASHER SWITCH (34)

Two-positions switch: the first tripping operates the front windscreen wiper, the
second operates the front and the rear windscreen washer.

REAR WINDSCREEN WIPER (7)

Press button (7) to engage the rear windscreen wiper.

4 - 32
 4 - COMMANDS AND INSTRUMENTS

STABILISER COMMAND SWITCHES (135)

(only for P38.12 PLUS – P38.13 PLUS – P38.14 PLUS – P40.17 PLUS – P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE –
P40.17EE)

The machine is equipped with a stabilising system consisting of 2 ground

supports.
The maximum load transmitted to the ground by each stabiliser is indicated on
each stabiliser itself by a specific sticker. Additional load distributing systems are
required if the ground is not solid.

The general operating conditions of this device are the following:

- carry out the machine stabilising operations on a sufficiently firm and

compact ground
- stabilise the machine at a standstill and with all 4 tyres resting correctly on
the ground
- place the gear selector (19) and drive direction (20) to neutral "N"
- lower the telescopic boom within the safety limit;

The machine can be considered to be stabilised when the front tyres are raised
off the ground. The dynamic load control display (D) in the cab must show the
symbol with the machine on stabilisers in field (221).

WARNING! Always work with the utmost care, especially when

handling loads. If this is the case, please make sure that the load falls
within the limits of the corresponding load chart, so as to prevent the
machine stability control system to step in with a consequent block of all
controls.

It is possible to lift loads on an uneven ground by correctly stabilising the machine in order to return it to the initial
operating conditions. Before proceeding to any lifting operation, check that the machine is correctly levelled using the
spirit-level (13) located in the cab.

If during operation with lowered stabilisers the machine needs to be supported on the wheels, it is necessary to check
that the weight of the load to be lifted falls within the limits for operations on wheels, as outlined in the machine's load
chart; such manoeuvres are otherwise prevented by the stability control system. Before performing this operation, it
is in any case advisable to lower and retract the telescopic boom completely.

To move stabilisers up or down, press and hold down the dedicated button. The movement execution speed is set with a
proportional ramp and reaches maximum speed within about 3 seconds of pressing the control. To make small stabiliser
movements, press the control switches briefly.

SWITCH REF. 135-X

A = right stabiliser descent

B = right stabiliser lifting

SWITCH REF. 135-Y

A = left stabiliser descent

B = left stabiliser lifting

IMPORTANT!
If the machine boom is raised beyond the safety limit, operating the stabilisers is prevented by a specific device.

END OF SECTION

4 - 33
 5 - OPERATING INSTRUCTIONS
CONTENTS

INTRODUCTION ............................................................................................................................................................................ 2

GENERAL INFORMATION ............................................................................................................................................................. 2

STANDARD FORKS ASSEMBLY................................................................................................................................................... 2

STANDARD FORKS DISASSEMBLY............................................................................................................................................. 3

RULES FOR LOAD TRANSPORT.................................................................................................................................................. 3

MACHINE OPERATING AREA....................................................................................................................................................... 3

HOW TO HANDLE A LOAD ........................................................................................................................................................... 4

INSTRUCTIONS FOR STARTING YOUR MACHINE ..................................................................................................................... 6

INSTRUCTIONS FOR DRIVING YOUR MACHINE ON THE ROAD ............................................................................................ 11

INSTRUCTIONS FOR THE CORRECT USE OF THE MACHINE IN THE VICINITY OF ELECTRICITY POWER
SUPPLY LINES ............................................................................................................................................................................ 14

USE OF THE MACHINE DEPENDING ON WIND STRENGTHS ................................................................................................. 14

END OF SECTION ....................................................................................................................................................................... 14

5-1
 5 - OPERATING INSTRUCTIONS

INTRODUCTION

This chapter provides the instructions for using your machine as a variable reach fork lift truck. Please follow the instructions
below very carefully, so as to ensure efficiency and utmost safety while working.

GENERAL INFORMATION

- when manoeuvring the loads never exceed the limits set in the load chart
- do not use counter-weights to alter the limits of the load chart
- never leave your machine unattended while the engine is running or when loads are hanging
- lifting people on the machine is absolutely forbidden if no platform, homologated and approved by Merlo S.p.A., is installed
- carrying a second operator on-board the machine is absolutely prohibited.

STANDARD FORKS ASSEMBLY

Standard forks are part of the standard equipment of your machine.

• TECHNICAL DATA OF STANDARD FORKS

For machines (P38.12 PLUS – P38.13 PLUS – P38.14 PLUS – P40.9 PLUS –
P37.12 PLUS – P40.17 PLUS – P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE
P40.17EE) the following forks are supplied as standard:

- Fork type: A0301- Standard fork

- Weight of a single fork: 85 kg
- Rated load capacity: 2250 kg
- Centre of gravity of the load ("P") from the fork heel: 500 mm

Machines (P60.10 – P60.10EE) are fitted as standard with the following forks:

- Fork type: A0302- Standard fork

- Weight of a single fork: 143 kg
- Rated load capacity: 3000 kg
- Centre of gravity of the load ("P") from the fork heel: 600 mm

Machines (P72.10 – P72.10EE) are fitted as standard with the following forks:

- Fork type: A0306- Standard fork

- Weight of a single fork: 190 kg
- Rated load capacity: 3750 kg
- Centre of gravity of the load ("P") from the fork heel: 600 mm

• INSTRUCTIONS FOR STANDARD FORKS ASSEMBLY

- place the forks on a compact and even surface

- shift the drive direction selector to the neutral position ("N") and apply the
parking brake
- rotate the carriage downwards, so as to bring it parallel to the ground
- extend the telescopic boom, so as to move closer to the fork couplings (Fig.1)
- raise the telescopic boom, while at the same time rotating the carriage
upwards, until the forks are correctly coupled. During this operation, the carriage automatically lifts safety pin "B" of the
forks (Fig. 2 and 3).

5-2
 5 - OPERATING INSTRUCTIONS

- check that safety pin "B" engages

correctly, and goes back to a
horizontal position once the forks are
coupled; this prevents the forks from
accidentally uncoupling. Do not use
the forks if the pin "B" is not returned
to safe position. (Fig.4)
- insert locking brackets "C" so as to
prevent the forks from sliding
sideways (Fig. 5).

STANDARD FORKS DISASSEMBLY

Proceed as follows to disassemble the

standard forks from the carriage
correctly and safely:

- these operations should be carried

out by a single operator
- always use the personal protection
systems shown in the paragraph
"SAFETY AND ACCIDENT
PREVENTION MEASURES" of
chapter "INTRODUCTION"
- lower the forks to the ground, and
check that they are correctly resting
on a flat, compact surface
- descend from the driver's cab
- lift pin 'B' from its safety position (Fig. 1) to a released position (Fig. 2), and check that it is kept in a lifted position
- climb into the cab again and carry out the fork removal operations with extreme caution. Perform the operations described
in paragraph 'STANDARD FORK ASSEMBLY' in reversed order.

RULES FOR LOAD TRANSPORT

- always handle loads slowly and with caution

- if you are not transporting any loads, you are allowed to drive your machine from one spot to another with the boom raised
to a maximum height of 2 metres from the ground
- if you are transporting a load, the boom must be in a transport position (see also paragraph "BOOM POSITION FOR ROAD
TRAVEL"), and the forks must be lifted to about 0.5 metres from the ground
- while driving your machine from one spot to another, avoid sharp acceleration and braking
- while driving your machine from one spot to another, always keep a low speed, and take all possible safety measures to
prevent the load being transported from shifting on or falling from your machine

MACHINE OPERATING AREA

- check soil condition and make sure that the working area is well lit
- make sure that nobody is standing in the machine operating area
- make sure that there are no overhead lines in the machine operating area
- make sure that the machine operating area is always sufficiently lit; should the standard lighting system your machine is
equipped with not be sufficient for the workplace, please contact either Merlo S.p.A. or your local dealer for additional
solutions which may suit your needs.
- make sure that all the windows and the rear-view mirrors of your machine are always perfectly clean; clean them at regular
intervals, so as to ensure good visibility over the machine operating area.

ATTACHMENTS AND ACCESSORIES

- only use accessories approved by Merlo S.p.A.

- check that the accessories of your machine are undamaged and work correctly
- check that the stability control system of your machine works correctly
- check that the accessories are correctly mounted on the tool carrier carriage
- always follow the load chart of the accessory being used
- never lift any load with only one fork
- never use ropes, chains or slings hitched to the forks, to the carriage or to the telescopic boom to lift any load. Always use
the attachments designed for this purpose, which are type-approved and guaranteed by Merlo S.p.A.

5-3
 5 - OPERATING INSTRUCTIONS

HOW TO HANDLE A LOAD

This paragraph describes all the operations required to correctly handle a load
with standard forks.

• CENTRE OF GRAVITY OF A LOAD

Before lifting a load, its weight and centre of gravity need to be established. Note
that the centre of gravity of a load on the forks is calculated at 500 mm (600 mm
for models P60.10 - P60.10EE - P72.10 - P72.10EE) from the heel of the forks
(Fig.1)

If irregular loads are manoeuvred, the centre of gravity needs to be calculated

transversely before each manoeuvre (Fig.2).

WARNING! Manoeuvring a load that exceeds the maximum

indicated in the machine's load chart is forbidden.

• MANOEUVRING A LOAD AT GROUND LEVEL

- make sure the ground where the load is to be placed is flat and firm
- position the machine near the load to be lifted with the telescopic boom
completely retracted and the forks in a horizontal position (Fig.4)
- turn the gearbox selector switch (19) and gear direction switch (20) to position
"N"
- level the machine perfectly using the crossways tilt corrector;
- regulate the width and centring of the forks in relation to the load to be lifted
(Fig.5)
- extend the boom, bring the forks under the load and lift it a few centimetres
(Fig.6)
- rotate the carriage a few degrees upwards and completely retract the
telescopic boom (Fig.7)

• MANOEUVRING A CIRCULAR-SHAPED LOAD

For handling circular shaped loads (barrels, cans etc.) installation of the
appropriate attachment, provided and type-approved by Merlo S.p.a., on the
machine carriage is necessary. In order to ascertain the attachment best suited
to the type of circular load to be handled, contact the nearest dealer.

• MANOEUVRING A HIGH LOAD

WARNING!
Before collecting a high load or before placing a load high up, correct
levelling of the machine needs to be carried out checking, with particular
attention, that the air bubble is in the central zone of the level. Never pick
up or lay down any loads from above if your machine is not levelled
correctly.
Never exceed the limits set in the load chart.

- check that the place where the load is to be positioned is flat and strong
enough to support the load
- check that the place where the load is to be positioned is within the operating
area of the machine and respects the load chart
- check that the surrounding ground is flat and resistant in order to support the
machine and the load to be handled
- move as near as possible to the area where the load is to be deposited
- prior to start any movement, set both speed range and direction selectors in
their neutral position "N".

5-4
 5 - OPERATING INSTRUCTIONS

If stabilisers are to be used (if the machine is equipped with front stabilisers),.
follow these instructions:

- correctly stabilise the machine as described in the relevant paragraph of this

manual remember that to stabilise the machine the telescopic boom must not
pass beyond the upper edge of the cab. if this is not the case, it will be
impossible to stabilise the machine (Fig. X)
- check that the machine is perfectly levelled using the spirit level in the cab

If intending to operate on tyres follow these instructions:

- level the machine using the crossways tilt corrector; remember that to level
the machine the telescopic boom must not pass beyond the upper edge of the
cab. if this is not the case, it will be impossible to use the crossways tilt
corrector (TILTING) (Fig.Y)
- prior to start any movement, set both speed range and direction selectors in
their neutral position "N".

WARNING! Manoeuvring loads suspended on cables, chains, slings

or other is prohibited if the machine is not equipped with the Merlo attachment specific to such use (hook on forks,
hook on carriage, crane boom, fly jib etc...)
When using compatible and type-approved Merlo attachments, always refer to the relevant load chart present in the
holder provided in the cab.
If operations with the platform must be carried out near overhead electricity cables, the person in charge must ask
whoever manages the cables and the area's health and safety authorities for the minimum safety distance from the
cables, so that all necessary precautions for avoiding accident risks can be taken.

- bring the forks into a horizontal position and approach the load with care, lifting and extending the telescopic boom the
minimum possible or, if necessary, slowly advancing the machine (Fig.8)
- position the forks under the load taking care that they insert easily (Fig.9)
- shift the gear selector switch (19) and direction switch (20) into position "N"
- lift the load a few centimetres and tilt the carriage upwards (Fig.10)
- if possible, slowly and carefully reverse the machine then lower and retract the telescopic boom to bring the load into the
transportation position (Fig.11)
- in the transport position, move the machine into the area where the load is to be placed
- lift and extend the telescopic boom until the load is above the stack; if necessary advance the machine with care. (Fig.12)
- shift the gear selector switch (19) and direction switch (20) into position "N"
- bring the forks into a horizontal position and correctly place the load on top of the stack, lowering and retracting the
telescopic boom (Fig.13). Reverse the machine in order to retract the forks

5-5
 5 - OPERATING INSTRUCTIONS

INSTRUCTIONS FOR STARTING YOUR MACHINE

WARNING!
Before starting to drive your MERLO machine all the information and safety instructions in this paragraph need to
have been read and understood.
It is particularly important to have a good knowledge of the positioning and functioning of all controls.

• GENERAL CONDITIONS

- always wear clothing suitable for driving a lift truck

- always remember to close the engine bonnet and other compartments
- adjust the seat to your own requirements in order to ensure safe and comfortable driving
- never drive with dirty, damp or oily hands or shoes
- always close the lower part of the cab door
- always fasten your seat belt and adjust it as described in the relative paragraph of chapter "CAB"
- before every journey check the correct functioning of the parking brake and the horn
- for driving on public roads it is necessary to select the steering on the front axle of the machine, bring the operating mode
selector switch (6) to the central position and turn on the rotating signal lamp on top of the cab
- never transport passengers in the cab and on no other part of the vehicle
- always respect the rules in force in the country where you are driving
- never extend parts of your body out of the cab window; always maintain a correct driving position
- manoeuvring the machine without a load must be done with the telescopic boom at a maximum of 2 metres above the
ground
- manoeuvring the machine with a load on the forks must be done with the telescopic boom at a maximum of 0.5 metres
above the ground
- always look ahead of the machine and use the wing mirrors and rear view mirror constantly to see the road
- always drive with extreme care and in particular control your speed on wet, uneven or slippery ground
- avoid sudden braking
- the forward/reverse gear change must always be done with the vehicle stationary
- do not leave the vehicle unattended with the engine running
- at night, light the working area using all the machine's headlights including the work lights (if present)
- be sure to have understood all of the machine's controls before starting to drive
- at the beginning of each working day, carry out all the checks described in the following paragraphs

5-6
 5 - OPERATING INSTRUCTIONS

• GENERAL CHECKS BEFORE STARTING THE ENGINE

NOTE! A P40.17PLUS was taken to list the parts to be checked. The same instructions apply to all models
included in this manual.

Carry out the following checks every day (before using the vehicle):

- keep all machine parts in due order and clean

- inspect the exterior of the machine to check that no screws or bolts are loose or missing and that there are no leakages of
hydraulic oil
- roof rotating flashing beacon (figure 1)
- water level in the radiator (figure 2)
- hydrostatic transmission oil level (figure 3)
- tyre pressure and condition (figure 4)
- presence, function and good condition of the safety belt (figure 5)
- adjust the seat to ensure that all the driver controls can be conveniently reached
- adjust the rear view mirrors to ensure good visibility from the driver's seat
- check the correct opening and closing of the upper and lower part of the driver's cab door

5-7
 5 - OPERATING INSTRUCTIONS

• CHECKS WITH THE IGNITION KEY (8) IN POSITION "R"

Turn the ignition key (8) to position "R" and carry out the following checks:

- warning light panel (figure 7)

- correct operation of all control switches (figure 8)
- front lights and direction indicators (figure 9)
- rear lights and direction indicators (figure 10)
- hazard warning lights
- hydraulic oil level (figure 11)
- buzzer (horn)
- reverse gear warning beeper

5-8
 5 - OPERATING INSTRUCTIONS

• CONTROL PANEL ACTIVATION

To switch on the machine control panel turn the ignition key (8) to "R".

At this point all the lights and indicators on the instrument panel come on for a short time (GENERAL CHECK function) and
then only these indicators remain on:

44 - battery charger indicator light

45 - engine oil pressure indicator light
55 - crab steering indicator light (only if selected)
57 - parking brake indicator light
58 - Coolant thermometer
59 - Fuel level indicator
62 - LCD display
208 - steering plant pressure indicator light

WARNING! Switch off the engine immediately should the light indicators fail to function as described. If the
crab steering warning light (55) is lit, use the appropriate lever to reset normal conditions.

• ENGINE START-UP

Before starting the engine, check that:

- the parking brake (37) is engaged

- the drive direction selector (20) is in neutral position "N".

Then turn the ignition key (8) as follows:

- turn the ignition key (8) to position "R" to turn on the instrument panel
- turn the ignition key (8) to position "HS" to start the diesel engine; when the
engine is running, release the key (8), which automatically turns to position
"R" again.

For models with KUBOTA engine

At temperatures below -5°C, the thermo-starter must be used to start up the engine:

- set the key to pos. "R"

- set the key to pos. "H" the indicator light (53) comes ON; hold the position for about 15 seconds.
- return the key to position "HS" and start the engine

IMPORTANT! Should the engine fail to start after 20 seconds, release the ignition key (8). Wait 2 minutes before trying
to start the engine again, so as to let the starter cool down.

Once the engine has started, check that:

- all the indicator lights on the instrument panel switch off except for the parking brake light (57)
- the engine rpm indicator (61) and the hour counter / odometer (62) start operating

5-9
 5 - OPERATING INSTRUCTIONS

Before driving your machine, check that:

- both the acoustic alarm and the indicator lights on both the instrument panel and the control panel are off
- the controls of the hydraulic system are in working order
- both the service brake and the parking brake are perfectly efficient (for further information please refer to chapter
"PERIODIC SAFETY CHECKS")
- the fuel tank is sufficiently full

• MACHINE START

NOTE! Depending on ground conditions, the machine could start moving before the operator is ready. The
procedure described below grants the operator full control of the machine.

With the engine running, follow the procedure below:

- check that the wheels are aligned with the chassis

- select the required steering mode
- press the service brake pedal and keep pressed fully down (15)
- disengage the parking brake
- select the desired gear with the gear selector (19)
- select the direction of movement using the direction selector (20)
- gradually press the accelerator pedal (14) and release the service brake (15) at the same time

WARNING!
The machine is fitted with a system which activates the intermittent sound alarm when, while the parking brake (37) is
applied, the drive direction selector (20) is activated.

• STOPPING THE ENGINE AND PARKING THE MACHINE

When parking the machine after a days' work, carry out the following operations:

- Shift the drive direction selector to the position “N”

- Select the neutral gear (N).
- Apply the parking brake.
- Fully retract the telescopic boom.
- Lower the forks to the ground.
- Let the engine idle for 2 minutes before stopping it.
- Turn the ignition key (8) to position "0"; the engine automatically stops
- Remove the ignition key (8) from the instrument panel.
- Shift the control lever of the boom extension cylinder forwards and backwards to release any air contained in the cylinder.
- If the machine is equipped with a safety chock, use it to block the wheels.
- Lock the cab door.

• CONTROL CHECK

The system signals a fault by means of a buzzer and the lighting up of the relative indicator light.
The indicator lights that are part of this CONTROL CHECK are:

• 44 - battery charger indicator light

• 45 - engine oil pressure indicator light
• 46 - brake oil level indicator light
• 47 - clogged engine air filter indicator light
• 48 - hydrostatic transmission oil tank level indicator light
• 49 - hydrostatic transmission oil temperature indicator light
• 57 - parking brake activation indicator light
• 93 - engine coolant temperature indicator light
• 132 - engine coolant level indicator light
• 133 - water in the diesel fuel indicator light
• 206 - cable failure indicator light
• 207 - MERLO SERVICE indicator light
• 208 - steering system low pressure indicator light

For all the information on the general CHECK CONTROL indicator lights see the instructions in the table "INDICATOR LIGHTS
ON THE INSTRUMENT PANEL" in the section "DESCRIPTION OF THE INSTRUMENT PANEL (C) in the chapter "CONTROLS
AND INSTRUMENTATION".
In any case the operator must immediately stop the engine and remove the cause of the anomaly (for the maintenance
operations refer to the relative chapter).

5 - 10
 5 - OPERATING INSTRUCTIONS

INSTRUCTIONS FOR DRIVING YOUR MACHINE ON THE ROAD

WARNING! Observe the laws in force.

The circulation of the machine on public roads is permitted only with the attachments foreseen and indicated in the
road traffic documents.
Lock the working tools with the special mechanical stops and install any prescribed protective devices.
The transport of loads on public roads is strictly forbidden.
You are reminded that the circulation of the machine on public roads with forks mounted is forbidden.

Before driving the machine on the road:

- make sure that the tyres are inflated to the correct pressure (as shown on the sticker applied on the rim), and that they are
in perfect condition for use
- make sure that all visual and acoustic alarms are in perfect condition, clean and in working order
- make sure that all the windows and the rear-view mirrors of your machine are clean, and that the latter are correctly
adjusted
- make sure that the beacon on the roof is correctly installed and in working order
- make sure that the fuel tank is sufficiently full
- align the wheels with the chassis and select front-axle steering
- completely lift the stabilisers (only P39.10)
- fully retract the telescopic boom, then lower it until the red stripe applied on the cab window (to the operator's right) is
aligned with the red stripe applied on the telescopic boom
- make sure that the attachment carriage is perpendicular to the ground: the carriage is in the correct position if the red stripe
on the carriage is aligned with the one on the boom head (see corresponding paragraph)
- turn operating mode selector switch key (6) to position "B" (the controls of the hydraulic system are disabled)
- switch on the rotary signal lamp, and make sure it works in daylight also
- switch on the low-beam headlights (if this is prescribed by the local highway code)
- close the cab door

• BOOM POSITIONING FOR ROAD

CIRCULATION

Before driving your machine on the

road, fully retract the telescopic
boom, then lower it until the red stripe
applied on the cab window is aligned
with the red stripe applied on the
telescopic boom.
Check also that the carriage is
perpendicular to the ground: the
correct position is given by the
alignment between the two red lines
(B) on the carriage and on the boom head.

• MAXIMUM INCLINES WITH UNLOADED VEHICLE

The following indications refer to the maximum inclines that the machine can tackle with no load on the forks. Before driving an
unloaded vehicle, it is necessary to position the telescopic boom in the position described in paragraph (BOOM POSITIONING
FOR ON-ROAD CIRCULATION).
The maximum inclines for your unloaded machine are:

- longitudinal: 45% with forks upstream

- longitudinal: 50% with forks downstream
- transverse: 25% (in both cases)

WARNING! The drawing below is by way of example only in order to explain better the concepts previously
expressed concerning the incline limits that can be achieved.

5 - 11
 5 - OPERATING INSTRUCTIONS

• MAXIMUM INCLINE WITH LOAD ON FORKS

- Ensure that the proper steering mode has been selected.

- Retract the boom fully.
- Raise the boom, rotate the carriage backwards (not to the stop) so that the load is approximately 50 cm from the ground
- Carry the load using the slow gear.
- The transport of loads on public roads is strictly forbidden.
- The maximum in line limits that can be achieved are:
35% with the load to the front, 20% (15% for the models P60.10 - P60.10EE - P72.10 - P72.10EE) with the load to the
rear, 10% in the transverse direction of the machine.

WARNING!!! The drawing below is by way of example only in order to explain better the concepts previously
expressed concerning the incline limits that can be achieved.

• TOWING OF THE MACHINE

Tow the machine only when no other options are available. If possible, appropriate rescue vehicles should be used. Keep in
mind that the towing force must be at least 1500 kg.

GENERAL STANDARDS FOR TOWING THE MACHINE

- towing of the vehicle must be carried out using the special points prepared for this purpose
- never use cables, belts or chains to tow the machine or to have it towed, since they can break
- never use cables, belts or chains to tow the machine or to have it towed if the braking system of the machine does not work
- always use a solid and suitably sized bar to tow the machine
- when towing the machine, an operator must always be sitting in the vehicle being towed
- never stand near vehicles while they are being towed
- the machine can be towed for short distances by vehicles of adequate size and weight and being compliant with the
national law as it stands

PREPARING THE MACHINE FOR TOWING

- Hook up the machine from the rear side using the specific towing hook (A) or
the holes available for fitting one.
- Turn the steering wheel until rear wheels are parallel with the side of the
machine.
- Select the front axle steering mode.
- If the battery is completely flat connect an external one, as outlined in chapter
"TROUBLE-SHOOTING", paragraph "STARTING THE ENGINE IN CASE OF
FLAT BATTERY".
- Place the gear and forward/reverse selector in the neutral position.

5 - 12
 5 - OPERATING INSTRUCTIONS

Release the parking brake following these instructions:

- Turn the ignition key to position R.

- Turn selector (37) to the left.
- Act on the emergency pump (28) in order to open the brake calliper (the
selector 37 stop lightening).
- If it is not possible to disable the hand brake, go on as described in the
chapter "FAILURE - CAUSES - REMEDIES" of this manual at the paragraph "
MALFUNCTIONING OF THE EMERGENCY PUMP".

WARNING!
Do not tow the machine over 24 Km/h (15 MPH).

• SECURING AND LIFTING OF THE MACHINE

To anchor and lift the machine, ONLY use the points indicated by the specific sticker as described below:

A) Machine lifting points B) Machine anchorage points

- Disassemble the vehicle attachments

- Assemble suitable clevis in each of the points indicated
- Lower and retract the vehicle boom completely
- Connect the cables to the previously assembled clevis.

The total weight of the machine is written on the identification plate on the outside the cab.

Keep in mind that each clevis and related cable must have a min. lift capacity greater than 2/3 of the vehicle's total weight.

The attachments must be lifted or anchored separately from the vehicle and following the instructions of the pertaining chapter
in this manual or attachments.

WARNING! Check that cables, hooks and lifting devices are in good condition and that their lift capacity is
sufficient for the weight to be handled.

5 - 13
 5 - OPERATING INSTRUCTIONS

• TRANSPORTATION OF THE MACHINE

- Load and unload the machine on a firm and level surface.

- Ensure that the brakes of the truck and trailer are engaged.
- Use a ramp or loading platform. The ramp must be strong, shallow angle and correct height.
- Drive the machine onto the ramp.
- Park the machine in the centre of the trailer bed.
- Place chock blocks in front and behind the wheels of the machine.
- Place the gear and forward/reverse selector in the neutral position.
- Engage the parking brake.
- Lower the boom until the forks lay on the trailer.
- Stop the engine, and remove the key.
- Lock the cab door.
- Fasten the machine to the trailer with chains or cables

WARNING ! Do not use just the parking brake but secure the machine to the trailer by external means also.

INSTRUCTIONS FOR THE CORRECT USE OF THE MACHINE IN THE VICINITY OF ELECTRICITY POWER SUPPLY
LINES

Before setting to work, check that there are no overhead utility lines in that area.
Should there be overhead utility lines, keep at a safe distance from them (at least 5 metres, as provided for by applicable laws).
However, you are advised to inquire the minimum safety distance from such lines from the operator of the said lines, as well as
from the authorities in charge of safety and health in the workplace.
Please note that the higher the voltage, the greater the safety distance should be.

USE OF THE MACHINE DEPENDING ON WIND STRENGTHS

Before using the machine, check whether wind strengths allow its safe operation at altitude.
Read the following table - showing the Beaufort scale - to estimate wind strengths.

WARNING!!
The maximum permissible wind strength for the operation of the access platform is 12.5 mps
This table is also available as a leaflet, to be found in its holder in the cab.

INSTRUCTIONS FOR USING THE TABLE CORRECTLY

- working conditions are good up to class 4 (green symbol)

- class 6 indicates that the machine is operating under hazardous
conditions. The yellow-red symbol indicates to work with extreme
caution, especially if working at a significant height
- from class 7 onwards (Beaufort scale has 12 classes) the machine
should not be used

WARNING!!
Never install or use on the machine, on its parts and attachments
subject to the action of the wind, components or materials (such as
panels, sheets or the like) which might have a “sail effect” and
decrease machine stability on windy days.

END OF SECTION

5 - 14
 6 - ORDINARY MAINTENANCE
CONTENTS

INTRODUCTION ............................................................................................................................................................................ 2

SAFETY INFORMATION AND GENERAL RULES ........................................................................................................................ 2

ENVIRONMENTAL INFORMATION ............................................................................................................................................... 2

INFORMATION ON ORIGINAL MERLO SPARE PARTS ............................................................................................................... 2

MAINTENANCE INFORMATION .................................................................................................................................................... 2

FUEL AND LUBRICANTS .............................................................................................................................................................. 3

SCHEDULED MAINTENANCE DURING THE MACHINE'S RUNNING-IN PERIOD ...................................................................... 6

COVERS......................................................................................................................................................................................... 9

ENGINE COMPARTMENT - NOMENCLATURE .......................................................................................................................... 11

MERLO PERIODIC MAINTENANCE SCHEDULE ....................................................................................................................... 12

EVERY 10 HOURS OR DAILY ..................................................................................................................................................... 14

EVERY 50 HOURS OR WEEKLY ................................................................................................................................................ 15

EVERY 500 HOURS OR EVERY 6 MONTHS .............................................................................................................................. 19

EVERY 1000 HOURS OR EVERY 12 MONTHS .......................................................................................................................... 24

EVERY 1500 HOURS OR EVERY 18 MONTHS .......................................................................................................................... 26

GENERAL MAINTENANCE .......................................................................................................................................................... 29

TROUBLE SHOOTING ................................................................................................................................................................. 34

END OF SECTION ....................................................................................................................................................................... 35

6-1
 6 - ORDINARY MAINTENANCE

INTRODUCTION

In this chapter you will find all the ordinary maintenance operations to be executed both during the running in period and
periodically.
Moreover, you can find all information concerning type of fuel, greases and oils to be used on your machine in order to assure
the highest reliability, efficiency and duration.

SAFETY INFORMATION AND GENERAL RULES

In order to ensure that the machine is used in maximum safety, reliability and efficiency conditions, it is key to regularly carry
out all ordinary maintenance operations following closely the instructions provided by the present operator manual.
Do not use the machine unless all maintenance operations and any necessary repair work have been executed.
Should the operator notice that the machine does not operate as it should or it does not meet all safety requirements, the
anomaly shall be immediately communicated to the person in charge.
Before carrying out any work on the machine, the engine must be stopped, the direction selector must be brought to its central
position and the gear selector must be in neutral gear.
It is strictly forbidden and highly dangerous to modify any machine component by changing its original structure. it is further
forbidden to change the hydraulic and electric setup or modify the safety systems. Otherwise, Merlo S.p.a shall be waived of
any liability and guarantee claim.

WARNING!! Maintenance must be performed by skilled and competent personnel. For any work on parts which
fall outside the scope of ordinary maintenance operations - as defined by the present operator manual - contact the
Merlo Technical Support Service.

ENVIRONMENTAL INFORMATION

WARNING! Always comply with the environmental laws of the country where the machine is used.
It is strictly forbidden to unload or discharge oils, filters or any other source of environmental pollution. Pay particular
attention to the safe disposal of such materials which are dangerous for people and the environment – in such cases,
contact the responsible organisations.
All appropriate personal protection devices must be worn when handling lubricants (gloves, masks, overalls, etc.).
In order to avoid personal burns or fires, do not work on heated fluids or components.

INFORMATION ON ORIGINAL MERLO SPARE PARTS

WARNING! Maintenance operations on Merlo machines must be carried out using original and approved spare
parts only. If non original spare parts are used, Merlo shall be waived of any liability and all machine guarantee terms
shall be deemed void.

MAINTENANCE INFORMATION

In the event of machine failure, the operator shall switch off the diesel engine as soon as possible, remove the ignition key, exit
the machine and check the extent of the problem. Please note that maintenance operations shall be carried out by skilled and
trained personnel with the machine idle.
It is also necessary that all maintenance operations are carried out indoors by a properly equipped workshop.

Before starting any maintenance operation, please make sure that the following conditions are met:

- never carry out maintenance operations you are not familiar with. Always follow the instructions provided in the Operator's
Manual and, if necessary, contact the Merlo Technical Assistance service
- place the machine on flat and compact ground, having a maximum slope of 3%.
- lower and fully retract the telescopic boom of your machine
- remove any loads or attachments fitted on the machine and place them on the ground.
- shift both the gearbox selector switch and the operating mode selector switch to the neutral position.
- switch off the diesel engine and take the ignition key out of the instrument panel.
- with the engine off, operate the control levers to relieve any residual pressure from the oil circuit.
- place wedges under both front and rear wheels of the machine to prevent accidental movements.
- always use personal protective equipment
- take all the necessary accident prevention measures for the kind of operation to be carried out.
- replace engine oil only when its temperature drops below 60°C.
- carry out all maintenance operations at least 4 hours after switching off the engine, so that any contact with hot machine
parts can be avoided.
- when using compressed air for cleaning and blowing operations, make sure that the maximum pressure is 2 bar. Always
wear protection goggles when using compressed air.

6-2
 6 - ORDINARY MAINTENANCE
- use either a ladder or an access platform - compliant with the law in force - if you need to carry out maintenance operations
on the machine at a height exceeding 1.50 m from the ground.
- if you need to carry out maintenance operations underneath the machine, use either a pit or an auto lift with appropriate
characteristics. For the total weight of the machine please refer to the identification plate applied on the outside of the cab.
- if you need to raise the telescopic boom to carry out maintenance operations, equip the working area with external supports
which can support the telescopic boom and prevent it from being lowered accidentally. For this purpose connect a sling to a
suitable hoisting device having a minimum load capacity of 2,000 kg.
- if you need to lift the machine from the ground to carry out maintenance operations, use a suitable lifting device which
complies with safety regulations; the coupling points on the machine are shown by a yellow triangular sticker.
- deflate the tire completely before carrying out any maintenance operations on the tyre or rim.
- while inflating tyres, never stand in front of the tire side-wall but to one side.
- never make welds on the rim if the tyre is still mounted, since this may lead to either an explosion or a fire.
- avoid any prolonged and repeated skin contact with fuels, lubricants or other fluids, since this may cause skin problems or
other syndromes.
- never swallow fuels, lubricants or other fluids.
- when cleaning or replacing filters, make sure there is adequate ventilation in order to prevent toxic fumes from
accumulating.
- never perform welding operations in enclosed rooms which are not properly ventilated.
- never perform welding operations on painted surfaces. Remove the paint with suitable products first, then wash the
surfaces and let them dry.
- be careful when removing caps from tanks, radiators, or cylinders: turn them cautiously to relieve any residual pressure.
- stay out of the way during draining operations, and always wear protection goggles. Slowly unscrew the draining screw by a
few turns to let either the condensate or the fluid come out.
- relieve pressure from circuits before carrying out maintenance operations.
- never try to identify leaks of pressurized fluids with your bare hands.

FUEL AND LUBRICANTS

Please follow these descriptions in order to know the type of fuel, oils and greases to be used on your machine.

• DIESEL FUEL

NOTE! The fuel used to fill the machine tank must comply with EN590 regulations.

For further details consult the manual of the relative engine.

- FUEL STORAGE

Carefully observe the following rules to correctly store the fuel:

- Store the diesel fuel in clean containers, away from direct sunlight and in a protected area.
- Before refuelling the machine, eliminate any dirt, water or sediment in the deposit tanks, as these may obstruct filters, the
injection pump or injectors. This is particularly necessary if diesel is stored for a long period of time.
- During cold weather, do not use antifreeze to remove water from the diesel, but rely solely on special additives for diesel
engines
- Do not rely only on the pre-filter found on the machine to completely eliminate water from the diesel fuel.

- FUEL TANK FILLING

Refuel with diesel at the end of each working day.

For correct refuelling, follow these instructions:

- Carefully clean the area of the fuel cap.

- Remove the fuel cap "T" by releasing its lock with the key provided.
- Add the fuel in the tank paying attention not to refill it to the limit; in fact, some
free space must be kept for fuel expansion
- Immediately clean any fuel spills.
- Screw the fuel cap "T" and lock it with the provided key so as to prevent any
tampering.

Fuel tank capacity = 150 lt.

Fuel reserve = 40 lt

WARNING! Handle the fuel with great care. Stop the engine before refuelling with diesel. Do not smoke while
filling up the tank or while working on the fuel system. Do not refuel or pour fuel in closed or nor sufficiently aired
environments.
In cold weather, use diesel with antifreeze additives only.

6-3
 6 - ORDINARY MAINTENANCE

• ANTI FREEZE

Refer to the relative engine workshop manual.

• OILS CHART FOR USE OF THE MACHINE IN NORMAL TEMPERATURES (0°C, + 40°C)

WARNING! The oil to be used for the replacement or top up can be chosen between the products indicated by
the manufacturer or between others available on the market; in any case they must have the characteristics indicated
in the table.
Although it is not possible to mix different oil brands, it is possible to top up the oil using a different brand to that
inside the system, providing that it complies with the specifications indicated and that the quantity required does not
exceed 10% of the total capacity of the system.
Different brand oil cannot be mixed.
Oil transportation and trade must be subject to European and local laws in force. Customers are kindly requested to
provide for their own supply following the above mentioned regulations. For control and replacement operations, refer
to the information in the instruction manual.
The oils chart is also enclosed, as a booklet, in container (21) inside the cab (please see Chapter "STICKERS WITH
CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB").

ENGINE OIL
SPECIFICATIONS
ENGINE SAE 10W-40 ACEA E3/E5/E7
ASTM D4985
COLOUR: RED -35%-
COOLANT VW TL 774D
TEMPERATURE: UP TO -25°C
MB325.3

HYDRAULIC CIRCUIT OIL

ESSO MOBIL SHELL Q8 OILS SPECIFICATIONS
HYDRAULIC
SYSTEM Viscosity
HYDRO
SERVICE at 40°C = 46cst
HVI 46 DTE 15 M TELLUS T 46 Q8 HANDEL-46
SYSTEM
UNIVIS N46
HYDROSTATIC Iso 3448 = 46
TRANSMISSION

BRAKING CIRCUIT OIL

ESSO MOBIL SHELL Q8 OILS SPECIFICATIONS
In conformity
BRAKING BRAKE FLUID MOBIL BRAKE BRAKE FLUID
FM VSS 116
CIRCUIT SUPER FLUID DOT 4
DOT 4

MECHANICAL GROUPS OIL

ESSO MOBIL SHELL Q8 OILS SPECIFICATIONS
GEAR BOX
DIFFERENTIALS
ESSO GEAR
REDUCTION MOBILUBE Q8 T 55 SAE 80W-90
OIL SPIRAX HD
HUB HD 80W-90 80W-90 MIL-L-2105C
GX 80W/90
CHAIN
TRANSFER
UNIT

6-4
 6 - ORDINARY MAINTENANCE

• OILS CHART FOR USE OF THE MACHINE IN ARCTIC TEMPERATURES (-15°C, + 30°C)

For different brands of oil, ensure that they have characteristics equal to the above ESSO products. Should you wish to change
the product brand, the system must be flushed clean of the original product. If using oil that is not compliant, any warranty on
all components of the hydraulic system will be immediately revoked.

ENGINE OIL
ENGINE Refer to the relative engine handbook.
COLOUR: RED -50%-
COOLANT
TEMPERATURE: UP TO -38°C

HYDRAULIC CIRCUIT OIL

HYDRAULIC
Hydraulic oil with viscosity at 40°C = 34.9 c St
SYSTEM ESSO
HYDROSTATIC UNIVIS N32
High viscosity index ISO 3448 = 32
TRANSMISSION

BRAKING CIRCUIT OIL

ESSO MOBIL SHELL Q8 OILS SPECIFICATIONS
BRAKE In conformity
BRAKING MOBIL BRAKE BRAKE FLUID
FLUID FM VSS 116
CIRCUIT OIL FLUID DOT 4
SUPER DOT 4

MECHANICAL GROUPS OIL

ESSO MOBIL SHELL Q8 OILS SPECIFICATIONS
GEAR BOX
DIFFERENTIALS
ESSO GEAR
REDUCTION MOBILUBE Q8 T 55 SAE 80W-90
OIL SPIRAX HD
HUB HD 80W-90 80W-90 MIL-L-2105C
GX 80W/90
CHAIN
TRANSFER
UNIT

• GREASES CHART FOR USE OF THE MACHINE IN NORMAL TEMPERATURES (0°C, + 40°C)

APPLICATIONS PRODUCT NOTES

Pivot pins, Greased joints, SPECIAL GREASE
Boom sliding pads (Internal) ROLOIL TIV
Plunger for quick uncoupling of attachments SPECIAL-MERLO
SPECIAL GREASE
Boom sliding pads (external) ROLOIL ULTRAGREASE
SPECIAL-MERLO
PBR Rubber grease
Parking brake calliper piston seals Vegetal
(Repco brake group)

IMPORTANT! "ROLOIL SPECIAL-MERLO" greases have been designed and manufactured especially for Merlo
machines. Therefore, to ensure maximum reliability and efficiency of your machine, use these products only, which
can be ordered from Merlo Technical Assistance Service.

• GREASES CHART FOR USE OF THE MACHINE IN ARCTIC TEMPERATURES (-15°C, + 30°C)

APPLICATIONS PRODUCT NOTES

Pivot pins and universal joints ESSO type CAZAR K2 Calcium, Penetration A.S.T.M.: 280 mm/10

For different brands of grease ensure they have properties equal to and are compatible with the above products.

6-5
 6 - ORDINARY MAINTENANCE

IMPORTANT! Your machine can operate at top efficiently only if clean lubricants are used. Before mounting
the pivot pins in the joints that mount plastic bushings, a film of "ESSO CAZAR K2" grease must be applied to the
latter to avoid oxidation.

SCHEDULED MAINTENANCE DURING THE MACHINE'S RUNNING-IN PERIOD

• INTRODUCTION

The instructions indicated below only relate to the maintenance operations during the machine's running-in period and
complement all other maintenance operations described in chapter "ORDINARY MAINTENANCE".
Machine maintenance operations must be carried out by skilled and qualified members of staff in an adequately ventilated
environment. The machine must be located on a flat level ground and the diesel engine must be off.

During the machine’s first 100 hours of running-in, carefully carry out the following operations:

- Regularly check the coolant level.

- Regularly check the oil level in the hydrostatic transmission and eliminate any leaks.
- Regularly check the engine air intake filter and make sure it is always in good conditions and free from any clogging.
- Regularly check that there is no oil spillage or leakage from the hydraulic oil system or the brake circuit; if necessary,
eliminate the fault.
- Regularly check the electrolyte level in the battery and the proper connection of the "+" and "-" terminals.
- Grease the indicated points (see also the table below).
- Check the correct tightening of components at the indicated torque (see also the table below).
- regularly check warning lights and indicators (light and sound) during operation.
- Accurately warm up the machine systems by executing a few idle movements
- after engine start, slowly warm up the engine, without revving .
- avoid running the engine at maximum power.
- avoid stressing the brakes.
- check the tension of auxiliary control belts.
- Pay attention to any fault or defect.

WARNING! For information on the times and interventions to carry out on diesel engines always refer to the
provided engine manual. Before carrying out any operation during the running-in period, carefully read the related
instruction in chapter "ORDINARY MAINTENANCE".
To determine the running-in and scheduled maintenance intervals, refer to the counter on the instrument panel.

• MAINTENANCE SCHEDULE FOR THE RUNNING-IN PERIOD

PERIOD (HOURS) COMPONENT OPERATION

Nuts and bolts of the transmission
Tighten to torque
After the first 10 hours components
Tighten to torque
Wheel columns
Nuts and bolts of the steering components
Tighten to torque
After the first 50 hours Nuts and bolts fastening the axles to the
Tighten to torque
chassis
Cardan joints Grease
After the first 100 hours
Hydrostatic transmission oil filter Replace
(servicing coupon)
Hydraulic oil return filter Replace

6-6
 6 - ORDINARY MAINTENANCE

• SCHEDULED MAINTENANCE AFTER THE FIRST 10 HOURS

NUTS AND BOLTS OF THE DRIVE COMPONENTS

Tighten the screws "V" of the universal joint coupling flanges to a torque of 11.7 kgm (115 Nm) (8 screws for each of the two
universal joints).

TYRES AND WHEEL COLUMNS

Check the tyre pressure with a pressure gauge and, if needed, inflate them
through valve "A".

The correct tyre inflation pressure is indicated on the sticker on the inside of the
wheel rim.

Check the correct tightening of the wheel columns "B" . If needed, tighten the
columns to a torque of 550 Nm.

• SCHEDULED MAINTENANCE AFTER THE FIRST 50 HOURS

NUTS AND BOLTS OF THE

STEERING COMPONENTS

FRONT BRIDGE (A)

Torque (30 kgm) the fastening screws

"A1" of the jack to the axle (4 screws).

REAR AXLE (P)

Torque the fastening screws "P1" of

the jack to the axle (4 screws).

REDUCTION HUB

Torque (32 Kgm) (Nm) the screws fastening the upper joint pin (4 screws for
each of the four reduction hubs).

6-7
 6 - ORDINARY MAINTENANCE

NUTS AND BOLTS FASTENING THE AXLES THE FRAME

FRONT BRIDGE (A)

Torque (13,5 Kgm) the crossways tilt

corrector securing screws of the jacks
(8 screws for each of the two jacks)
Torque (70 Kgm) the horizontal long-
life tie-rods clamping nuts (2 nuts for
each of the four tie-rods)

REAR AXLE (P)

Tighten the 8 fixing screws "V2" of the

rear axle to the chassis, with a torque
of 45Kgm.

To better understand the position of the "V2" screws which fasten the front (A) and rear (P) axles to the frame, refer to the
drawing below:

• SCHEDULED MAINTENANCE AFTER THE FIRST 100 HOURS

CARDAN JOINTS

Grease the front (F) and rear (R) universal joints at the indicated points:
A – grooved profiles
B - crossings

HYDROSTATIC TRANSMISSION OIL FILTER

For information on the hydrostatic transmission oil filter replacement, refer to the specific paragraph "EVERY 500 HOURS".

HYDRAULIC OIL RETURN FILTER

For information on the hydraulic oil filter replacement, refer to the specific paragraph "EVERY 500 HOURS".

6-8
 6 - ORDINARY MAINTENANCE

COVERS

Before carrying out some ordinary maintenance operations on your machine, you
are required to either remove or open the following covers:

- COVER 1

COVER 1 is located in the front-central part of the machine chassis and contains
certain components of the front differential, front universal joint, braking system
and Long-life tie-rods. To remove COVER 1, unscrew the screw with an
appropriate wrench

- COVER 2

COVER 2 is located between the engine and the cab and houses the universal
joints, gearbox and hydrostatic engine . To remove COVER 2, unscrew the 3
screws shown in the picture with an appropriate wrench

- COVER 3

COVER 3 is located next to the cab and contains the hoses and fittings of the
hydraulic system. To remove COVER 3, unscrew the 5 screws shown in the
picture with an appropriate wrench

- COVER 4

COVER 4 is located in the rear part of the machine and contains components of
the telescopic boom (slide pads, lock valve for the extension jack, etc.). To
remove COVER 4, unscrew the 3 screws shown in the picture with an
appropriate wrench

- COVER 5

COVER 5 (engine bonnet) houses the machine's diesel engine and all related components (filters, small tanks, radiator,
battery, inlet pipes, pumps, etc). Proceed as follows to open COVER 5:

- release the lock using the key "S" provided

• pull lever "L" towards yourself
• lift the bonnet completely until it automatically stays open

The bonnet is held open by a gas strut placed inside the engine compartment.

Proceed as follows to close COVER 5:

• lower the bonnet completely

• push lever "L" towards the machine
• use key "S" supplied to lock the engine bonnet

WARNING!!
NEVER open the bonnet while the engine is running.
To avoid the engine bonnet opening and to prevent moving or hot parts from accidentally coming into contact with
non-authorised personnel, the security keylock on the engine bonnet must be locked. Keep the "S" key together with
the engine ignition key (8).

6-9
 6 - ORDINARY MAINTENANCE

- COVER 6

COVER 6 is located in front of the cab and houses the machine electronic control
unit. Proceed as follows to remove COVER 6:

- open the lock using the specific key provided

- slide protective cover in the direction shown by the arrow

To re-close the cover, proceed as follows:

- fit the cover in its seat

- push the cover fully into place
- close the lock using the special key provided

- COVER 7

The electrical box containing the fuses, the relays and the electronic boards of
the machine can be found under COVER 7, which is located behind the driver's
seat.

Proceed as follows to open COVER 7:

• unscrew fixing screws "V"

• remove COVER 7

Proceed as follows to close COVER 7:

• rest COVER 7 on the two lower supports of the electrical box

• tighten fixing screws "V"

6 - 10
 6 - ORDINARY MAINTENANCE

ENGINE COMPARTMENT - NOMENCLATURE

Pay particular attention to the position of the engine compartment components mentioned in this paragraph, because they will
be mentioned again and described in the MAINTENANCE paragraphs.

• (P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.17PLUS – P40.9PLUS – P60.10 – P72.10)

DEUTZ 74 kW (100CV)

1) Diesel engine
2) Hydrostatic transmission oil level small tank
3) Engine coolant level small tank
4) Engine air intake filter
5) Engine air intake pipe
6) Hydrostatic transmission oil filter
7) Hydrostatic pump
8) Diesel oil filter
9) Engine oil dipstick
10) Engine oil filler cap
11) Radiator
12) Battery
13) Fuses and relays
14) Gear box oil bleeding small tank
15) Chain transfer unit

• (P38.13EE – P40.17EE – P60.10EE – P72.10EE)

KUBOTA 74 kW (100CV)

1) Diesel engine
2) Hydrostatic transmission oil level small tank
3) Engine coolant level small tank
4) Engine air intake filter
5) Engine air intake pipe
6) Hydrostatic transmission oil filter
7) Hydrostatic pump
8) Diesel oil filter
9) Engine oil dipstick
10) Engine oil filler cap
11) Radiator
12) Battery
13) Gear box oil bleeding small tank

• (P38.12 – P38.13 – P38.14 – P40.17)

KUBOTA 55,4 kW (75CV)

1) Diesel engine
2) Hydrostatic transmission oil level small tank
3) Engine coolant level small tank
4) Engine air intake filter
5) Engine air intake pipe
6) Hydrostatic transmission oil filter
7) Hydrostatic pump
8) Diesel oil filter
9) Engine oil dipstick
10) Engine oil filler cap
11) Radiator
12) Battery
13) Gear box oil bleeding small tank

6 - 11
 6 - ORDINARY MAINTENANCE

MERLO PERIODIC MAINTENANCE SCHEDULE

This paragraph contains the periodic maintenance schedule which has to be applied to the machine by strictly following the
predetermined time intervals. If the machine is used in particularly heavy duty conditions, maintenance shall be carried out at
shorter intervals.

Machine maintenance is scheduled as follows:

- hourly bands (every 10 hours, 50 hours, 500 hours, 1000 hours, 1500 hours)
- regular intervals (daily, weekly, every 6 months, every 12 months, every 18 months)

Hourly bands and regular intervals are linked in the following way:

1) EVERY 10 HOURS OR DAILY

2) EVERY 50 HOURS OR WEEKLY
3) EVERY 500 HOURS OR 6 MONTHS
4) EVERY 1000 HOURS OR 12 MONTHS
5) EVERY 1500 HOURS OR 18 MONTHS

The operator must perform ordinary machine maintenance in relation to which of the 2 situations (hourly or interval) occurs first.

All maintenance operations must be performed in a cyclic manner. At each maintenance interval, also carry out the operations
described in the previous intervals. For instance, every 1,000 hours, also carry out the maintenance operations foreseen at
500, 50 and 10 hour intervals. The 5 scheduled maintenance bands, indicated in the table below, will be described in further
detail in the following paragraphs.

WARNING!
• Maintenance of your machine must be performed by skilled and competent personnel.
• To perform maintenance operations correctly, place the machine on flat, firm ground.
• Before performing the maintenance task, make sure that the diesel engine is OFF and that the battery cut-off switch
(if fitted) is in the OFF position
• For more information about the oils and greases to be used in machine maintenance procedures, refer to the
paragraph "FUELS AND LUBRICANTS" in this section and the OIL TABLE in the section "COMMAND STICKERS -
BROCHURES IN CA". Lubricators which are not listed in the maintenance table shall be periodically greased
according EVERY 1000 HOURS OR 12 MONTHS in relation to machine use conditions.
• Always use original spare parts approved by Merlo S.p.a.
For information on maintenance times and interventions to carry out on diesel engines always refer to the engine
manual supplied as standard with the machine.
It is recommended to note the maintenance work date in order to carry out operations on a regular basis.

6 - 12
 6 - ORDINARY MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

COMPONENT * EVERY 10 HOURS OPERATION
Hydraulic oil Check level and top up
Hydrostatic transmission oil Check level and top up
Engine cooling system Check level and top up
Tyres and wheel bolts Inspect
Safety belts Inspect
COMPONENT * EVERY 50 HOURS OPERATION
Boom sliding pads (Internal) Grease
Reduction hub articulation Grease
Brakes pads Check wear
Tires and stud bolts Check pressure and stud bolts tightening
Air ventilation filter Clean
Diesel pre-filter (only for DEUTZ engines) Drain water
Engine air intake hoses Check connections
Battery Check electrolyte level and terminals
Engine air filter Clean
Brake fluid Check level
Sliding pads of the telescopic boom (outer pads) Check
Plunger for quick uncoupling of attachments Grease
COMPONENT EVERY 500 HOURS OPERATION
Hydraulic oil tank bleeder filter Replace the filter
Reduction hub oil Check level
Differential oil Check level
Gear box oil Check level
Cap screws and bolts Check tighten
Universal joints Grease
Fuel tank Drain water and sediments
Hydrostatic transmission oil filter Replace
Hydraulic oil filter on return line Replace
Engine air filter Replace the filter
Sliding pads of the telescopic boom (inner pads) Check
Pipeline guide pipe (only for models P40.9PLUS –
Check
P60.10 – P60.10EE – P72.10 – P72.10EE)
Diesel pre-filter (only for KUBOTA engines) Check
Chain transfer unit oil (only for DEUTZ engines) Check level
COMPONENT EVERY 1000 HOURS OPERATION
Articulated joints Check the play and grease
Boom sliding pads (External) Grease
Anti-dust filter Replace
Hydraulic pipes/hoses Inspect
COMPONENT EVERY 1500 HOURS OPERATION
Hydrostatic transmission oil Replace
Hydraulic oil Replace
Gear box oil Replace
Differential oil Replace
Reduction hub oil Replace
Brake fluid Replace

6 - 13
 6 - ORDINARY MAINTENANCE

EVERY 10 HOURS OR DAILY

• HYDRAULIC OIL

To check the hydraulic oil level it is necessary to:

- place the machine on a perfectly even ground

- lower and retract the telescopic boom completely
- switch off the Diesel engine
- use indicator "A" to check that the hydraulic oil level is between the minimum
(MIN) and the maximum (MAX) level.
- if necessary, remove the filler cap (B) and top up (also see paragraph FUELS
AND LUBRICANTS).

NOTE! To ensure the machine's optimum performance, regularly

check the oil level in the hydraulic system, and top up the oil if necessary.

• HYDROSTATIC TRANSMISSION OIL

Check the level of the hydrostatic transmission oil present in tank "A".

WARNING!! Do not remove cap "B" unless the engine is cold.

Release all pressure before fully removing the cap.

The hydrostatic oil level must be visible in the indicator glass "C", located near the
drain plug.
If the level is low, add specific oil (also see paragraph FUELS AND LUBRICANTS).
Re-tighten cap "B" and check for any leak in the system.

• COOLING SYSTEM

Check the engine coolant level.

CAUTION !!! Do not remove cap "B" unless the engine is cold. Release all pressure before fully removing the
cap. For further information, refer to the attached engine manual.

The coolant level in the expansion tank "A" must be between the "MIN" and "MAX" marks indicated on the tank.
If the engine coolant level is low, top up with a coolant available on the market.
Tighten the filler cap and check the cooling system for loose connections and leaks.

6 - 14
 6 - ORDINARY MAINTENANCE

• TYRES AND STUDS BOLTS

Check that the wheel studs are tightened and the tyres are properly inflated. Inspect tires for damages or excessive wear daily.

• SAFETY BELTS

Check the presence, function and the good condition of safety belt.

WARNING!
Do not use the machine on site if the safety belt is not in efficient working condition.

EVERY 50 HOURS OR WEEKLY

• SLIDING PADS OF THE TELESCOPIC BOOM (INNER PADS)

The internal sliding pads must be greased to guarantee optimal performance of

the telescopic boom. To carry out this operation correctly, proceed as follows:

- Fully retract the telescopic boom

- apply the specific product for the boom sliding pads (internal) with the
lubricators "A" (see paragraph "FUELS AND LUBRICANTS")
- extend and retract the boom a few times so as to evenly distribute the grease
inside the pads.

• ARTICULATED JOINT OF THE WHEEL REDUCTION HUBS

To ensure optimum performance of the wheel reduction hubs, grease them as

follows:

- stop the machine

- apply some specific grease onto the couplings of the wheel reduction hubs
through greasing points "A" and "B" until grease comes out (see section
"FUELS AND LUBRICANTS")
- repeat this operation on all the couplings of the wheel reduction hubs
- perform a few steering cycles to spread grease uniformly inside the wheel
reduction hubs

NOTE ! To facilitate the greasing of the wheel reduction hubs, it is

possible to steer the front wheels in such a way as to get a better view of the greasers "A" and "B"

• BRAKE PADS

Check the wear of break pads as follows:

- stop the diesel engine

- lie under the machine until you reach the area where brake callipers are located
- Check pads "A" on both sides of the bridge
- Repeat the operation for the other bridge

6 - 15
 6 - ORDINARY MAINTENANCE

If the thickness of the friction material is less than 2 mm, replace the pads.

WARNING! The maintenance and replacement of brake pads must be carried out by skilled and competent
personnel. Contact Merlo Technical Assistance Service.

• TYRES AND WHEEL STUDS

Check the tyre pressures with an accurate pressure gauge,"A" = inflating valve.
Check the tightening (550 Nm) of the wheel locking stud bolts (B).

WARNING!
The tyres which can be used on the machine are those indicated in the
Merlo List and/or in the machine registration document (if provided).

• CAB VENTILATION SYSTEM FILTER

To check its cartridge, follow the instructions below:

- Unscrew fastening screws "V"

- Extract the cab ventilation filter
- Clean the filter using a jet of compressed air
- Check the filter wear condition and, if needed, replace it with a new filter with
the same features

• DIESEL PRE-FILTER

(only for models with DEUTZ 74 kW engine)

Drain the water :

- Loosen the drain screw (A)

- Leave the liquid to drain for a few seconds.
- Tighten the screw (A)

After discharging the water from the diesel pre-filter it is not necessary to bleed the
supply system

• ENGINE AIR INTAKE HOSES

Tighten the connecting clamps and check the status of the rubber pipes.

6 - 16
 6 - ORDINARY MAINTENANCE

• BATTERY

WARNING! Before working on the battery, carefully read the

instructions in chapter "ELECTRICAL SYSTEM". Keep the battery and its
compartment clean and the terminals covered with Vaseline grease to avoid
corrosion.
Disconnect negative (-) terminal cable before you charge the battery or work
on the electrical system.

Check the electrolyte level and terminals. Wipe battery with damp cloth. Clean the
terminals with a stiff brush. If necessary, wash battery with baking soda solution:
0.1 kg. added to 1 lt. of water.

• ENGINE AIR FILTER

A) cover
B) filter cartridge
C) safety cartridge
D) filter body
E) open / close devices

Check the integrity of the cartridge:

- if the clog warning lamp (47) lights

- if the engine smokes excessively
- if the motor looses power

OPERATING INSTRUCTIONS

- remove the filter cover by using the release devices "E"

- pull out the filter cartridge "B" from its seat

The filter cartridge "B" can be cleaned by following the instructions here below:

- direct a jet of compressed air not over 5 bars from the inner side to the outer
side of the cartridge;
- tap the cartridge against your palm (makeshift solution), taking care not to
damage it;
- clean the cartridge by washing it in a special solution (this operation is allowed
but not recommended)

WARNING! It is strictly forbidden to use petrol or warm fluids to clean

the filter cartridge.

If it is not possible to clean the filter cartridge using one of the 3 methods
indicated, it will have to be replaced with another one having the same features.

- check that the filter cartridge is not damaged and that there are no tears or
small holes. If not, it will have to be replaced with another one having the same
features.
- clean the inside of the filter body (D) and the cover (A).
- insert the filter cartridge "B"
- close the cover "A" using the specific clamping devices "E"

WARNING! It is strictly forbidden to use petrol or warm fluids to clean the filter cartridge.
The special pre-filtering devices must be installed if the machine is used in particularly dusty environments.

6 - 17
 6 - ORDINARY MAINTENANCE

• BRAKE FLUID

To check the brake oil level, proceed as follows:

- place the machine on a perfectly even ground

- switch off the Diesel engine
- remove cover "A".
- remove the cap "B" from the control tank

The oil level must be about 3.5 cm from the upper brim of the tank. a slight decrease in the level is due to the normal wear of
brake pads.
This level must never be less than the minimum "MIN"; if necessary, top up to the indicated level without going over the
maximum level ("MAX"). For the type of brake oil to use, refer to paragraph "OIL TABLE" in chapter "STICKERS WITH
CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB".

WARNING!
Significant lowering of fluid level is due to system leakages. Seek the help of skilled personnel to check the system.
Be careful when filling up the appropriate small tank with brake fluid, as it is particularly toxic and could ruin painted
or plastic surfaces.

• SLIDING PADS OF THE TELESCOPIC BOOM (OUTER PADS)

Perform the following checks on all the outer sliding pads of each boom:

1 - visual inspection of outer sliding pads to check for wear

2 - visual inspection of outer sliding pads to check for wear uniformity
3 - visual inspection of the boom surface to check for any indentations due to the
sliding of outer sliding pads
4 - visual inspection of outer sliding pads to check for any burrs or large shavings
(plastic powder is accepted)

Should either condition "1" or "2" occur, please contact Merlo Technical
Assistance Service.
Should either condition "3" or "4" occur, please proceed as follows:

- remove grease from the telescopic boom surface

- adjust the telescopic boom as described in the paragraph "GENERAL MAINTENANCE"
- apply a layer of specific Merlo grease on the telescopic boom, as described in paragraph "OUTER SLIDING PADS OF THE
TELESCOPIC BOOM"

Should the problem persist, please contact Merlo Technical Assistance Service for repair.

NOTE! While extending and retracting the telescopic boom, some paint might be removed from the areas
where the outer pads of the telescopic boom slide. This is to be considered absolutely normal, and it does not
interfere with the correct operation of the telescopic boom.

6 - 18
 6 - ORDINARY MAINTENANCE

• GREASING THE QUICK UNCOUPLING PLUNGER OF THE ATTACHMENTS

Periodically grease the quick uncoupling plunger of the attachments to ease

sliding and prevents rust from forming inside the cylinder chamber.

To perform this operation correctly, please follow the instructions below:

- lower the telescopic boom

- stop the machine
- apply 30 ml of specific grease (see paragraph "FUELS AND LUBRICANTS")
with lubricator "B"
- start the engine, and perform a few plunger lifting cycles (plunger "A"). During
the first cycle, plunger "A" may move slowly, since the grease applied needs
to flow from the plunger to the spring. This delay is more significant at low
temperatures.
Excess grease inside the chamber is expelled from the side of plunger "A" during the first cycle.

EVERY 500 HOURS OR EVERY 6 MONTHS

• HYDRAULIC SUMP BLEED FILTER

Replacement of the filter cartridge:

- Unscrew the fastening screw (1)

- Remove the cap (2)
- Remove the cartridge (3) and replace it with a new one having the same
characteristics
- Reinstall the cap (2).
- Tighten the fastening screw (1)
- Check that the lower washer is in the correct position (4).

Start the machine and check for any leak in the hydraulic system.

• REDUCTION HUB OIL

Carry out the following operations to correctly check the oil of the wheel reduction
hubs:

- work on one reduction hub at a time

- remove the cap "A"
- check that the oil level is about 93mm from the edge of the cap "A"
- if necessary, top up with specific oil (see the "OIL TABLE" in chapter
"STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB")
- put back the cap "A"

6 - 19
 6 - ORDINARY MAINTENANCE

• FRONT AND REAR DIFFERENTIAL OIL

Carry out the following operations to

check the oil of the front and rear
differentials:

- remove the cap "A" on the front

bridge "A" as well as on the rear
bridge "P"
- check that the differential oil
reaches the edge of the hole.
- if necessary, top up with specific
oil (see the "OIL TABLE" in
chapter "STICKERS WITH
CONTROL DESCRIPTIONS -
LEAFLETS IN THE CAB")
- reinstall and tighten cap "A".

• GEAR BOX OIL

To check the gearbox oil level, first remove protection housing "1" (see
paragraph "COVERS"). Then carry out the following operations:

- Remove cap "A"

- Check that the gearbox oil reaches the edge of the hole
- If necessary, top up with the specific oil (see "OIL TABLE" in chapter
"STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB")
- Reinstall and tighten cap "A".
- Refit the protection cover "1".

• UNIVERSAL JOINTS

Grease the points indicate every 200 hours

when used under heavy duty conditions.

FRONT AXLE

Universal joints between gear box and

differentials :

F Front universal joint

R Rear universal joint

Grease points shown in the picture:

A universal joint splines

B universal joint carrier

REAR AXLE

Universal joints inside axles:

A universal joint splines

B universal joint carrier

6 - 20
 6 - ORDINARY MAINTENANCE

• FUEL TANK

Carry out the following operations to discharge any water or sediment from the
fuel tank:

- Place an appropriately sized container underneath discharge cap "A"

- loosen discharge cap "A" using an appropriate hexagonal wrench.
- discharge the water and sediments contained in the tank.
- Tighten discharge cap "A".

Tighten to torque (15 Nm).

• HYDROSTATIC TRANSMISSION OIL FILTER

Replace the hydrostatic transmission filter:

- place an appropriately sized container underneath filter "A"

- loosen filter "A"; use an appropriate chain or belt extractor to carry out this operation
- collect the oil that flows out
- remove filter "A"
- fill the new filter with specific oil through the appropriate external holes (see paragraph "FUELS AND LUBRICANTS")
- top up the oil in the tank and wait for the air to exit.

• HYDRAULIC OIL RETURN FILTER

Filter replacement:

- remove the cover (A) and the filter (B) with the related seals;
- replace the filter (B) and reinstall all above items, taking care not to damage
the seals.

The hydraulic oil intake filter (C) does not require maintenance.

6 - 21
 6 - ORDINARY MAINTENANCE

• ENGINE AIR FILTER

A) cover
B) locking device
C) filter cartridge
D) safety cartridge
E) filter body

- remove the filter cover by using the release devices (E)

- pull out the filter cartridge (B) from its seat
- pull out the safety cartridge (C) from its seat
- fit a new safety cartridge (C) in its seat
- fit a new filter cartridge (B) in its seat
- clean the inside of the filter body (D) and the cover (A).
- close the cover (A) using the specific clamping devices (E)

• SLIDING PADS OF THE TELESCOPIC BOOM (INNER PADS)

A visual inspection of the inner sliding pads "B" is necessary to ensure maximum
reliability, performance and durability of the telescopic boom.
To inspect the inner sliding pads of the telescopic boom, remove rear case "4"
first (see also paragraph "COVERS").
Perform the following checks on the inner sliding pads of the telescopic boom:

1- visual inspection of inner sliding pads to check for wear

2- visual inspection of inner sliding pads to check for wear uniformity
3- visual inspection of inner sliding pads to check for any breaks
4- visual inspection of inner sliding pads to check for any burrs or large shavings (plastic powder is accepted).

Should any of the above conditions occur, please contact Merlo Technical Assistance Service.

• SCREWS AND BOLTS

Check tightness. See torque chart in this manual (section MACHINE TECHNICAL INFORMATION). The nuts and bolts control
instructions of some machine parts are indicated in the paragraph RUNNING-IN PERIOD.

• PIPELINE GUIDE PIPE

(only for models P40.9 PLUS –

P60.10 – P72.10 – P60.10EE –
P72.10EE)

Completely extend the boom and

grease (about 200 cc) in the points
shown (A).

6 - 22
 6 - ORDINARY MAINTENANCE

• DIESEL OIL FILTER

(only for models with KUBOTA engine)

Check the clogging of the diesel oil filter "A" in the following way:

- stop the machine engine.

- inspect the diesel oil filter "A"

If the diesel filter is excessively dirty, clean it as follows:

- remove the retaining clamps "B" and disconnect the diesel oil filter from
pipelines
- directing a jet of compressed air in the opposite direction to the flow of fuel to
remove any sediments present in the filter
- inspect the inside of the filter and verify that the mesh is in good condition and
free from obstructions; otherwise replace it with a part from the Merlo Technical
Assistance service
- replacing the filter, connecting the pipelines and securing the retainer clamps
"B"

WARNING! The diesel oil filter has an arrow on the plastic casing which indicates the flow direction of the fuel;
replacing the filter on the engine, paying particular care that it is in the correct direction. Otherwise it will lose its
protective efficacy.

• CHAIN TRANSFER UNIT OIL

Check the oil level inside the chain

transfer unit:

- the chain transfer unit is located

inside the engine compartment;
- remove the cap "A"
- check that oil reaches the lower
edge of the hole
- if necessary, top up with specific oil
(see paragraph "FUELS &
LUBRICANTS")
- put back the cap "A"

6 - 23
 6 - ORDINARY MAINTENANCE

EVERY 1000 HOURS OR EVERY 12 MONTHS

• ARTICULATED JOINTS

Check the play on the articulated joints of the indicated components. If the play is more than 1 mm, replace the related
bushings.
Lubricate the articulated joints of the indicated components that are equipped with greaser.

A) Wheel reduction hubs - B) Front axle - C) Rear axle - D) Boom - E) Carriage - F) Fork jack
G) Lifting jack - H) Offset jack - L) Stabilisers (if fitted to the machine)

NOTE! A P40.17PLUS has been selected to explain this maintenance operation. The instructions are also valid
for all other machines included in this Operator's Manual.

WARNING!
To use the machine in particularly harsh conditions (dusty, muddy environments, etc) or for continuous and
prolonged daily use, the indicated components must be greased EVERY 50 HOURS or WEEKLY.

6 - 24
 6 - ORDINARY MAINTENANCE

• BOOM SLIDING PADS (EXTERNAL)

- Fully extend the telescopic boom

- Carefully clean the boom sliding surface, removing the residual grease
- Using a cotton wad, evenly spread a thin layer of grease (see paragraph
"FUELS AND LUBRICANTS") over the entire boom sliding surface
- Carry out a few boom extension and retraction cycles so as to evenly
distribute the product.

WARNING!
Only the recommended product can be used; a different product could
cause serious damages to the sliding surface of the boom. More frequent
greasing is required when using the machine in particularly demanding
conditions.

By way of example only, the boom of a P40.17 PLUS machine (3

extensions) is shown. Perform the same operations for the telescopic
boom on your machine (1 or 2 extensions depending on the model).

• AIR VENTILATION FILTER

Replace the filter of the cab ventilation system as follows:

- Unscrew fastening screws "V"

- Extract the cab ventilation filter
- Replace the filter with a new one with the same features
- refit the filter, tightening the fastening screws "V"

• HYDRAULIC HOSES

Perform the following checks on the hydraulic hoses:

1) visual check for any oil leaks

2) visual check for any marks on the hydraulic hoses which might be indicative of
future oil leaks (photo 1)
3) visual check for any mechanical scraping or grazing on the external protection of
the hydraulic hoses (photo 2)

Should any of the conditions above occur, replace the defective hose as soon as
possible, so as to prevent the problem from getting worse.

NOTE! Photos 1 and 2 show some examples of problems which might

occur on hydraulic hoses.

6 - 25
 6 - ORDINARY MAINTENANCE

EVERY 1500 HOURS OR EVERY 18 MONTHS

• HYDROSTATIC TRANSMISSION SYSTEM

Replace the oil from the hydrostatic transmission system

1) Radiator
2) Tank
3) Hydrostatic pump
4) Hydrostatic motor
5) Hydrostatic transmission filter
6) Hand pump

The total capacity of the system is 12 litres

WARNING! Use only hydrostatic oil shown in

paragraph FUEL AND LUBRICANTS ..

OIL REPLACEMENT

WARNING! Oil change in the hydrostatic transmission

must be performed by skilled and qualified personnel.

- unscrew the caps of the radiator (1) and hydrostatic oil tank (2)
- remove the filter (5) and drain the oil into a container; to
perform this operation, proceed in the manner described in the
Filter Replacement Paragraph “EVERY 500 HOURS”
- disconnect pipe "F" located beneath the hydrostatic motor (4),
then drain the oil from the system into a container.
- once the oil has been completely drained, reconnect piping "F"
in its correct position
- install a new filter (5) for the hydrostatic transmission
- The system must be filed with specific hydraulic oil, filtered at
10-micron and supplied at a pressure of about 2.5 bar.
- For this purpose use a hand pump "M" as shown in the photo
(6). Pour the oil into the hydrostatic pump through pressure
inlet (fitting M16x2) until the tank is filled

- close radiator cap (1)

- close cap (2) of the tank
- Remove the hand pump from the pressure connection and
close the cap

The system must be bled after filling; follow the instructions below:

- closing the bonnet, get in the cab and start the engine
- leave the engine running for about 2 minutes
- switch off the engine
- wait 2 minutes to allow the air to bleed completely from the
system.
- open the bonnet and check that the oil level in the tank is
between the MIN and MAX marks. If not top up the level with
the specific oil (see paragraph FUEL AND LUBRICANTS in
this chapter).

Repeat this procedure until, having left the engine running for about 2 minutes, the oil level is within the MIN and MAX marks
on the tank.

6 - 26
 6 - ORDINARY MAINTENANCE

• HYDRAULIC OIL

To correctly change the hydraulic oil, do as follows:

- Fully retract and lower the telescopic boom

- Stop the machine diesel engine
- Remove filling cap "B"
- Extract and clean the magnets
- Remove discharge cap "C" and empty the hydraulic oil into an appropriate container
- Close the discharge cap "C"
- Pour some new hydraulic oil through the filler cap "B"; use only the hydraulic oil indicated in the "OIL TABLE" in chapter
"STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB"
- Check that the level of the hydraulic oil poured into the system is about 5 mm from the upper edge of the indicator glass
"A". Close the filling cap "B".

The total capacity of the system is 105 litres (140 litres for P40.17 – P40.17PLUS – P40.17EE)

• GEAR BOX OIL

To correctly change the gearbox oil,

do as follows:

- Stop the machine diesel engine

- open covering housing "2" as
described in paragraph
"COVERS" in section
"ORDINARY MAINTENANCE"
- remove the filler cap "A"
- Remove discharge cap "B" and
collect the gearbox oil in an
appropriate container
- close the discharge cap "B"
- Pour some new gearbox oil through filler cap "A" until it starts flowing out; use only the gearbox oil indicated in the "OIL
TABLE" in chapter "STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB"
- Close the filler cap "A".

SYSTEM CAPACITY

The total capacity of the system is 3 litres.

• BRAKE FLUID

The replacement of brake fluid and bleeding of the system must be performed by qualified personnel.
The overall capacity of the system is 300 ml

6 - 27
 6 - ORDINARY MAINTENANCE

• FRONT AND REAR DIFFERENTIALS OIL

To correctly change the differential oil, do as follows:

- Stop the machine diesel engine

- work on one differential at a time
- remove the filler cap "A"
- remove the discharge cap "B" and collect the differential oil in an appropriate container
- close the discharge cap "B"
- pour some new differential oil through the filler cap "A" until it starts flowing out; use only the differential oil indicated in the
"OIL TABLE" in chapter "STICKERS WITH CONTROL DESCRIPTIONS - LEAFLETS IN THE CAB" Close the filler cap "A".

Repeat the same operations for the other differential of the machine as well.

SYSTEM CAPACITY

The total capacity of the system is 5,3 litres

FRONT AXLE "A" REAR AXLE "P"

• REDUCTION HUB OIL

NOMENCLATURE

A filler cap
B discharge cap
C bleeder cap

To correctly change the wheel reduction oil, do as follows:

- position the machine on a flat and solid surface

- work on one reduction hub at a time
- remove the filler cap "A"
- remove the discharge cap "B" and drain the oil into a container
- put back the discharge cap "B"
- put in the new oil for the wheel reduction hubs through the filler cap "A" until it
comes out (use only wheel reduction oil that is compatible with that shown in
the "OIL TABLE" in the chapter "STICKERS WITH CONTROL
DESCRIPTIONS - LEAFLETS IN THE CAB")
- put back the filler cap "A"

Repeat the same operations for the other reduction hubs as well.

SYSTEM CAPACITY

The total capacity of the system is 1.3 litres.

6 - 28
 6 - ORDINARY MAINTENANCE

GENERAL MAINTENANCE

• INTRODUCTION

This chapter describes all the general maintenance operations to be performed on the machine based on its actual operating
conditions, without following any particular schedule.

WARNING! Carefully read the instructions in chapter ORDINARY MAINTENANCE before carrying out the
following operations.

• ADJUSTMENT OF THE BOOM PADS AND/OR CARRIAGE PARALLEL INCLINATION

(only for P37.12 PLUS – P38.12 PLUS – P38.13 PLUS – P38.14 PLUS – P40.17 PLUS – P38.12 – P38.13 – P38.14 – P40.17
– P38.13EE – P40.17EE)

Should clearance between boom sections and sliding pads result excessive
and/or carriage is not parallel to the ground it is necessary to extend the boom by
approx. 30 cm. and proceed as follows:

- remove the protective casing "P"

To adjust horizontal clearance:

- loosen the side lock nuts (A)

- tighten dowels (A) fully, in the same way on both sides to centre the boom
- loosen the dowels by 1/2 a turn to give the necessary clearance and
tighten the lock nuts.

To adjust vertical clearance:

- loosen the lower lock nuts (B)

- tighten the lower dowels (B) fully then loosen them by 1 turn to give the necessary clearance and tighten the lock nuts.

To make best use of the pads it is advisable and cost-effective to swap their position above - below..

• SLIDING SHOE ADJUSTMENT OF THE TELESCOPIC BOOM

(ONLY FOR P40.9 PLUS – P60.10 – P72.10 – P60.10EE – P72.10EE)

If play between the boom sections becomes excessive or the carriage is not
correctly parallel to the ground, the sliding shoes of the boom need to be
adjusted as follows:

- position the machine on a flat, perfectly level surface

- engage the parking brake

- correctly level the machine (if fitted with TILTING or SUSPENSIONS)

- remove the protective mufflers "P" from the lock nuts

- loosen the side sliding shoes and the lower M12 screws

6 - 29
 6 - ORDINARY MAINTENANCE

- connect an overhead crane "C" to the head of the telescopic boom (as shown in the photo) in such a way as to lift the
second boom bringing it into contact with the first boom. It is also possible to rest the carriage on the ground on a perfectly
flat plate, small-sized and positioned centrally with respect to the boom, and then to lower the telescopic boom in such a
way as to raise the second boom bringing it into contact with the first. In both cases never force the manoeuvre bringing
about contact between the booms so as not to damage the structure of the telescopic boom.

- lay a 1 metre gauge rod "X" on the carriage in a symmetrical manner

- place a spirit level "Y" in the middle of the rod "X"

- loosen all the lower dowels and then tighten them starting with the ones in the middle of each slide and continuing in a criss-
cross manner. Loosen by 1 turn all the lower dowels and tighten the counter nuts.

- loosen all the side dowels (on both sides of the boom) and then tighten proceeding in a criss-cross manner. Loosen by 1/2
turn all the side dowels and tighten the counter nuts.

- remove the bridge crane or, in the event a ground blockage was used, lift the machine's telescopic boom.

- on the spirit level "Y" check that the carriage is level.

- if the carriage is not level, you need to adjust the lower runner that you intend to lower.
To do this you have to unscrew the two M12 screws of the lower runners and then loosen the dowels of the upper runner on
the same side of the boom that has to be lowered.

- unscrew the outer lower dowels “H” of the slide that should lower and use the middle dowel "G" until the spirit level shows
that the carriage is perfectly level.

- tighten all the dowels in question working in a criss-cross manner, and then loosen the side dowels by half a turn and the
upper dowels by 1 turn

- tighten all the counter nuts

- fully extend the telescopic boom, making sure that the inclination percentage of the boom never exceeds the value of
±0.3%.

After adjusting the running pads of the boom there might be non-symmetrical play between the runners themselves and the top
of the boom, as shown in the photo.

6 - 30
 6 - ORDINARY MAINTENANCE

• BRAKE SYSTEM BLEED

Bleeding consists in eliminating the air inside the system. This operation must be performed each time hydraulic parts of the
system are disassembled.
Carry out the operations needed to bleed the brake system on both axles and just on the callipers that have the special screw
"A"

- fully depress the brake pedal.

- loosen the bleeder screw (A).
- close the bleeder screw (A).
- pump the brake pedal repeatedly.
- repeat from the first point until the fluid exits the bleeder screw without air.

• CLEANING OF THE MACHINE AND ATTACHMENTS

WARNING! All the described operations have to be carried out with the engine off (it is advisable to remove
the ignition key from the instrument panel).

To clean correctly follow these instructions:

- wear suitable personal protective equipment (gloves, masks, glasses, overalls, etc.)
- do not use flammable liquids and acids or products which could chemically attack the vehicle parts
- do not clean moving or overheated parts.
- the same products used for cleaning cars can be used to clean the inside of the cab. Pay particular attention to remove
the build-up of dust, grease or other from the machine's controls.
- to clean the outside of the vehicle and the engine, it is advisable to use a pressure washer, keeping in mind the following:
- make sure that all filler caps (of the radiator, of the oil tank for both the hydraulic system and the hydrostatic
transmission, of the fuel tank) are tightened correctly, and check that the handle of the battery cut-out switch is in the
"ON" position (for further information please refer to chapter "ELECTRICAL EQUIPMENT")
- do not use water pressure and temperature higher than 100 bar and 80° C respectively
- keep the washing nozzle at not less than 20 cm from the surface being cleaned
- do not insist with the jet on one point only but wash with wide movements.
- take care not to turn the jet directly on identification plates in order not to damage them
- After washing, carefully dry the glass screens and the rear-view mirror.

• CATALYTIC DEPURATOR (on request)

If the exhaust is excessively smoky, eliminate the cause by taking the required
action on the engine.

If this problem has lasted for a long time, the catalytic depurator must be
disassembled from the machine and cleaned inside simply by immersing it in
warm soapy water.
It must then be rinsed carefully and left to dry. DO NOT USE detergents or
solvents.

In any case, such cleaning must be performed at intervals of no less than 200
hours.

6 - 31
 6 - ORDINARY MAINTENANCE

• ENGINE COOLING SYSTEM

For coolant replacement operations. Contact an Authorised Workshop.

• ENGINE OIL

Periodically check the engine oil as

follows:

- position the machine on a level

surface and turn off the diesel
engine
- wait a few minutes to allow the
engine to cool and drain the engine
oil inside the sump
- check the oil lever by extracting the
dipstick "A"; the level must be
above the "minimum" mark

WARNING! Do not start the

diesel engine if the oil level is below
the "minimum" mark.
Do not fill the engine oil tank above
the "maximum" level.
To obtain more precise information,
it is advisable to check the oil level
before starting the work day and in
any case when the engine is cold.
For all other information concerning
the use and maintenance of the
diesel engine, refer to the related
manual.

If necessary, unscrew the filler cap (B)

and top up with engine oil indicated in
paragraph “FUEL AND LUBRICANTS”

6 - 32
 6 - ORDINARY MAINTENANCE

• WINDSCREEN WASHER LIQUID TANK

Fill tank "A" situated inside the cab with the specific liquid available on the
market.

• GEAR BOX OIL BLEEDING TANK

The gearbox oil breather small tank is located inside the engine compartment and
is maintenance-free.

WARNING!
Never add oil or any other liquid into the small tank (A).

6 - 33
 6 - ORDINARY MAINTENANCE

TROUBLE SHOOTING

Should your machine not work correctly, please refer to the following table, so as to identify and eliminate the cause of the
problem. The operator is allowed to carry out just some operations, while the most complex ones shall be carried out by Merlo
Technical Assistance service.

FAILURE CAUSE REMEDY

- Oil level is too low/too high Restore the correct oil level
- Oil type is not suitable Change the oil type
- Oil is dirty or contains water Change the oil
- Oil is cold at start Let the oil warm up
HYDRAULIC - Leak in the system Eliminate the leak
SYSTEM - Presence of air in the oil Eliminate air
- Hoses throttling Eliminate constriction
- Return filter is dirty/ clogged Replace the filter
Should you notice any other failures in the hydraulic system (pump, valves, cylinders, etc.),
please contact Merlo Technical Assistance service.
- Battery is flat Charge it
- Electrolyte level is low Fill it up
- Connections are slack/ rusted Restore normal conditions
ELECTRICAL
SYSTEM - Fuses are blown Search for failure cause – Replace fuses
- Alternator belt is slack Adjust belt tension
Should you notice any other failures in the electrical equipment, please contact Merlo
Technical Assistance service.
Replace brake pads. Please contact Merlo
- Excessive brake pad wear
BRAKING Technical Assistance service
SYSTEM - Low brake fluid level Check the system for any leak, then fill it up
- Air in the system Purge air from the system
Please refer to the troubleshooting section in the Engine Manual. For any operations other
ENGINE than routine maintenance to be carried out on certain parts (injection pump, injectors,
valves, etc.), please contact Merlo Technical Assistance service.
HYDROSTATIC
For these operations please contact Merlo Technical Assistance service.
TRANSMISSION

• STARTING THE ENGINE WITH FLAT BATTERY

WARNING! Before working on the battery, carefully read the

instructions found in paragraph "BATTERY" and in chapter "ELECTRICAL
SYSTEM". Check polarity before connecting the cables. Avoid any contact
between the two cables.

If the battery is flat, the engine can be started as follows:

1) Take an emergency battery having the same characteristics and two cables.
2) Connect the cable to the (+) and (-) of the battery inside the machine and,
then, to the correspondent (+) and (-) of the emergency battery.
3) Start the engine and disconnect the cables.

6 - 34
 6 - ORDINARY MAINTENANCE

• MALFUNCTIONING OF THE EMERGENCY PUMP TO DISENGAGE THE

PARKING BRAKE

If it is not possible to release the parking brake using the emergency pump, act
as follows (see paragraph "TOWING OF THE MACHINE" in the section
"OPERATING INSTRUCTIONS"):

- chock the wheels to lock the machine in place

- hold the brake calliper chamber (A) still
- fully loosen the adjusting screw (B)

Before restarting the vehicle tighten the adjusting screw and make sure the
system is working correctly.

• "EMERGENCY" FUNCTION

(only for models with DEUTZ engine)

Using the "EMERGENCY" function, in the

event of an electronic fault with the
hydrostatic transmission (for example the
machine does not move either forwards or
backwards), it is possible to reset the
movements at about 40% of the maximum
speed.

Rotating the ignition key "8" to "R" the

luminous selector "A" flashes; when the
engine starts it switches off.

Activating the system:

- Luminous selector (A) on "0" = emergency function disengaged (the selector is off)
- Indicator light selector (A) on "1" = emergency function engaged (the selector is ON).

WARNING!
Never remove the cover of the box, this should only and exclusively be carried out by personnel from the technical
assistance service of MERLO S.p.A.

END OF SECTION

6 - 35
 7 - PERIODIC SAFETY INSPECTIONS
CONTENTS

PERIODIC INSPECTION RECORD SHEET .................................................................................................................................. 2

SOUND-VISUAL ALARMS AND MOVEMENT BLOCKING OF THE ANTI-OVERTURN SYSTEM ................................................ 6

STEERING OPERATING MODES ................................................................................................................................................. 7

PLATES AND INSTRUCTIONS ...................................................................................................................................................... 7

STABILISERS COMMAND LOCK .................................................................................................................................................. 7

CROSSWAYS LEVELLING "TILTING" COMMANDS LOCK .......................................................................................................... 7

USE AND MAINTENANCE INSTRUCTIONS MANUAL ................................................................................................................. 7

POWER STEERING UNIT CALIBRATION PRESSURE ................................................................................................................ 7

HYDRAULIC SYSTEM OIL PRESSURE ........................................................................................................................................ 7

JACK LOCKING VALVES............................................................................................................................................................... 8

PARKING BRAKE .......................................................................................................................................................................... 8

SPIRIT LEVEL CALIBRATION ....................................................................................................................................................... 8

CONTROL OF THE CHAINS FOR THE EXTENSION AND RETRACTION OF THE BOOM ......................................................... 9

END OF SECTION ....................................................................................................................................................................... 13

7-1
 7 - PERIODIC SAFETY INSPECTIONS

PERIODIC INSPECTION RECORD SHEET

The following card must be reproduced (i.e. photocopied) and used to record the inspections to be carried out following the
periods as reported in the table. If the box between the line and the column is not highlighted, inspection is not necessary. The
operations hereafter listed must be carried out following the deadlines in working hours or in months, whichever come first.
Inspections of the machine and following recording on the card must be carried out by the person in charge of the operations
(e.g. Owner, site manager, etc.). The duly filled in cards must be kept by the machine user and must be at disposal for possible
checking by the authorized inspection organism.

P37.12 PLUS

TYPE OF MACHINE CHASSIS NUMBER NAME OF CONTROLLER

PERIOD IN HOURS / MONTHS

Every Every Every
FUNCTION TO BE CHECKED 250 hours or 2 months 500 hours or 6 months 1000 hours or 1 year
Control Restoration Control Restoration Control Restoration
Date Date Date Date Date Date
Functioning of the anti-overturn system
.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
acoustic alarm

Functioning of the anti-overturn system

.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
visual alarm

Functioning of the anti-overturn system

.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
movement locking
Functioning of the locking system of the
levelling and shifting command distributor .../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
with raised boom
Make sure that the operating and
.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
maintenance instruction manual is in the cab

Check spirit level calibration .../.../... .../.../... .../.../... .../.../... .../.../... .../.../...

Check the maximum pressure in the

.../.../... .../.../... .../.../... .../.../...
oleodynamic system

Check the jack locking valves .../.../... .../.../... .../.../... .../.../...

Check the parking brake .../.../... .../.../... .../.../... .../.../...

Check of the three steering operating modes .../.../... .../.../... .../.../... .../.../...

Check the power steering unit calibration

.../.../... .../.../... .../.../... .../.../...
pressure

Check the boom extension and retraction

.../.../... .../.../... .../.../... .../.../...
chains
Check, inside the cab and on the machine,
for the presence and condition of the .../.../... .../.../...
instruction plates

Signature: Machine total working hours:

WARNING! Before beginning any of the checking operations (described below) which require machine
movement, make sure there are no people or objects in its radius of operation. Furthermore, for operations which
require a load to be lifted, ensure that the machine is on a compact surface and is fully level.
Should any anomalies be identified during these checks, do not use the machine before they have been resolved.

7-2
 7 - PERIODIC SAFETY INSPECTIONS

(P38.12 - P38.12 PLUS - P38.13 - P38.13 PLUS - P38.14 - P38.14 PLUS – P38.13EE)

TYPE OF MACHINE CHASSIS NUMBER NAME OF CONTROLLER

PERIOD IN HOURS / MONTHS

Every Every Every

FUNCTION TO BE CHECKED 250 hours or 2 months 500 hours or 6 months 1000 hours or 1 year
Restoratio Restoratio
Control Restoratio Control Control
n n
Date n Date Date Date
Date Date
Functioning of the anti-overturn system
.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
acoustic alarm

Functioning of the anti-overturn system visual

.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
alarm

Functioning of the anti-overturn system

.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
movement locking

Check the stabiliser and levelling control

.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
distributor locking system with the boom raised

Make sure that the operating and maintenance

.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
instruction manual is in the cab

Check spirit level calibration .../.../... .../.../... .../.../... .../.../... .../.../... .../.../...

Check the maximum pressure in the

.../.../... .../.../... .../.../... .../.../...
oleodynamic system

Check the jack locking valves .../.../... .../.../... .../.../... .../.../...

Check the parking brake .../.../... .../.../... .../.../... .../.../...

Check of the three steering operating modes .../.../... .../.../... .../.../... .../.../...

Check the power steering unit calibration

.../.../... .../.../... .../.../... .../.../...
pressure

Check the boom extension and retraction

.../.../... .../.../... .../.../... .../.../...
chains
Check, inside the cab and on the machine, for
the presence and condition of the instruction .../.../... .../.../...
plates

Signature: Machine total working hours:

WARNING!
Before beginning any of the checking operations (described below) which require machine movement, make sure
there are no people or objects in its radius of operation. Furthermore, for operations which require a load to be lifted,
ensure that the machine is on a compact surface and is fully level.
Should any anomalies be identified during these checks, do not use the machine before they have been resolved.

7-3
 7 - PERIODIC SAFETY INSPECTIONS

(P40.9 PLUS - P60.10 - P72.10 – P60.10EE – P72.10EE)

TYPE OF MACHINE CHASSIS NUMBER NAME OF CONTROLLER

PERIOD IN HOURS / MONTHS

Every Every Every

FUNCTION TO BE CHECKED 250 hours or 2 months 500 hours or 6 months 1000 hours or 1 year
Restoratio Restoratio
Control Restoratio Control Control
n n
Date n Date Date Date
Date Date
Functioning of the anti-overturn system
.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
acoustic alarm

Functioning of the anti-overturn system visual

.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
alarm

Functioning of the anti-overturn system

.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
movement locking
Functioning of the locking system of the
levelling and shifting command distributor with .../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
raised boom
Make sure that the operating and maintenance
.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
instruction manual is in the cab

Check spirit level calibration .../.../... .../.../... .../.../... .../.../... .../.../... .../.../...

Check the maximum pressure in the

.../.../... .../.../... .../.../... .../.../...
oleodynamic system

Check the jack locking valves .../.../... .../.../... .../.../... .../.../...

Check the parking brake .../.../... .../.../... .../.../... .../.../...

Check of the three steering operating modes .../.../... .../.../... .../.../... .../.../...

Check the power steering unit calibration

.../.../... .../.../... .../.../... .../.../...
pressure
Check, inside the cab and on the machine, for
the presence and condition of the instruction .../.../... .../.../...
plates

Signature: Machine total working hours:

WARNING!
Before beginning any of the checking operations (described below) which require machine movement, make sure
there are no people or objects in its radius of operation. Furthermore, for operations which require a load to be lifted,
ensure that the machine is on a compact surface and is fully level.
Should any anomalies be identified during these checks, do not use the machine before they have been resolved.

7-4
 7 - PERIODIC SAFETY INSPECTIONS

(P40.17 – P40.17PLUS – P40.17EE)

TYPE OF MACHINE CHASSIS NUMBER NAME OF CONTROLLER

PERIOD IN HOURS / MONTHS

Every Every Every
FUNCTION TO BE CHECKED 250 hours or 2 months 500 hours or 6 months 1000 hours or 1 year
Control Restoration Control Restoration Control Restoration
Date Date Date Date Date Date
Functioning of the anti-overturn system
.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
acoustic alarm
Functioning of the anti-overturn system
.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
visual alarm
Functioning of the anti-overturn system
.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
movement locking
Check the stabiliser and levelling control
distributor locking system with the boom .../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
raised
Make sure that the operating and
.../.../... .../.../... .../.../... .../.../... .../.../... .../.../...
maintenance instruction manual is in the cab

Check spirit level calibration .../.../... .../.../... .../.../... .../.../... .../.../... .../.../...

Check the maximum pressure in the

.../.../... .../.../... .../.../... .../.../...
oleodynamic system

Check the jack locking valves .../.../... .../.../... .../.../... .../.../...

Check the parking brake .../.../... .../.../... .../.../... .../.../...

Check of the three steering operating modes .../.../... .../.../... .../.../... .../.../...

Check the power steering unit calibration

.../.../... .../.../... .../.../... .../.../...
pressure
Control of the attachment points and the
.../.../... .../.../... .../.../... .../.../...
adjustment of the boom extension chains
Check, inside the cab and on the machine,
for the presence and condition of the .../.../... .../.../...
instruction plates

Signature: Machine total working hours:

WARNING!
Before beginning any of the checking operations (described below) which require machine movement, make sure
there are no people or objects in its radius of operation. Furthermore, for operations which require a load to be lifted,
ensure that the machine is on a compact surface and is fully level.
Should any anomalies be identified during these checks, do not use the machine before they have been resolved.

7-5
 7 - PERIODIC SAFETY INSPECTIONS

SOUND-VISUAL ALARMS AND MOVEMENT BLOCKING OF THE ANTI-OVERTURN SYSTEM

Your machine is fitted with two micro-switches (one on the right rear axle shaft and one on the left rear axle shaft) which control
the anti-overturn system. Inasmuch, carry out the safety check on both rear axle shafts, proceeding as follows:

WARNING! When carrying out the following operations, it will necessary to leave the driver's cab. Always
switch off the engine before leaving the driver's seat.
It is recommended to use a load with a weight of about 2/3 of the maximum load for the test.

1) Operate on solid, level ground

2) Fit the forks on the machine
3) Choose a load whose weight is known with a good approximation (± 10%)
4) Pick up the load with the forks (Fig.5)
5) Make sure that the machine is level and centred in reference to the longitudinal axis; also check that the wheels are aligned
to the chassis frame
6) Lift the load to about 500 mm above ground (Fig.6)
7) Ascend with the right tyre on a step having a minimum height of 10 cm
8) Tilt the machine crossways and clockwise (see "CROSSWAYS TILT CONTROL LEVER" in section "COMMANDS AND
INSTRUMENTS") in order to bring the right hand rear semi-axle to the end of its travel
9) Extract the boom until the point where the anti-overturn system intervenes (sound and visual alarm, block of movements)
10) Check the length of the boom in reference to the "X" letter which is the closest to the fixed part of the boom
11) On the basis of the load used for the test, check if the "X" letter where the system has intervened matches the letter
foreseen by the machine's load chart found in the cabin. The tolerance for system intervention is ± 400 mm in relation to
what is indicated in the diagram (Fig. 7)

12) Completely retract the telescopic boom

13) Place the load on the ground
14) Drive off the step under the rear right wheel
15) Reset the crossways tilt corrector in the central position
16) Ascend with the left tyre on a step having a minimum height of 10 cm
17)Tilt the machine crossways and anticlockwise (see "CROSSWAYS TILT CONTROL LEVER" in section "COMMANDS AND
INSTRUMENTS") in order to bring the left hand rear semi-axle to the end of its travel
18) Carry out the test operations indicated in points (9) to (15)

The test is successfully passed only if - when carrying put the above mentioned operations - the anti-overturn system works
correctly on both sides of the rear axle. If even one of the two anti-overturn control systems does not work correctly, do not use
the machine and contact the Technical Assistance Service of Merlo S.p.A.

7-6
 7 - PERIODIC SAFETY INSPECTIONS

STEERING OPERATING MODES

Make sure the steering system is working correctly in the three modes envisaged:

- four-wheel coordinated steering

- steering on the front axle
- crab steering

PLATES AND INSTRUCTIONS

Make sure all the plates are present on the machine, and the various instruction pages are actually in the removable container
in the cab. They must all be in good condition.
The main ones are shown in the relative chapters of this manual. If they are illegible or have been lost, you must request
replacements (giving the serial number on the specific part as a reference).

STABILISERS COMMAND LOCK

- Raise the boom until its lower part (without load) coincides with the upper corner of the cab.
- Operate the stabiliser command. The control must be locked.
- Lower the boom and repeat the commands, making sure they can be activated in this condition.

CROSSWAYS LEVELLING "TILTING" COMMANDS LOCK

- Raise the boom until its lower part (without load) coincides with the upper corner of the cab.
- Activate the TILTING command. The control must be locked.
- Lower the boom and repeat the commands, making sure they can be activated in this condition.

USE AND MAINTENANCE INSTRUCTIONS MANUAL

Make sure the manual is effectively in the cab and in good condition. In case of loss or damage, request a duplicate indicating,
if possible, the reference code at the bottom of the cover, otherwise use the SAV number of the machine.

POWER STEERING UNIT CALIBRATION PRESSURE

- Stop the engine and remove the ignition key.

- Connect the pressure gauge cable to the pressure connection on the pump (as for the HYDRAULIC OIL SYSTEM
PRESSURE check).
- Start the engine
- Hold the transmission in neutral position
- Accelerate to approx. 1800 rpm
- Turn the steering wheel on full lock to any side of the machine and continuing to exert a slight force and read the pressure
gauge in the cab
- System pressure should be over 180 bar (180 kg/cm²)

HYDRAULIC SYSTEM OIL PRESSURE

- Stop the engine and remove the ignition key.

- Connect the small cable in the engine bay to the pressure socket "A"
- Start the engine
- Fully retract the telescopic boom.
- Accelerate to 2,400 rpm, while keeping boom retraction activated.
- Check on the gauge in the cab that the pressure is between 205 and 215 Bar.

WARNING! If the gauge indicates a pressure value different from that

expected, please ask for assistance from qualified Merlo Service personnel.
When the checking of the pressure is ended, disconnect the small hose from
the pump and rearrange it in the engine compartment.

7-7
 7 - PERIODIC SAFETY INSPECTIONS

JACK LOCKING VALVES

- Start the engine Pick up a load, using the forks, weighing at least 2/3 of
the machine's maximum capacity.
- Hook a plumb line (about 3 metres long) near the end of the forks
- Stabilise the machine (if the machine is equipped with stabilisers)
- Raise the boom to a height of about 3.5 metres
- Extend the boom by about 0.5 metres
- Stop the engine and operate the distribution levers as to lower the boom
and to rotate the forks downward.
- Release the levers
- Measure the distance "D" between the end of the plumb line and the
ground
- Lock the cab and wait approx. 30'.
- Repeat the measurement.

The difference between the two measurements must not be over 25 mm, in case the difference is over 25 mm contact the
MERLO service centre.

PARKING BRAKE

- Start the engine and engage 2nd gear.

- Check that the gear is engaged by driving the machine for a short distance.
- Engage the parking brake.
- Whilst keeping one foot on the brake, engage the forward drive and accelerate to a speed to approx 1600 rpm.
- Slowly release the brake pedal.
- If the machine does not move, accelerate again to maximum rpm. The machine must remain at a standstill.

SPIRIT LEVEL CALIBRATION

Check the correct calibration of the

spirit level on the machine
dashboard.

- position spirit level "A" of a

minimum length of no less than
400 mm (as shown).
- level the machine using the
relative devices mounted on the
machine (stabilizers, tilting or
suspension type). If the machine
is not fitted with any of these
devices, move the machine to an
area of flat ground in order to
find a point at which the spirit
level in the level gauge "A" is perfectly centred.
- Turn screw "C" until the air bubble is perfectly central in the machine's spirit level "B".

7-8
 7 - PERIODIC SAFETY INSPECTIONS

CONTROL OF THE CHAINS FOR THE EXTENSION AND RETRACTION OF THE BOOM
(only for models P40.17 – P40.17PLUS – P40.17EE)

INSPECTION OF CHAINS

a) chains inside the boom

To check the integrity and the state of wear of chains "A", as well as their correct fitting on combs "B", extend the telescopic
boom completely and perform the inspection through the slots on the second and third boom (fig.1), third and fourth boom
(fig.2).

7-9
 7 - PERIODIC SAFETY INSPECTIONS

b) chains outside the boom

To check the integrity and the wear level of chains "A", of pulleys "B" and their correct fitting on combs "C", the telescopic boom
of the machine must be placed parallel to the ground and the inspection carried out:

X – with the boom retracted

Y – with the boom extended

c) Completely retract the telescopic boom and check that the measurements indicated (A and B) are about 30 mm; If this is not
the case, the chains must be adjusted.

CHAIN ADJUSTMENT

Before adjusting the chains, the springs (D) have to be disassembled proceeding
as follows:

- Take the threaded bar (E), the washer (F) and the nut (G) from the pocket
behind the seat. Fully screw the threaded bar (E) into the hole on the pin.
- Insert the washer (F) and screw the nut (G) onto the threaded bar up to about
L=10 mm as shown in the photo.
- Carefully unscrew the retainer nut (H) of the spring so that it is completely
released; then remove the threaded bar (E), the nut (H) and the spring (D).
- Repeat the same operation also for the other pin

Proceed to adjust the chains as follows:

- The distance between the second and third boom (position A) is adjusted by using the adjusting screws "A", that between
the third and fourth boom (position B) is adjusted using the adjustments screws "B".
- To reduce the distance between the booms the corresponding lower adjustments screws need to be loosened, then the top
ones tightened to obtain a distance of 30 mm (adjust the position "A" using the adjustment screw on the cab side, then the
other adjustment screw needs to be tightened until the same length as the uncovered threading is obtained; In any event,
make sure that the position (M) is no more than 50 mm).
Tighten the corresponding lower cab side adjustment screw until the spring pack is at the position (N) indicated in the
photo; fully extend the booms, then bring them in by about 50 cm and tighten the remaining adjustment screws so as to
bring the other chains parallel to the first.
- To increase the distance between the boom the corresponding upper adjustment screws need to be loosened, then the
lower ones need to be tightened until the booms are brought to a distance of about 35 mm; retract the booms to the correct
distance by carrying out the operations reported in the previous point.

7 - 10
 7 - PERIODIC SAFETY INSPECTIONS

Re-assemble the springs on the

pins, proceeding as follows:

- Insert the spring (D) then screw in

the threaded bar (E).
- Insert on the threaded bar, in the
following order: the retainer nut (H)
of the spring, the washer (F) and
the nut (G).
- Screw on the nut (G) until the
retainer nut (H) is brought into
contact with the pin; screw on the
retainer nut (H) of the spring until it
is closed on the adjustment nut.
- Then remove the threaded bar (E),
the nut (H) and the spring (D) and put them back in the pouch.

Extend the telescopic boom completely, and place it parallel to the ground; measure the distance between the chains and the
lower surface of the second and third boom sections (make the measurement in mid-length of the chain).
Then retract the boom by about 50 cm and check that the distance measured previously has increased by about 5 cm; if not,
see point (b) of the section "INSPECTION OF THE CHAINS".

LUBRICATION OF CHAIN RETURN

PINS

While checking the telescopic boom

chains you are required to grease the
chain return pins.

Grease the chain return pins shown in

the photo (1) until grease comes out.

GREASING THE SUPPORT PIN OF

THE CHAIN RETURN PULLEY OF
THE INTERNAL BOOM CHAINS

- stand at the rear right of the

machine
- raise the telescopic boom until the
greasing hole "A" can be seen
- grease, until grease comes out,
the support pin of the internal
boom "B" chain return pulley

7 - 11
 7 - PERIODIC SAFETY INSPECTIONS

INSPECTION OF THE TELESCOPIC BOOM CHAIN STRETCHING WITH SLIDE RULE "R"

It is advisable to perform the following operations every 1,000 operating hours.

This check shall not replace the compulsory inspections of the chain status in compliance with national provisions and
regulations.

Perform the following operations to check chain stretching:

- extend the machine boom completely and rest the carriage on the ground.
- stop the machine engine.
- take slide rule "R" from the pocket behind the driver's seat.

Perform the inspection as described in the example below.

• EXAMPLE

- by using slide rule "R", on the ruler side (R1), measure the pitch of chain link "A" in a point of the chain taken at random. In
this example A=19. (Fig. 1)
- by referring to the table shown on the rule face (R2), trace the real pitch "A" of the chain being inspected. In this example
the value closest to the measured one is A=19.05.
The lower line "B" indicates the number of chain links to be inspected; in this example the number of chain links to be
inspected is B=12 (Fig. 2).

7 - 12
 7 - PERIODIC SAFETY INSPECTIONS

- place rule "R" into contact with the chain, so that the v-shaped notch can be inserted into a chain link pin; perform this
operation with side "R2" of the rule facing the operator (fig. 3)
- starting from the v-shaped notch, count the number "B" of chain links to be inspected; since in this case B=12, count 12
chain links.
- check that the 12th chain link does not reach or go beyond the dashed end part of rule "R" on which "C % 3" is written; this
limit represents the maximum permissible extension of the chain due to wear. In this example the chain does not reach the
maximum limit ("C % 3"), therefore it passes the inspection successfully and does not need to be replaced.

- if the 12th chain link either reaches or goes beyond the maximum limit shown by the dashed area "3 % C", this means that
excessive stretching occurred and that the chain needs to be replaced. (fig. 4)

WARNING!
Perform this inspection in several points of the chain, especially next to the snub pulleys.
Should clear signs of malfunction be found on the chain, replace it even though it has not yet reached its limit
extension (equal to 3%).

END OF SECTION

7 - 13
 8 - ATTACHMENTS AND OPTIONAL EXTRA
CONTENTS

ATTACHMENTS ............................................................................................................................................................................. 3

ATTACHMENT IDENTIFICATION PLATE ...................................................................................................................................... 3

ATTACHMENT MAINTENANCE..................................................................................................................................................... 3

ATTACHMENT HANDLING ............................................................................................................................................................ 3

ASSEMBLY OF ATTACHMENTS WITH QUICK-COUPLING......................................................................................................... 4

HYDRAULIC CONNECTION OF QUICK-COUPLING ATTACHMENTS......................................................................................... 4

CONTROL OF HYDRAULICALLY FUNCTIONING ATTACHMENTS ............................................................................................. 5

DISMANTLING OF ATTACHMENTS WITH QUICK COUPLING.................................................................................................... 5

ATTACHMENTS COMPATIBLE WITH VEHICLES MANUFACTURED BY MERLO S.p.A. ........................................................... 6

VARIANTS AND ACCESSORIES................................................................................................................................................. 19

GENERAL INSTRUCTIONS FOR THE USE OF THE MACHINE APPROVED AS ITALIAN OPERATIVE .................................. 19

REAR DIFFERENTIAL LOCKING ................................................................................................................................................ 21

SECURING THE MACHINE FOR TRANSPORTATION BY TRAILER ......................................................................................... 21

SUN BLIND................................................................................................................................................................................... 21

REAR HYDRAULIC OUTLET ....................................................................................................................................................... 22

REAR HYDRAULIC OUTLET ....................................................................................................................................................... 23

REAR WHEEL CENTRING INDICATOR ON THE MACHINE AXIS ............................................................................................. 23

FIXED BUILDING SITE TOW HOOK ........................................................................................................................................... 24

"EEC" MULTI-POSITION TOWING HOOK................................................................................................................................... 24

PROVISION FOR MIXING BUCKET CONTROL .......................................................................................................................... 25

REAR ELECTRICAL CONNECTION ............................................................................................................................................ 26

CAR RADIO .................................................................................................................................................................................. 26

WORK LIGHTS ............................................................................................................................................................................ 26

WINDSCREEN WIPER ON ROOF............................................................................................................................................... 26

FITTING ACTIVE HYDRO-PNEUMATIC SUSPENSIONS FOR PANORAMIC ............................................................................ 27

JOYSTICK (4 FUNCTIONS) ......................................................................................................................................................... 28

8-1
 8 - ATTACHMENTS AND OPTIONAL EXTRA
JOYSTICK (5 FUNCTIONS) ......................................................................................................................................................... 29

MULTI-FUNCTION CONTROL JOYSTICK ................................................................................................................................... 30

GRAMMER EXTRA-COMFORT PNEUMATIC SEAT ................................................................................................................... 31

TYRE SEAT .................................................................................................................................................................................. 32

CYCLONE PRE-FILTER............................................................................................................................................................... 32

A/C SYSTEM ................................................................................................................................................................................ 33

FAULTS WITH DIRECTION INDICATORS ON AGRICULTURAL TRAILERS ............................................................................. 33

END OF SECTION ....................................................................................................................................................................... 33

8-2
 8 - ATTACHMENTS AND OPTIONAL EXTRA

ATTACHMENTS

This section of the handbook is about one range of MERLO attachments which can be assembled on the vehicles described in
this handbook. These attachments can be coupled and released using the locking hydraulic system control from the cab.
The procedures to perform the operations previously mentioned are described in the manual. Refer to the relevant paragraph
for the assembly and disassembly of the forks.
Carefully read the given information before handling, assembling, using or removing any attachment.
The attachments which need more instructions about their use will be described one by one in a leaflet attached to this manual.
The attachment is designed and built following Merlo specifications. In order to avoid accidents and to ensure good
performance, the attachment must not be changed from that approved by Merlo S.p.A. and it must not be used for any purpose
other than that for which it is intended by design.

WARNING! Do not handle, assemble, use or remove any attachment not described in this manual (or in the
leaflet attached) until pertaining instructions have been received, read and understood. The attachments can be
assembled and used only on vehicles for which they have been requested.
MERLO S.p.A. is not responsible for the use of attachments not produced by them or whose assembly on the standard
vehicle has not been explicitly approved.

ATTACHMENT IDENTIFICATION PLATE

All attachments manufactured by Merlo are equipped with an identification plate.

This plate provides the operator with various identification data regarding the
attachment:

1) Attachment model
2) Manufacturing number
3) Attachment weight
4) Maximum load capacity
5) Maximum operating pressure

Should you need to order any spare parts, please provide the Manufacturer with
the data marked with numbers "1" and "2" above.

ATTACHMENT MAINTENANCE

In order to use the attachment safely and efficiently, you must service it regularly, strictly following the instructions of this
manual (or in the attached leaflet). Do not use the attachment until the servicing and the necessary repairs have been made.

DAILY OR EVERY 10 HOURS:

- Inspect the attachment in order to check that it is clean and there is no damaged or missing parts.
- Check the correct fastening of the hinge pins and related locks.
- Check there are no oil leaks from the attachment.

WARNING! Maintenance must be performed by skilled and competent personnel. For operations on parts
which are not part of the normal maintenance, contact the MERLO assistance service.

ATTACHMENT HANDLING

To lift the attachment, use the hitching points shown by the reference plate (see
figure). Pay particular attention to any notes and remarks regarding handling. The
total weight of the attachment is shown on its identification plate.

WARNING! Keep people away from the surrounding area when

handling the attachment.
Check that cables, hooks and lifting devices are in good condition and that
their lift capacity is sufficient for the weight to be handled.

8-3
 8 - ATTACHMENTS AND OPTIONAL EXTRA

ASSEMBLY OF ATTACHMENTS WITH QUICK-COUPLING

- a standard loader has been chosen to illustrate the operations required for the installation of a quick-coupling attachment;
the following operations apply to any attachment manufactured by Merlo that is equipped with the same coupling system.
- read and make sure to understand all the instructions regarding the attachment you purchased, which are provided either in
the following paragraphs or in the attached manual. Pay particular attention to safety warnings and to any notes on how to
install and handle the attachment.
- make sure that the equipment is resting on a compact flat surface, and that it cannot accidentally topple over
- drive your machine close to the couplings of attachment "A", with the carriage rotated downwards (Fig. 1).
- slightly raise the telescopic boom (Fig. 2).
- activate the control to lift the quick-coupling piston "P" (see paragraph "MAIN DISTRIBUTOR LEVER", in the chapter
"CONTROLS AND INSTRUMENTS"), while at the same time rotating the carriage upwards, so as to hitch the attachment
(Fig. 3)
- release button on the control joystick
- raise the telescopic boom by about 1.5 metres, and check that quick coupling cylinder "P" is correctly engaged in its locking
position on the carriage.

WARNING! Keep people away from the surrounding area when installing equipment. Consult the data plates
inside the driver's cab so that the machine's load limits in relation to the various positions of the boom are not
exceeded.
Before starting the assembly of the attachments with quick coupling, make sure that the machine's carriage does not
have any attachment fitted.
Never position yourself underneath the attachment to check the correct insertion of the locking pin.
Do not use the attachment if the locking pin is not correctly inserted.
Lower the telescopic boom and repeat the procedure.

- stop the diesel engine

- unscrew the ring nut from quick coupling [A], and disconnect hose "C" that
feeds the quick coupling cylinder "P"
- connect hose "C" to coupling "D"; this prevents the attachment from
accidentally uncoupling from the carriage if the quick-coupling cylinder "P" is
unintentionally operated.

HYDRAULIC CONNECTION OF QUICK-COUPLING ATTACHMENTS

Should the attachment installed on the carriage feature hydraulically controlled

functions, connect hoses "E", from the attachments, to the quick couplings
marked with letters [A] and [B], on metal sheet "L".

The connection diagram, also shown on the joystick sticker in the cab, foresees
that the quick coupling marked with the letter [A] must be used for the oil delivery
to the attachment, while the quick coupling marked with the letter [B] must be
used for the oil return. (see also paragraph "CONTROL JOYSTICK" chapter
"CONTROLS AND INSTRUMENTS").

8-4
 8 - ATTACHMENTS AND OPTIONAL EXTRA

CONTROL OF HYDRAULICALLY FUNCTIONING ATTACHMENTS

Consult the control plate of the

attachment in order to ascertain its
maximum operating pressure.
To control the hydraulic attachment,
use the right joystick thumb-wheel (1)
as follows:

- rotate the right roller to position "3"

to send oil to the hydraulic conduit
"A" on the head of the boom.
(opening claws, valves, hatches,
etc.)
- rotate the right roller to position "4"
to send oil to the hydraulic conduit
"B" on the head of the boom.
(closing claws, valves, hatches, etc.)

Other types of manoeuvre will be described in the instructions relevant to the attachments.

DISMANTLING OF ATTACHMENTS WITH QUICK COUPLING

To remove a quick-coupling attachment from the carriage, please refer to the

following instructions:

- a standard loader has been chosen to illustrate the operations required for
the disassembly of a quick-coupling attachment; the following operations
apply to any attachment manufactured by Merlo that is equipped with the
same coupling system.
- read and make sure to understand all the instructions regarding the
attachment you purchased, which are provided either in the following
paragraphs or in the attached manual. Pay particular attention to safety
warnings and to any notes on how to install and handle the attachment.
- make sure that the attachment rests on compact, flat ground.
- engage the parking brake, shift both the gearbox selector (19) and the drive
direction selector (20) to position "N".
- if you need to remove attachments that feature hydraulic functions,
disconnect hoses "E" from quick couplings [A] and [B] placed on metal sheet
"L" (Fig. 5).
- disconnect hose "C" that feeds quick coupling cylinder "P" from the coupling
"D" and connect it to the quick coupling [A]. (Fig.6)
- lower the machine's telescopic boom so that the equipment is resting on the
ground
- activate the control to lift the quick-coupling piston "P" (see paragraph "MAIN
DISTRIBUTOR LEVER", in the chapter "CONTROLS AND INSTRUMENTS"),
while at the same time rotating the carriage downwards, so as to uncouple
the attachment (Fig. 7)
- release button on the control joystick
- if necessary, slightly lower the telescopic boom, so as to release the
attachment (Fig. 8)
- retract the telescopic boom, and cautiously back up (Fig. 9)

8-5
 8 - ATTACHMENTS AND OPTIONAL EXTRA

WARNING! Keep people away from the surrounding area when uninstalling equipment. Consult the data plates
inside the driver's cab so that the machine's load limits in relation to the various positions of the boom are not
exceeded.
Never force the attachment on to the ground to carry out uncoupling.

ATTACHMENTS COMPATIBLE WITH VEHICLES MANUFACTURED BY MERLO S.p.A.

The attachments described in this paragraph are those available at the time the manual was published. For increased safety,
before using any type of attachment, always check all of the relevant data given in the type-approval charts applied to the
attachment.

• EXTRA LARGE FORK CARRIAGE

To install this attachment on the carriage, carry out the same operations
described in paragraph "INSTALLATION OF QUICK-COUPLING
ATTACHMENTS" in this chapter.
Install this attachment on the carriage if you need a larger distance between the
forks.
The installation of this attachment on the carriage implies the following reduction
of the load capacity shown in the load chart:

- Liftable load (W) with an extra large fork carriage = machine load chart "D" -
attachment weight "P" shown on the attachment identification plate.

• FEM III FORK CARRIAGE

To install this attachment on the carriage, carry out the same operations
described in paragraph "INSTALLATION OF QUICK-COUPLING
ATTACHMENTS" in this chapter.
Install this attachment on the carriage if you need to use FEM III FORKS.
The installation of this attachment on the carriage implies the following reduction
of the load capacity shown in the load chart:

- Liftable load (W) with FEM III fork carriage = machine load chart "D" -
attachment weight "P" shown on the attachment identification plate.

• TRAVELLING LIFT FITTED ON A STANDARD CARRIAGE

To install this attachment on the carriage, carry out the same operations
described in paragraph "INSTALLATION OF QUICK-COUPLING
ATTACHMENTS" in this chapter.
The attachment is comprised of a fixed part, coupled to the standard carriage,
and a mobile part, which shifts the load lifted on the FEM III FORKS transversely
with respect to the telescopic boom of your machine.
The installation of this attachment on the carriage implies the following reduction
of the load capacity shown in the load chart:

- Liftable load (W) with a travelling lift fitted on the standard carriage = machine
load chart "D" - attachment weight "P" shown on the attachment identification
plate.

8-6
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• CARRIAGE WITH FLOATING FORKS

To install this attachment on the carriage, carry out the same operations
described in paragraph "INSTALLATION OF QUICK-COUPLING
ATTACHMENTS" in this chapter.
Install this attachment on the carriage if the digging angle with the carriage in a
folded position is required to be 5° wider than the standard one offered by your
machine.
The installation of this attachment on the carriage implies the following reduction
of the load capacity shown in the load chart:

- Liftable load (W) with floating forks fitted on the carriage = machine load chart
"D" - attachment weight "P" shown on the attachment identification plate.

• FORK FOR CARRIAGE ATTACHMENT FEM III (ONLY FOR P37.12 PLUS - P38.12 PLUS - P38.13 PLUS - P38.14 PLUS -
P40.9 PLUS – P40.17 PLUS – P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE)

- Weight of a single fork: 83 kg

- Rated load capacity: 2150 kg
- Centre of gravity of the load ("P") from the fork heel: 500 mm

Assembly of forks on the FEM carriage is carried out as follows:

- assemble the carriage FEM as described in the paragraph ASSEMBLY OF

ATTACHMENTS WITH QUICK COUPLING in this chapter
- position the machine with the carriage near the FEM forks
- lift the safety pin "A"
- insert the forks from the two extremities following the direction of the arrow
- arrange the forks in the desired position
- lower the safety pin "A" inserting it correctly in one of the slots provided on
the carriage

WARNING!
Always check to ensure that the
forks are correctly secured on the
carriage so as to prevent any
lateral sliding and possible
escape.
Fitting this attachment demands a
reduction in the useful loads in the
diagram equal to the weight of the
FEM carriage.

• FORK FOR CARRIAGE ATTACHMENT FEM IV (ONLY FOR P60.10 - P72.10 – P60.10EE – P72.10EE)

- Weight of a single fork: 131 kg

- Rated load capacity: 3000 kg
- Centre of gravity of the load ("P") from the fork heel: 600 mm

Assembly of forks on the FEM carriage is carried out as follows:

- assemble the carriage FEM as described in the paragraph ASSEMBLY OF ATTACHMENTS WITH QUICK COUPLING in
this chapter
- position the machine with the carriage near the FEM forks
- lift the safety pin "A"
- insert the forks from the two extremities following the direction of the arrow
- arrange the forks in the desired position
- lower the safety pin "A" inserting it correctly in one of the slots provided on the carriage

8-7
 8 - ATTACHMENTS AND OPTIONAL EXTRA

WARNING!
Always check to ensure that the
forks are correctly secured on the
carriage so as to prevent any
lateral sliding and possible
escape.
Fitting this attachment demands a
reduction in the useful loads in the
diagram equal to the weight of the
FEM carriage.

• FORK EXTENSION

The standard fork is inserted into the

extension and secured by means of
pin "1" behind the heel of the fork (2).
Each fork extension bears a plate with
the following details:

A = Maximum applicable load at 1000

mm (1200 mm for P60.10 - P72.10)
from the heel of the forks
B = Progressive manufacturing number of each month
C = Month of manufacture (starting from January of each year with the letter "A")
D = Last figure of the year of manufacture
E = Permitted fork dimensions (width, thickness, minimum length)

(P37.12 PLUS - P38.12 PLUS - P38.13 PLUS - P38.14 PLUS - P40.9 PLUS – P40.17 PLUS – P38.12 – P38.13 – P38.14 –
P40.17 – P38.13EE – P40.17EE)
• Weight: 50 kg; • Rated load capacity: 1125 kg; • Centre of gravity of the load ("P") from the fork heel: 1000 mm

(P60.10 - P72.10 – P60.10EE – P72.10EE)

• Weight: 60 kg; • Rated load capacity: 1500 kg; • Centre of gravity of the load ("P") from the fork heel: 1200 mm
Always check to ensure that the pin has been correctly fitted to prevent the risk of the tools accidentally becoming unhitched.
Check that the load has been correctly applied.

• DIGGING BUCKET

Assemble the attachment on the carriage as described in the paragraph

INSTALLATION OF QUICK-COUPLING ATTACHMENTS in this chapter and use
it with the auxiliary controls in the cab as described in the paragraph CONTROL
OF HYDRAULICALLY FUNCTIONING ATTACHMENTS.

• (P37.12 PLUS - P38.12 PLUS - P38.13 PLUS - P38.14 PLUS - P40.9 PLUS –
P40.17 PLUS – P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE)

- Weight: (A706) = 420 kg : (A701) = 400 kg

- Max capacity: (A706) = 1000 l : (A701) = 900 l

• (P60.10 - P72.10 – P60.10EE – P72.10EE)

- Weight: (A704) = 525 kg : (A707) = 420 kg

- Max capacity: (A704) = 1200 l : (A707) = 1000 l

TRANSPORT: Circulation on public roads with the bucket connected is only allowed if the appropriate protection, included with
the attachment, is applied.

8-8
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• 4X1 BUCKET (800 l) - (1000 l) - (1250 l)

Assemble the attachment on the carriage as described in the paragraph

INSTALLATION OF QUICK-COUPLING ATTACHMENTS in this chapter and use
it with the auxiliary controls in the cab as described in the paragraph CONTROL
OF HYDRAULICALLY FUNCTIONING ATTACHMENTS.

- Weight: (A0800) = 680 kg; (A0820) = 710 kg; (A0870) = 750 kg

- Max capacity: (A0800) = 800 l; (A0820) = 1000 l; (A0870) = 1250 l

TRANSPORT: Circulation on public roads with the bucket connected is only

allowed if the appropriate protection, included with the attachment, is applied.

WARNING! (BUCKET, 4 X 1 BUCKET): the excavation or loading of

loose material using the machine with extended boom, may cause serious
damage to the boom itself; MERLO S.p.A. strongly recommends not to
perform such operation and will not be held responsible for any damage
arising from this use.

8-9
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• RE-HANDLING BUCKET

Assemble the attachment on the carriage as described in the paragraph INSTALLATION OF QUICK-COUPLING
ATTACHMENTS in this chapter and use it with the auxiliary controls in the cab as described in the paragraph CONTROL OF
HYDRAULICALLY FUNCTIONING ATTACHMENTS.

(A0710)
- Weight: 400 kg • Max specific weight of the material: 1800 (Kg/m3) • Max
capacity: 1250 l
- A = 2240 ; B= 1180 ; C = 1050

(A0712)
- Weight: 415 kg • Max specific weight of the material: 1800 (Kg/m3) • Max
capacity: 1350 l
- A = 2400 ; B= 1510 ; C = 1065

(A0717) *
- Weight: 410 kg • Max specific weight of the material: 1800 (Kg/m3) • Max
capacity: 1800 l
- A = 2500 ; B= 1190 ; C = 1050

(A0720)
- Weight: 495 kg • Max specific weight of the material: 900 (Kg/m3) • Max
capacity: 2000 l
- A = 2400 ; B= 1515 ; C = 1065

(A0780)
- Weight: 610 kg • Max specific weight of the material: 900 (Kg/m3) • Max capacity: 2500 l
- A = 2400 ; B= 1680 ; C = 1170

(A0781) *
- Weight: 610 kg • Max specific weight of the material: 900 (Kg/m3) • Max capacity: 2500 l
- A = 2500 ; B= 1780 ; C = 1220

* (only for P60.10 - P72.10 – P60.10EE – P72.10EE)

TRANSPORT: Circulation on public roads with the bucket connected is only allowed if the appropriate protection, included with
the attachment, is applied.

8 - 10
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• MULTIPURPOSE BUCKET WITH GRAB

Assemble the attachment on the carriage as described in the paragraph

INSTALLATION OF QUICK-COUPLING ATTACHMENTS in this chapter and use
it with the auxiliary controls in the cab as described in the paragraph CONTROL
OF HYDRAULICALLY FUNCTIONING ATTACHMENTS.

(A0838) Weight: 620 kg; Max capacity: 1200 l

(A0840) Weight: 590 kg; Max capacity: 1000 l
(A0841) Weight: 550 kg; Max capacity: 900 l
(A0846) * Weight: 800 kg; Max capacity: 2350 l

* (only for P60.10 - P72.10 – P60.10EE – P72.10EE)

TRANSPORT: Circulation on public roads with the bucket connected is only

allowed if the appropriate protection, included with the attachment, is applied.

• LIFTING HOOK ON FORKS

- Weight: 70 kg
- The working load of the attachment corresponds to that of the machine's load chart.

The hook needs to be inserted in the standard fork and fixed to it with the relevant pins (1) and the relevant staples (2).
When this attachment is purchased, standard supply includes the summary booklet in the cab (inside the load chart folder -
21).

WARNING! Always check the correct fitting of the pins in order to avoid the accidental release of the
attachment.

• CARRIAGE-MOUNTED HOOK

Assemble the attachment on the carriage as described in the paragraph

ASSEMBLY OF ATTACHMENTS WITH QUICK COUPLING in this chapter.

- Weight: 75 kg
- The working load of the attachment corresponds to that of the machine's load
chart.

When this attachment is purchased, standard supply includes the summary

booklet in the cab (inside the load chart folder - 21).

• MATERIAL BASKET

Assemble the attachment on the carriage as described in the paragraph

ASSEMBLY OF ATTACHMENTS WITH QUICK COUPLING in this chapter and
use it with the auxiliary controls in the cab.

- Weight: 200 kg
- Load of attachment: 1000kg

WARNING! To be used for carrying materials only. It is forbidden to

use the attachment to lift people. Always check that the door is correctly
closed to avoid the accidental spillage of material from the attachment.

8 - 11
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• FLY-JIB WITH WINCH

Light weight trestle structure, highly rigid under load. A shape bent forward
permits to reach an operating height as high as that of the machine combined
with the jib height, keeping the hook clear of the machine. High-resistance anti-
spin rope complete with pulley and rope guide at the jib end (A1300). The winch
is equipped with block valves and descent control valves as well as hook ascent
and descent limiting devices.
Block with safety hook slewing over 360°.

• (P37.12 PLUS - P38.12 PLUS - P38.13 PLUS - P38.14 PLUS - P40.9 PLUS –
P40.17 PLUS – P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE)

(A1300A)
A = 3520 mm; Weight: 215 kg; Attachment capacity: 600kg

(A1310A)
A = 1900 mm; Weight: 240 kg; Attachment capacity: 1500 kg

(A1215)
A = 1500 mm; Weight: 200 kg; Attachment capacity: 2000 kg
For attachment assembly, operating and maintenance instructions, refer to the
relevant manual.

• (P60.10 - P72.10 – P60.10EE – P72.10EE)

(A1320B)
A = 4010 mm; Weight: 265 kg; Attachment capacity: 900 kg
For attachment assembly, operating and maintenance instructions, refer to the
relevant manual.

WARNING! For machines equipped with stabilisers, the use of this

attachment is foreseen with the machine properly stabilized.
This attachment has a rated load capacity lower than the maximum load
capacity of your machine. Therefore, before installing the attachment,
please check that your machine is equipped with a load limiter.
All load charts refer to the machine standing still on flat, firm ground, with
its wheels aligned with its chassis.

8 - 12
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• FLY JIB

Light weight trestle structure, highly rigid under load. A shape bent forward
permits to reach an operating height as high as that of the machine combined
with the jib height, keeping the hook clear of the machine.
Safety hook slewing over 360°.

Assemble the attachment on the carriage as described in the paragraph

INSTALLATION OF QUICK-COUPLING ATTACHMENTS in this chapter and use
it with the auxiliary controls in the cab as described in the paragraph CONTROL
OF HYDRAULICALLY FUNCTIONING ATTACHMENTS.

• (P37.12 PLUS - P38.12 PLUS - P38.13 PLUS - P38.14 PLUS - P40.9 PLUS –
P40.17 PLUS – P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE)

(A1200A)
A = 3225 mm; Weight: 115 kg; Attachment capacity: 600kg

(A1210A)
A = 1908 mm; Weight: 85 kg; Attachment capacity: 1500 kg

• (P60.10 - P72.10 – P60.10EE – P72.10EE)

(A1220B)
A = 3897 mm; Weight: 165 kg; Attachment capacity: 900 kg

WARNING! For machines equipped with stabilisers, the use of this

attachment is foreseen with the machine properly stabilized.
This attachment has a rated load capacity lower than the maximum load
capacity of your machine. Therefore, before installing the attachment, please
check that your machine is equipped with a load limiter.
All load charts refer to the machine standing still on flat, firm ground, with its
wheels aligned with its chassis.

To transport the attachment on the machine, follow these instructions:

- place the attachment on specific support "A"

- secure the rear part of the attachment by fitting pin P" and cotter pin "C" in the
specific holes on both sides.
- secure the front part of the attachment using specific fastener "B" and locking it
with pin "P1" and cotter pin "C1"

In this condition, it is not possible to open the engine bonnet; if the bonnet has to
be opened, perform the following operations:

- release the front part of the attachment by removing fastener "B", pin "P1" and
cotter pin "C1".
- rotate the attachment outwards until it is possible to open the engine bonnet
completely.

WARNING! FLY-JIB WITH WINCH When you place the attachment on

the ground, check that the rope is not crushed.

8 - 13
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• CONCRETE SKIP

(500 l)
- Weight: 255 kg
- Door opening: Manual (A1400) or Hydraulic (A1410)
- Max capacity: 500 l

(700 l)
- Weight: 275 kg
- Door opening: Manual (A1420) or Hydraulic (A1430)
- Max capacity: 700 l

To assemble the concrete skip on the machine proceed as follows:

- Insert the forks into the appropriate locations

- Fix the forks to the concrete skip inserting the relative pins "P" into the relative slots,
- Insert spring clips "C".

The skip can be mounted both on the front or side in relation to the machine.

WARNING!
Always ensure that the pins are correctly mounted to prevent the risk of the tools accidentally becoming unhitched.

The concrete may be unloaded in two ways, according to the chosen configuration:

- MANUAL
- HYDRAULIC

MANUAL

Open the concrete unloading flap by means of lever "L".

Re-close once all the concrete has been unloaded.

SYSTEM

Connect the hydraulic hoses "I" of the attachment to the hydraulic fittings located on the boom head.
The concrete unloading flap is hydraulically opened by means of cylinder "M" controlled by the attachment control lever located
inside the cab (see relative paragraph in the chapter entitled "CONTROLS AND INSTRUMENTS").
Once operations are complete disconnect the hydraulic hoses "I" and replace in their respective holders.

8 - 14
 8 - ATTACHMENTS AND OPTIONAL EXTRA

ATTACHMENT MAINTENANCE

Lubricate the concrete unloading flap operating cylinder "M" every 50 working hours, on the lubrication points shown (ref. 1)

• CONCRETE MIXER

For attachment assembly, operating and maintenance instructions, refer to the

relevant manual.

• DOUBLE LOG CLAMP

Assemble the attachment on the carriage as described in the paragraph INSTALLATION OF QUICK-COUPLING
ATTACHMENTS in this chapter and use it with the auxiliary controls in the cab as described in the paragraph CONTROL OF
HYDRAULICALLY FUNCTIONING ATTACHMENTS.

- Weight: 480 kg
- Attachment load corresponds to the machine's diagram

• DRUM CLAMP

Attachment for grasping 1 drum or

similar items.
Clamp rotation of 180° or 360°.
This attachment requires the machine
to be pre-set for a DUAL-FUNCTION
ACCESSORY.

- Weight: 220 kg
- Load of attachment: 600kg

8 - 15
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• MANURE FORK WITH CLAW

Assemble the attachment on the

carriage as described in the
paragraph INSTALLATION OF
QUICK-COUPLING ATTACHMENTS
in this chapter and use it with the
auxiliary controls in the cab as
described in the paragraph
CONTROL OF HYDRAULICALLY
FUNCTIONING ATTACHMENTS.

- Weight: (A2300) = 550 kg; (A2301) = 430 kg

- Attachment:capacity (A2300) = 1200 kg; (A2301) = 1000 kg

• HAY BALE FORK WITH CLAW

Assemble the attachment on the carriage as described in the paragraph

INSTALLATION OF QUICK-COUPLING ATTACHMENTS in this chapter and use
it with the auxiliary controls in the cab as described in the paragraph CONTROL
OF HYDRAULICALLY FUNCTIONING ATTACHMENTS.

Fork suitable for loading one or two bales on top of each other, with hydraulically-
positioned upper retainer claw.

- Weight: 240 kg
- Maximum load of attachment: 1500 kg

• BALE FORK WITH 2/3 TIPS, TIP-OVER

Fork suitable for loading one or two bales on top of each other, with pull-out upper guard.
Assemble the attachment on the carriage as described in the paragraph ASSEMBLY OF ATTACHMENTS WITH QUICK
COUPLING in this chapter and use it with the auxiliary controls in the cab.

(A2333) (A2331)
- Weight: 215 kg - Weight: 205 kg
- Load of attachment: 1500 kg - Attachment capacity: 1500 kg

(A2334) (A2332)
- Weight: 190 kg - Weight: 210 kg
- Attachment:capacity 1000 kg - Attachment capacity: 1000kg

8 - 16
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• HAY BALE FORK WITH SLIDING GUARD

Fork suitable for loading one or two bales on top of each other, with height-
adjustable, hydraulically operated upper guard. height adjustment means that
this equipment is ideal for stacking bales up to the roof where the height of the
last load is variable.
Assemble the attachment on the carriage as described in the paragraph
INSTALLATION OF QUICK-COUPLING ATTACHMENTS in this chapter and use
it with the auxiliary controls in the cab as described in the paragraph CONTROL
OF HYDRAULICALLY FUNCTIONING ATTACHMENTS.

- Weight: 255 kg
- Maximum load of attachment: 1500 kg

• CARRIAGE WITH WINCH

For attachment assembly, operating and maintenance instructions, refer to the relevant manual.

• (P37.12 PLUS - P38.12 PLUS - P38.13 PLUS - P38.14 PLUS - P40.9 PLUS – P40.17 PLUS – P38.12 – P38.13 – P38.14 –
P40.17 – P38.13EE – P40.17EE)

- Weight: 215 kg
- Attachment:capacity 2400 kg

• (P60.10 - P72.10 – P60.10EE – P72.10EE)

- Weight: 500kg
- Attachment:capacity 5000 / 6000 kg

8 - 17
 8 - ATTACHMENTS AND OPTIONAL EXTRA

• BALE GRIPPER

Assemble the attachment on the carriage as described in the paragraph INSTALLATION OF QUICK-COUPLING
ATTACHMENTS in this chapter and use it with the auxiliary controls in the cab as described in the paragraph CONTROL OF
HYDRAULICALLY FUNCTIONING ATTACHMENTS.

(A2402) • Weight: 195 kg; • Capacity: 1000 kg / (A2405) • Weight: 250 kg; • Capacity: 1200 kg
(A2406) • Weight: 195 kg; • Capacity: 1000 kg / (A2407) • Weight: 175 kg; • Capacity: 1200 kg
(A2408) • Weight: 250 kg; • Capacity: 1200 kg / (A2413) • Weight: 295 kg; • Capacity: 1200 kg

8 - 18
 8 - ATTACHMENTS AND OPTIONAL EXTRA

VARIANTS AND ACCESSORIES

This chapter describes all the available accessories for this vehicle, based on the Merlo official price list.

WARNING! Use Merlo S.p.A. approved accessories only, type-approved for use on your vehicle.

Before using any accessory mentioned in the present chapter, it is necessary to read and fully understand the instructions on
its operation. If the installation or operation of the accessory is not entirely clear, please contact your dealership or Merlo
Technical Support Service.

WARNING! It is forbidden to use an accessory without reading and understanding its installation and
operation instructions.
Should more than one accessory be installed on the machine, the relative controls may be in a position that differ
from that indicated in the manual supplied with the machine. In any event please refer to the symbol that appears next
to the command itself, so that even if it should be in a different position it can be identified by the relative symbol
which is described in the manual.

GENERAL INSTRUCTIONS FOR THE USE OF THE MACHINE APPROVED AS ITALIAN OPERATIVE

NOTE!
The items in annex II of the Directive 2009/144/CE, as amended by the Directive 2010/52/CE, point 4.1 to the letter
d,f,p,q, point 4.2 to the letter b,d,e,g,k and the points 4.5.1.3, 4.5.2, 4.5.3 do not apply.

• POSITIONING POINTS FOR THE HYDRAULIC JACKS APPLICATION

If the machine has to be lifted in order to replace a tyre, the hydraulic jacks can be applied at the points indicated below:

A) front jacking point: place the hydraulic jack in correspondence to the central part of the machine's front axle, as indicated by
the arrow
B) rear jacking point: place the hydraulic handler in the central-rear part of the machine, as indicated by the arrow

Refer to "DETERMINATION TABLE OF THE TOTAL MASS, THE LOADS PER AXLE AND THE LOAD CAPACITY OF THE
TYRES" in this chapter to select the hydraulic jack type to suit Your needs.

• GENERAL INDICATIONS ON THE USE OF ATTACHMENT OR TRAILERS

CONNECTED TO THE MACHINE

Before using Your machine with a towed attachment or fitted on a trailer,

carefully observe the instructions shown in the use and maintenance manual of
the machine and in the manual of the attachment or trailer connected. Otherwise
do not use the above indicated combinations.

WARNING!
It is forbidden to linger in the area between the machine and the vehicle or
the attachment being towed.

• DETERMINATION TABLE OF THE TOTAL PERMITTED MASS, THE LOADS

PER AXLE AND THE LOAD CAPACITY OF THE TYRES

Refer to following table for information on the total permitted masses on the front
and rear axle and the maximum applicable load on the tyres of Your machine.

This information is also useful for the determination of the hydraulic jack to be
used for the tyre replacement operations. (see paragraph "POSITIONING
POINTS FOR THE HYDRAULIC JACK APPLICATION" of this chapter).

8 - 19
 8 - ATTACHMENTS AND OPTIONAL EXTRA

PERMITTED LOAD ON TYRES PER

TECHNICALLY PERMISSIBLE MASS (kg)
MACHINE AXLE (kg)
TOTAL FRONT REAR FRONT REAR
P37.12 PLUS 8900 5000 5000 5000 5000
P38.12 / PLUS 8900 5000 5000 5000 5000
P38.13 / PLUS / EE 9050 5000 5000 5000 5000
P38.14 / PLUS 9400 5500 5600 5500 5600
P40.9 PLUS 8360 5000 5000 5000 5000
P40.17 / PLUS / EE 10980 5000 6500 5000 6500
P60.10 / EE 10000
7300 7500 7300 7500
P72.10 / EE 10500

• DETERMINATION TABLE OF THE MAXIMUM ALLOWED LIMITS FOR TOWED MASSES

Refer to the following table for information on the maximum allowed limits for towed masses, the determination of the maximum
load on the rear towing hook and the available braking systems for the trailer.

NOTE! The information regarding maximum allowed limits for towed masses are also shown in the type
approval plate in the front part of the cab (see paragraph "IDENTIFICATION AND TYPE APPROVAL PLATES" in
chapter "MACHINE TECHNICAL SPECIFICATIONS").

TOWING CAPACITY (kg)

MACHINE VERTICAL LOAD ON HOOK (kg)
NO BRAKES
P37.12 PLUS 1500 (on request) 250
P38.12 / PLUS - -
P38.13 / PLUS / EE - -
P38.14 / PLUS - -
P40.9 PLUS - -
P40.17 / PLUS / EE 1250 (on request)
P60.10 / EE
- -
P72.10 / EE

• DETERMINATION TABLE OF THE VIBRATIONS LEVEL (complying with the Directive 78/764/EEC)

The following table contains the vibration values transferred from the driver's seat divided according to the brand and type of
the seat installed on the machine. Check what model is in Your cab and refer to the information shown below.

Aws [m/s²] (*)

SEAT MODEL CATEGORY CLASS APPROVAL DRIVER’S MASS
(Dir.78/764)
light 1,13
KAB Seating 11T6 A I / II / III e11 0997
heavy 1,01
light 1,13
KAB Seating 156, 15T6, 15E1, 15T1 A I / II / III e11 0995
heavy 1,01
light 1,64
SEAT ACTIVIO SERIES – S698 A II / III e13 0021
heavy 0,64
light 1,17
SEAT ACTIVIO SERIES – S55 A II / III e13 0020
heavy 0,98
light 1,04
GRAMMER MSG95 A II / III 100514
heavy 0,64
light 0,68 (**)
SEAT FULLY --- --- ---
heavy 0,55 (**)

(*) Aws = correct value of the rms value of the weighted seat vibration (complying with Directive 78/764/EEC)

(**) according to EN13490:2001

8 - 20
 8 - ATTACHMENTS AND OPTIONAL EXTRA

REAR DIFFERENTIAL LOCKING

Operated using button (A):

button pressed = lock engaged

button released = lock disengaged

When warning light (88) is ON, it indicates that the differential lock is engaged.

IMPORTANT! Do not operate the steering with differential lock

engaged on tarmac or compact surfaces.
Leave the lock ON only for operations with silage.

SECURING THE MACHINE FOR TRANSPORTATION BY TRAILER

To secure your machine correctly to a

trailer (e.g. for transportation), you
must use appropriate ropes or chains
attached exclusively to the rings
marked "A" welded on to the chassis.
The machine has a total of 4
anchorage rings (2 at the front and 2 at
the rear).

WARNING! Do not use the

anchorage rings marked "A" to tow
or lift the machine.

SUN BLIND

In the rest condition, the sun blind "A", is rolled up at the upper end of the cab window. (Fig1).
In order to cover the upper area of the cab window, unroll the sun blind "A" until it is hooked to the appropriate fastening
brackets "B" (Fig. 2).
If you also need to cover a part of the cab's front window, unroll the sunblind "A" further until it is hooked to fastening brackets
"C" (Fig. 3).

8 - 21
 8 - ATTACHMENTS AND OPTIONAL EXTRA

REAR HYDRAULIC OUTLET

The provision for mixing bucket control may be of 2 types depending on the distributor fitted to the machine:

- if the machine is fitted with levers, the mixing bucket is operated using control lever (2) (configuration 1)

- if the machine is fitted with a joystick, the mixing bucket is operated using the joystick (1) (configuration 2)

The 2 options available are analysed separately below; cross-check your machine to verify which configuration applies and
refer to the relative section for the operating instructions.

• CONFIGURATION 1

- place the lever (2) in direction "L" or "M" to activate the corresponding rear hydraulic sockets (see photo)

• CONFIGURATION 2

- rotate the right roller of the joystick (1) to position "3A" to activate the corresponding hydraulic connection.

- rotate the right roller of the joystick (1) to position "4B" to activate the corresponding hydraulic connection.

WARNING! The hydraulic system of the rear hydraulic outlet is not equipped with valves or seals able to
support lifted loads (for example a dumb body). For these kind of use verify that the attachment is equipped with
appropriate blocking system against accidental load descent.
Before operating with the rear hydraulic outlet, be sure to have disconnected both the hydraulic circuit of the
attachment locking system and the hydraulic line to the attachment fitted to the front carriage.
With work completed, disconnect the rear hydraulic outlets; if not, when using the attachment fitted to the front
carriage, the equipments linked to the rear hydraulic outlet would be activated.
The maximum working pressure of the rear hydraulic outlet is 210 bar.

8 - 22
 8 - ATTACHMENTS AND OPTIONAL EXTRA

REAR HYDRAULIC OUTLET

To understand the operation of the rear hydraulic connection, refer to the following instructions:

- selector "S" on "0": the rear hydraulic connections are deactivated and the functions of the joystick (1) are those described
in chapter "COMMANDS AND INSTRUMENTS"

- selector "S" on "1": to control the rear hydraulic connection, turn the right wheel of the joystick (J) to "3A" or "4B" to use the
corresponding rear hydraulic connections

- selector "S" on "2": the oil is sent in a continuous manner to the hydraulic connection "3A" without using the joystick (J).

WARNING! The hydraulic system of the rear hydraulic outlet is not equipped with valves or seals able to
support lifted loads (for example a dumb body). For these kind of use verify that the attachment is equipped with
appropriate blocking system against accidental load descent.
Before operating with the rear hydraulic outlet, be sure to have disconnected both the hydraulic circuit of the
attachment locking system and the hydraulic line to the attachment fitted to the front carriage.
With work completed, disconnect the rear hydraulic outlets; if not, when using the attachment fitted to the front
carriage, the equipments linked to the rear hydraulic outlet would be activated.
The maximum working pressure of the rear hydraulic outlet is 210 bar.

REAR WHEEL CENTRING INDICATOR ON THE MACHINE AXIS

Before carrying out a transfer on public roads, it is mandatory to align the wheels
of the rear bridge to the longitudinal axis of the machine by proceeding as
follows:

- select the four wheel coordinated steering or crab steering

- carry out the steering manoeuvre until the rear axle wheels are parallel to the
machine axis. the operator is notified that alignment is completed by indicator
"A" which lights up on control panel "P1".

Before carrying out a transfer on public roads, select steering on the front axis
(lever 29 in position "B").

8 - 23
 8 - ATTACHMENTS AND OPTIONAL EXTRA

FIXED BUILDING SITE TOW HOOK

Mount the fixed tow hook (A) for building sites if:
- it is necessary to tow the vehicle on public roads (see also paragraph
"MACHINE TOWING" in chapter "OPERATING INSTRUCTIONS")

- it is necessary to tow trailers or other equipment within a building site. In this

case, the maximum towable weight must be less than 4000 kg.

The maximum vertical load on the towing hook is indicated inside the registration
documents for public road circulation.

WARNING!
It is forbidden to use this type of hook to tow trailers or other equipment on
public roads.

"EEC" MULTI-POSITION TOWING HOOK

The "EEC" towing hook is used to tow farm equipment without braking systems,
with a maximum gross weight of 6000 kg.

The maximum vertical load on the towing hook is indicated inside the registration
documents for public road circulation.

The towing hook is installed on a plate with lateral slides so as to vertically slide
in multiple positions.

• nomenclature

A) "EEC" towing hook

B) upper position
C) slides for the sliding of the hook

WARNING! The use of the "EEC" towing hook on public roads may
be subject to restrictions in certain countries. The user must contact their local dealer before towing loads or
equipment on public roads.

To attach a trailer to the "EEC" towing

hook (figure 1), proceed as follows:

- remove the lower clip "A"

- remove the retaining pin "B"
- insert the eyelet of the equipment
inside the housing of the hook
- insert the pin "B"
- secure the pin "B" with the clip "A"
- connect the trailer lights to the
appropriate electrical outlet (see
relevant paragraph)

To move the towing hook onto the

multi-position plate, follow the
instructions below (figure 2):

- if you want to use the highest positions of the slide, lift the upper guard "B"
- extract the release device "D"
- grasp the handle "E", lift and move the hook to the desired height
- lower the handle "E" and check that the device "D" is correctly inserted

1 - 24
 8 - ATTACHMENTS AND OPTIONAL EXTRA

PROVISION FOR MIXING BUCKET CONTROL

The provision for mixing bucket control may be of 2 types depending on the distributor fitted to the machine:

- if the machine is fitted with levers, the mixing bucket is operated using control lever (2) (configuration 1)
- if the machine is fitted with a joystick, the mixing bucket is operated using the joystick (1) (configuration 2)

The 2 options available are analysed separately below; cross-check your machine to verify which configuration applies and
refer to the relative section for the operating instructions.

- CONFIGURATION 1

OPENING THE PROPELLER HOUSING

Press the button (A) and move the lever (2) to position "L"; when the guard is
completely open, release the button.

CLOSING THE PROPELLER GUARD

The propeller guard will close automatically when the mixing bucket is rotated
upwards.

PROPELLER ROTATION

Place the lever (2) in position (L) and hold it there.

WARNING! If the button (A) is pressed and the lever (2) is in position "L", when the bucket is rotated upwards,
the safety device prevents propeller rotation. If the machine remains in this condition, the oil may overheat.
Propeller rotation with the guard open is only allowed when loading inert material, operating from the cab and using
the bucket as a loader.

OPENING AND CLOSING THE CONCRETE DISCHARGE HATCH

Activate propeller rotation first and then the discharge using the remote control supplied (see relative paragraph in the
equipment manual).

- CONFIGURATION 2

To use the mixing bucket correctly on a machine equipped with the optional
joystick, refer to the following instructions:

OPENING THE PROPELLER HOUSING

Press the button (R) and turn the RH thumb-wheel into position "G"; when the
guard is completely open, release this button.

CLOSING THE PROPELLER GUARD

The propeller guard will close automatically when the mixing bucket is rotated
upwards.

PROPELLER ROTATION

Turn the RH wheel into position (G) and hold it there

WARNING! If the button (R) is pressed and the RH thumb-wheel is turned to position "G", when the bucket is
rotated upwards, the safety device prevents propeller rotation. If the machine remains in this condition, the oil may
overheat.
Propeller rotation with the guard open is only allowed when loading inert material, operating from the cab and using
the bucket as a loader.

OPENING AND CLOSING THE CONCRETE DISCHARGE HATCH

Activate propeller rotation first and then the discharge using the remote control supplied (see relative paragraph in the
equipment manual).

1 - 25
 8 - ATTACHMENTS AND OPTIONAL EXTRA

REAR ELECTRICAL CONNECTION

For the electrical connection of the direction indicators and all the lights of the
towed equipment use "A" socket.

For the electric connection (according to ISO 1724-80) consult the enclosed
electric diagram.

CAR RADIO

The radio is installed in the compartment under the left glove box.

The image is by way of example only and may not correspond to the radio
actually fitted in the vehicle.

For information on the use of the radio, refer to the corresponding manual.

WORK LIGHTS

To use the work lights, follow the instructions below:

• ON THE CAB

- Turn the ignition key (8) to position "R" (instrument panel on).
- Press the button (A) to switch on the front work headlights.
- Press the button (P) to switch on the rear work headlights.

• ON THE TELESCOPIC BOOM

- Turn the ignition key (8) to position "R" (instrument panel on).
- Press the button (S) to switch on the work headlights on the boom.

WINDSCREEN WIPER ON ROOF

To activate the windscreen wiper on the vehicle roof, press button "C" located on
the electric motor of the wiper itself.

1 - 26
 8 - ATTACHMENTS AND OPTIONAL EXTRA

FITTING ACTIVE HYDRO-PNEUMATIC SUSPENSIONS FOR PANORAMIC

PROCEDURE

The active hydro-pneumatic suspension system ensures better comfort for the operator in the cab while driving a medium-high
speed and at the same time improves machine road-holding while also protecting the mechanical structures and the load
carried against blows caused by road bumps and travel over irregular ground.
It is also advised to use these suspensions for transporting loads over irregular ground since the active system is designed to
adapt to the weight carried (from 0 to MAX) without affecting ground clearance .
When loading-unloading materials on flattish and firm ground (e.g. asphalted depots), it is advisable to deactivate the active
hydro-pneumatic suspension system to ensure better working precision.

OPERATING INSTRUCTIONS

The system envisages two user modes - MANUAL and AUTO - selected using
selector switch "S". (Fig. 1)
in MANUAL mode, it is possible to perform commands involving the crossways
tilt corrector.
Movement is obtained by pressing buttons "P1" and "P2" and halts automatically
when these buttons are released. The command must only be given with the
machine at a standstill. (Fig.2)

P1 = anticlockwise chassis levelling

P2 = clockwise chassis levelling

IMPORTANT! In MANUAL mode, if the machine boom is raised

beyond the locking device intervention limit, operation of the crossways tilt
correcter is prevented.

In AUTO mode, the suspension effect as such is obtained, ensuring maximum

driving comfort during trips with and without loads.
By turning the selector switch "S" into position AUTO, the machine presets for
this operation; if all safety conditions are respected, a led comes ON, the
suspension is activated and jacks "M" slide out by approx. 40mm. (Fig.3)

In AUTO mode, the suspension activates itself only if:

- the machine boom is not raised beyond the lock device intervention limit
- crossways chassis movement is in the central position (indicator light 56
OFF).

If these safety conditions are not upheld, the led does not come ON and the
suspension is not activated. In the event of system faults, contact Merlo
Technical Assistance service.

WARNING!!
If, when turning selector switch "S" into the AUTO position, the jacks do not slide out or slide out incorrectly, contact
Merlo Technical Assistance Service.
When the machine is fitted with active suspensions on the front axle (EAS), it is not possible to perform crossways
levelling operations at full load but exclusively with a maximum weight of 3000Kg.
If absolutely necessary, it is possible to perform crossways machine levelling with loads greater than 3000 kg by
performing complete movement in advance of the part opposite to jack "M" which is to be lifted.
Make sure that machine is correctly levelled before attempting any lifting operations.
Pay careful attention when activating/deactivating the suspension system since the machine is raised/lowered by
about 40mm.
Load handling on uneven surfaces is permitted by using frame levelling device to level the machine chassis to the
proper position. Check correct levelling using the spirit level in the cab.

PERIODICAL SAFETY CONTROLS

Check the calibration of the hydro-pneumatic accumulators every 1000 hours.

This operation must be carried out by Merlo Technical Assistance Service.

1 - 27
 8 - ATTACHMENTS AND OPTIONAL EXTRA

JOYSTICK (4 FUNCTIONS)

4 main movements can be performed with this joystick (2 movements controlled by

the lever of the joystick and 2 movements controlled by wheels R1 and R2).

1) LIFTING/LOWER OF THE TELESCOPIC BOOM

2) UPWARD/DOWNWARD ROTATION OF THE FORKS
3) EXTENSION/RETRACTION OF THE TELESCOPIC BOOM
4) COMMAND FOR ATTACHMENTS INSTALLED ON THE CARRIAGE

The first two movements are carried out by moving the joystick in the longitudinal
and transverse direction, while the remaining two movements are performed using
the control wheels "R1" and "R2".

The speed of the movement to be made is proportional to:

- the inclination given to the control joystick (the greater the movement of the
joystick, the greater the speed of the movement)

- the rotation of the control wheels "R1" and "R2" (the greater the rotation, the
greater the speed of the movement)

- the rpm of the diesel engine (the higher the rpm of the engine, the greater the
speed of movement).

The movement stops automatically when the joystick or related wheel is released.
Depending on load conditions, it is possible to combine movements.

• JOYSTICK LEVER (1) IN POSITION:

A= boom lifting
B= boom descent
C= tilting of forks downward
D= tilting of forks upward

- CONTROL WHEEL "R1"

1 = extension of the telescopic boom

2 = retraction of the telescopic boom

- CONTROL WHEEL "R2"

3 = attachments release/attachments command

4 = attachments command

- JOYSTICK "U" ENABLING BUTTON

Press and hold button "U" to enable the joystick (1) commands. The indicator light (209) on the control panel (P1) lights to
indicate to the operator the enabling of the joystick controls

WARNING! Before operating the machine, please mark off the area where the machine needs to be operated, in
order to keep both people and vehicles away from it.
Should you need to operate the machine near overhead lines, the person in charge of safety shall require the
minimum safety distance from such lines to the manager of said lines, as well as from the authorities in charge of
safety and health in the workplace; in this way all necessary precautions shall be taken and potential accidents shall
be prevented. For further information please refer to paragraph "INSTRUCTIONS FOR A CORRECT USE OF THE
MACHINE NEAR OVERHEAD LINES" in chapter "OPERATING INSTRUCTIONS".

1 - 28
 8 - ATTACHMENTS AND OPTIONAL EXTRA

JOYSTICK (5 FUNCTIONS)

5 main movements can be performed with this joystick (2 movements controlled

by the lever of the joystick and 3 movements controlled by wheels R1, R2 and
R3).:

1) LIFTING/LOWER OF THE TELESCOPIC BOOM

2) UPWARD/DOWNWARD ROTATION OF THE FORKS
3) EXTENSION/RETRACTION OF THE TELESCOPIC BOOM
4) COMMAND FOR ATTACHMENTS INSTALLED ON THE CARRIAGE (AUX)
5) COMMAND FOR ATTACHMENTS INSTALLED ON THE CARRIAGE (AUX 1)

Press and hold button "U" to enable the joystick (1) commands.

The first two movements are carried out by moving the joystick in the longitudinal
and transverse direction, while the remaining three movements are performed
using the control wheels "R1", "R2" and "R3". The speed of the movement to be
made is proportional to:

- the inclination given to the control joystick (the greater the movement of the
joystick, the greater the speed of the movement)

- the rotation of the control wheels "R1", "R2" and "R3" (the greater the
rotation, the greater the speed of the movement)

- the rpm of the diesel engine (the higher the rpm of the engine, the greater the
speed of movement).

The movement stops automatically when the joystick or related wheel is

released. Depending on load conditions, it is possible to combine movements.

• JOYSTICK LEVER (1) IN POSITION:

A= boom lifting
B= boom descent
C= tilting of forks downward
D= tilting of forks upward

- CONTROL WHEEL "R1"

1 = extension of the telescopic boom

2 = retraction of the telescopic boom

- CONTROL WHEEL "R2" (AUX)

3 = attachments release/attachments command

4 = attachments command

- CONTROL WHEEL "R3" (AUX 1)

5 = attachments command
6 = attachments command

WARNING! Before operating the machine, please mark off the area where the machine needs to be operated, in
order to keep both people and vehicles away from it.
Should you need to operate the machine near overhead lines, the person in charge of safety shall require the
minimum safety distance from such lines to the manager of said lines, as well as from the authorities in charge of
safety and health in the workplace; in this way all necessary precautions shall be taken and potential accidents shall
be prevented. For further information please refer to paragraph "INSTRUCTIONS FOR A CORRECT USE OF THE
MACHINE NEAR OVERHEAD LINES" in chapter "OPERATING INSTRUCTIONS".

- ELECTRICAL CONNECTION OF DUAL-FUNCTION ACCESSORIES

Move the plug from socket "A" to support socket "B". The dual-function attachments are equipped with an electric cable which
must be connected to the electrical outlet "A" on the head of the boom.

1 - 29
 8 - ATTACHMENTS AND OPTIONAL EXTRA

MULTI-FUNCTION CONTROL JOYSTICK

Thanks to this accessory, your machine is fitted with an electro-mechanical single-

lever joystick for performing 8 hydraulic functions

• Position A: lift telescopic boom

• Position B: lower telescopic boom

• Position C: rotate carriage upwards

• Position D: rotate carriage downwards

• Position E: extend telescopic boom

• Position F: retract telescopic boom

• Position G: release attachments installed on carriage

• Position H: • command for attachments installed on carriage

• Button L: shift machine to right

• Button M: shift machine to left

• Button R: AUX1 (first hydraulic function)

To activate the first hydraulic function of the attachment mounted on the machine,
press the button (R) and simultaneously turn the right-hand thumb-wheel in
position "G" or "H" to select the movement direction.

• Button S: AUX2 (second hydraulic function)

To activate the second hydraulic function of the attachment mounted on the

machine, press the button (S) and simultaneously turn the right-hand thumb-wheel
in position "G" or "H" to select the movement direction.

• Button T: AUX3 (third hydraulic function)

To activate the third hydraulic function of the attachment mounted on the machine, press the button (T) and simultaneously turn
the right-hand thumb-wheel in position "G" or "H" to select the movement direction.

The movement speed required is proportional to the angle given to the joystick (the larger the angle of the joystick the higher
the movement speed), the rotation of the control thumb-wheels (the larger the rotation of the thumb-wheels the higher the
movement speed) and diesel engine rpm (the higher the diesel engine rpm the higher the movement speed).
Depending on load conditions, it is possible to combine machine movements.
Movements stop automatically when the joystick, control thumb-wheel or button are released.

To enable the operation of the joystick it is necessary to press and keep pressed the red button (U) located on the rear.

WARNING! Before operating the machine, please mark off the area where the machine needs to be operated, in
order to keep both people and vehicles away from it.
Should you need to operate the machine near overhead lines, the person in charge of safety shall require the
minimum safety distance from such lines to the manager of said lines, as well as from the authorities in charge of
safety and health in the workplace; in this way all necessary precautions shall be taken and potential accidents shall
be prevented. For further information please refer to paragraph "INSTRUCTIONS FOR A CORRECT USE OF THE
MACHINE NEAR OVERHEAD LINES" in chapter "OPERATING INSTRUCTIONS".

On request, it is possible to have the control joystick (1) mounted on the right armrest of the seat; in this case, however, the
joystick installed is a proportional electronic type, although the commands and functions available are the same as those
described in this paragraph.
Before starting to use the proportional electronic joystick, check the correct locking of the armrest in the work position.

To electrically connect the attachment to the machine proceed as follows:

- remove the protection from the support connection "B"

- move the electrical plug "S" from the socket "A" to the support socket "B"
- connect the plug coming from the equipment to the electrical connection "A" on the machine

1 - 30
 8 - ATTACHMENTS AND OPTIONAL EXTRA

GRAMMER EXTRA-COMFORT PNEUMATIC SEAT

The pneumatic seat Grammer is installed in place of the standard one. Therefore, the following instructions replace those found
in chapter "CAB" of the present operator manual.

WARNING! It is forbidden and it is extremely dangerous to adjust the driver's seat while the vehicle is moving.
Position the driver's seat so that the driver can easily reach the vehicle controls.

1) SEAT FORWARD/BACKWARD SLIDING

To regulate the seat horizontal sliding, lift lever "A" and move the seat forwards or backwards until the desired position is
reached. Once the seat has been adjusted, release lever "A" and check that the seat is locked into the desired position.

2) BACKREST ADJUSTMENT

Rest your back on the backrest, then lift lever "B" to incline it as desired. Once the seat has been adjusted, release lever "B"
and check that the backrest is locked into the desired position.

3) LUMBAR ADJUSTMENT

Rotate handle "C" in both directions to adjust the desired lumbar support level.

4) SUSPENSION ADJUSTMENT

This pneumatic seat can automatically adjust to the ideal height and suspension level according to your body weight.
To correctly adjust the seat height and suspension, properly sit on the seat, then lift lever "D" for a few seconds; the seat
automatically assumes the ideal position.
If the set height is not comfortable, you can still manually use lever "D" to raise or lower the seat.
If, while driving, the seat dampens the roughness of the road by reaching its top or bottom end stop, the system automatically
regulates the seat height, so that the maximum driving comfort is always ensured.

5) ACTIVATION OF THE LONGITUDINAL ANTI-SHOCK SYSTEM

Your pneumatic seat is fitted with a longitudinal anti-shock system which makes driving on roads and working at a building site
more comfortable.
Lever "E" is used to activate the anti-shock system: when in position "1" the anti-shock is enabled, in position "0" it is disabled.

6) SAFETY BELT

The safety belt use conditions are the same as those found in paragraph "CAB".

7) DOCUMENT POCKET

Always keep the use and maintenance manual of your vehicle in the document pocket "G", located behind the seat.

1 - 31
 8 - ATTACHMENTS AND OPTIONAL EXTRA

TYRE SEAT

SEAT SHIFT (1):

Lift lever "S" upwards, slide the seat forwards or backwards to obtain the required position and release the lever.

HEIGHT ADJUSTMENT (2):

The seat height can be adjusted by means of the hand lever "M", placed on the front side of the seat frame.
To lower the seat, pull the hand lever "M" outwards
To lift the seat, turn the ignition key in position "R" and press the hand lever "M".

SUSPENSION ADJUSTMENT (3):

To adjust the seat suspension use handle "A" located at the front side of the seat frame. Sit on the seat and turn the handle
until just the right degree of suspension is achieved for one's weight. (direction "R" to harden the suspension, direction "S" to
soften the suspension)

BACKREST ADJUSTMENT (4):

Sit with your back firmly against the backrest.
Lift lever "L" upwards to position the backrest to the required angle.

DOCUMENT HOLDER POCKET (5)

Located behind the seat for holding the machine documentation and small objects.
Always keep the "USE AND MAINTENANCE INSTRUCTIONS MANUAL" in the document holder pocket (T).

The machine is fitted with a pneumatic seat with a longitudinal anti-shock system making driving on the road and site
operations more comfortable (6):

- rotate lever "C" to position "Z" to engage the longitudinal suspension

- rotate lever "C" to position "Y" to disengage the longitudinal suspension making the seat rigid.

WARNING! It is forbidden and it is extremely dangerous to adjust the driver's seat while the vehicle is moving.
Position the driver's seat so that the driver can easily reach the vehicle controls.

CYCLONE PRE-FILTER

Remove the material deposited in pre-filter "A" as follows:

- remove wing nut "A"

- remove cover "C"
- remove decanting unit "D" and empty it completely taking care not to allow
impurities to fall in the air inlet hole.

WARNING!! Whenever the container becomes completely full, the

pre-filter function is lost.

1 - 32
 8 - ATTACHMENTS AND OPTIONAL EXTRA

A/C SYSTEM

To cool your cab correctly, follow the advice below:

- open all the air vents in the cab

- after a prolonged stay in the sun it is necessary to air the cab by opening all
the windows for a few minutes and putting the ventilation control (36) on the
second speed (for further information see the section "HEATING" in the
chapter "CONTROLS AND INSTRUMENTS").
- check that the heating controls (35) are on "C". If this is not the case, turn
the knob to close the heating cock.
- For maximum efficiency and reliability of the A/C system, we recommend
that you periodically clean the condenser; this component is located in the
top spoiler behind the driver's cab.
- should the A/C system become less efficient, check the coolant level. Have
this operation carried out by qualified and competent personnel

CLASSIFICATION OF COMPONENTS

- knob (35) in position "A": heating on

- knob (35) in position "C": air-conditioning on

- selector (36) on "0": ventilation off (not to be used with the selector switch "35" in position "C")
- selector (36) on "1": ventilation activated at the first speed
- selector (36) on "2": ventilation activated at the second speed

OPERATING INSTRUCTIONS

To correctly activate the air-conditioner "A", follow the instructions below:

- place the knob (35) in position "C";

- turn the selector (36) to "1" or "2"
- Turn the selector "A" to position "1"

WARNING! Do not activate the air-conditioner "A" if the fan control (36) is on "0" since it drastically reduces
the system's efficiency and can produce ice on the evaporator. Any water leaks under the vehicle are due to the
normal discharge of condensate produced by the dehumidification effect of the air-conditioner.

FAULTS WITH DIRECTION INDICATORS ON AGRICULTURAL TRAILERS

(only for models P37.12PLUS E P40.9PLUS)

If the machine is equipped on request

with type approval as an agricultural
tractor and a trailer has been
correctly connected, operation of the
LED (205) on the instrument panel
(C) is activated. The operation of this
LED (205) may bring about possible
faults in the direction indicator
system. Consequently, carry out the
following instructions:

• trailer not connected to the

machine: Indicator light (205) always OFF

• trailer connected to the machine, direction indicators activated and LED (205) ON and flashing simultaneously with LED (52):
no fault in the trailer's direction indicator system (fig.1)

• trailer connected to the machine, direction indicators activated and LED (205) ON and flashing in alternation with LED (52):
fault in the direction indicator system. Identify the cause of the problem and carry out the
action needed to solve it. (for example, replace the bulb, check the connection, etc) (fig.2)

END OF SECTION

1 - 33
 9 - HYDRAULIC CIRCUIT DIAGRAMS
CONTENTS

HYDROSTATIC TRANSMISSION DIAGRAM................................................................................................................................. 2

HYDRAULIC SYSTEM DIAGRAM .................................................................................................................................................. 6

END OF SECTION ....................................................................................................................................................................... 11

9-1
 9 - HYDRAULIC CIRCUIT DIAGRAMS

HYDROSTATIC TRANSMISSION DIAGRAM

(valid for models P37.12PLUS – P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.17PLUS – P60.10 – P72.10)

9-2
 9 - HYDRAULIC CIRCUIT DIAGRAMS

REFERENCE DESCRIPTION

4 Diesel engine
5 Hydrostatic oil tank
6 Variable delivery hydrostatic pump
7 Heat exchanger
9 Variable displacement hydrostatic engine
26 Throttle
10 Speed selection rams
60 Filter-holder block
61 Bypass
84 Rams for differential-lock (OPTIONAL)
85 Servobrake
86 Cartridge filter
88 Thermal contact
90 Pressure connection
105 Parking brake calliper
125 Emergency pump
127 Solenoid valve block
128 Solenoid valves block (OPTIONAL)

9-3
 9 - HYDRAULIC CIRCUIT DIAGRAMS

(valid for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE – P60.10EE – P72.10EE)

9-4
 9 - HYDRAULIC CIRCUIT DIAGRAMS

REFERENCE DESCRIPTION

4 Diesel engine
5 Hydrostatic oil tank
6 Variable delivery hydrostatic pump
7 Heat exchanger
9 Variable displacement hydrostatic engine
26 Throttle
10 Speed selection rams
60 Filter-holder block
61 Bypass
84 Rams for differential-lock (OPTIONAL)
85 Servobrake
86 Cartridge filter
88 Thermal contact
90 Pressure connection
105 Parking brake calliper
125 Emergency pump
127 Solenoid valve block
128 Solenoid valves block (OPTIONAL)

9-5
 9 - HYDRAULIC CIRCUIT DIAGRAMS

HYDRAULIC SYSTEM DIAGRAM

(valid for models P38.12PLUS – P38.13PLUS – P38.14PLUS – P40.17PLUS)

9-6
 9 - HYDRAULIC CIRCUIT DIAGRAMS

REFERENCE DESCRIPTION

1 Inlet filter
2 Return filter
3 Variable delivery pump
4 ENGINE
12 Volume recovery valve
17 Power steering unit
18 Steering distributor
19 Steering jack
22 Pressure gauge
23 Main distributor
24 Extension jack lock valve
25 Lifting jack
26 Throttle ø1mm
27 Extension jack
29 Chassis side movement jack
30 Fork / compensation (offset) valve
31 Compensation (offset) jack
32 Fork jack lock valve
33 Fork jack
36 Front fast-acting couplings
37 Front fast-acting couplings
42 Quick coupling
63 Stabilisers jack lock valve
64 Stabiliser jacks
67 Quick-uncoupling jack
68 Lifting jack lock valve
69 Levelling distributor
90 Pressure connection
94 Accumulator
96 Angle correction jacks
97 Angle correction jack block valves
102 One-way choke valve
144 Emergency over-ride solenoid
154 3-way capacity adjustment valve

9-7
 9 - HYDRAULIC CIRCUIT DIAGRAMS

(valid for models P37.12 PLUS – P40.9 PLUS – P60.10 – P72.10 – P60.10EE – P72.10EE)

9-8
 9 - HYDRAULIC CIRCUIT DIAGRAMS

REFERENCE DESCRIPTION

1 Inlet filter
2 Return filter
3 Variable delivery pump
4 Diesel engine
12 Volume recovery valve
17 Power steering unit
18 Steering distributor
19 Steering jacks
22 Pressure gauge
23 Main distributor
24 Extension jack lock valve
25 Lifting jack
26 Throttle ø 1 mm
27 Extension jack
29 Side movement jack
30 Fork / compensation (offset) valve
31 Compensation (offset) jack
32 Fork jack lock valve
33 Fork jack
36 rear quick couplings Ø 1/2" (OPTIONAL)
37 Front fast-acting couplings Ø 1/2"
42 Fast-acting coupling Ø 1/2"
67 Quick-uncoupling jack
68 Lifting jack lock valve
69 Levelling distributor
90 Pressure connection
94 Accumulator
96 Angle correction jacks
97 Angle correction jack block valves
102 Unidirectional throttling valves
144 Emergency over-ride solenoid
154 3-way capacity adjustment valve

9-9
 9 - HYDRAULIC CIRCUIT DIAGRAMS

(valid for models P38.12 – P38.13 – P38.14 – P40.17 – P38.13EE – P40.17EE)

9 - 10
 9 - HYDRAULIC CIRCUIT DIAGRAMS

REFERENCE DESCRIPTION

1 Inlet filter
2 Return filter
3 Variable delivery pump
4 Diesel engine
12 Volume recovery valve
17 Power steering unit
18 Steering distributor
19 Steering jacks
22 Pressure gauge
23 Main distributor
24 Extension jack lock valve
25 Lifting jack
26 Throttle ø 1 mm
27 Extension jack
29 Side movement jack
30 Fork / compensation (offset) valve
31 Compensation (offset) jack
32 Fork jack lock valve
33 Fork jack
36 rear quick couplings Ø 1/2" (OPTIONAL)
37 Front fast-acting couplings Ø 1/2"
42 Fast-acting coupling Ø 1/2"
63 Stabilisers jack lock valve
64 Stabiliser jacks
67 Quick-uncoupling jack
68 Lifting jack lock valve
69 Levelling distributor
90 Pressure connection
94 Accumulator
96 Angle correction jacks
97 Angle correction jack block valves
102 Unidirectional throttling valves
144 Emergency over-ride solenoid
154 3-way capacity adjustment valve

END OF SECTION

9 - 11
 10 - ELECTRICAL SYSTEM
CONTENTS

GENERAL FEATURES................................................................................................................................................................... 2

BATTERY ....................................................................................................................................................................................... 2

FUSES ............................................................................................................................................................................................ 3

END OF SECTION ......................................................................................................................................................................... 4

10 - 1
 10 - ELECTRICAL SYSTEM

GENERAL FEATURES

Your telescopic handler is equipped with a 12 volt electrical system with the negative pole grounded.

BATTERY

The battery on your machine is located inside the engine compartment.

NOMENCLATURE OF THE BATTERY COMPARTMENT:

(+) Positive pole

(-) Negative pole

The main features of the battery are listed below:

• Capacity in 20 hours = 100 Ah

• Cold start current = 850 A

• Specific weight: a fully charged battery shall have an electrolyte with a specific
weight of 1.260. If this value is lower than 1.215, the battery needs to be charged.

The specific weight of the electrolyte may only be different if you work in countries having either a tropical climate or a cold
climate.
In a tropical climate the readout for a fully charged battery shall be equal to 1.225.
In a cold climate the readout for a fully charged battery shall be equal to 1.280.

• Inspection of the electrical equipment: regularly check the condition of cable harnesses and electrical connections.

WARNING! All inductive loads (electric motors, solenoid valves, etc.) are protected by internal diodes in order
to avoid current peaks when switched off, for this reason never swap the input polarities.

• sulphuric acid:

WARNING!! Sulphuric acid in batteries is a poison and can cause severe burns. Avoid contact with skin, eyes,
and clothes. When working around batteries, protect eyes and face from battery fluid and possible explosions.

If you accidentally come into contact with the sulphuric acid contained in the battery, proceed as follows:

External measures:

- wash your skin with water

- rinse your eyes for 15 minutes
- seek immediate medical advice

Internal measures:

- drink plenty of water or milk

- soon afterwards drink milk of magnesia, beaten eggs, or vegetable oil
- seek immediate medical advice

IMPORTANT! Before carrying out any work on the electrical equipment, disconnect the negative cable from
the battery. The gases contained in the battery may explode. Keep cigarettes, sparks and flames away from the
battery.
Never use connection cables and never work on the connections if you are not familiar with the correct procedure to
be followed.
When you either charge a battery or use a battery in an enclosed room, make sure that the room is well ventilated.
Keep batteries away from children. Make sure that the vent plugs are tightened correctly, and check the electrolyte
level at regular intervals.

10 - 2
 10 - ELECTRICAL SYSTEM

FUSES

Electrical circuits are protected by fuses and relays located in the ENGINE COMPARTMENT and COVER "7" in the cab (see
paragraph COVERS in section "ORDINARY MAINTENANCE"). If a fuse blows, first find the cause and then replace it with a
new one with the same features.
If any accessories on request have been ordered, the affected fuses are placed on the side of the general one.

• FUSES IN COVER 7

Position Type Description

Power supply UAE
F1 15A
Starting key
Electric socket inside cab (25A)
F2 20A
Portable light socket (cigarette lighter)
Air conditioning compressor clutch
F3 30A
Direct power supply for accessories (BVC)
F4 40A Glowplug (if present)
F5 30A Power supply starting motor relay
Car-radio (fitting)
F6 15A Optional cab connector
Power supply accessories under key (BSC)
Joy-stick supply
F7 15A
UAE signal
F8 15A Horn
FUSE

F9 15A Beam lights

F10 10A Lower beam lights
F11 15A Fitted for rear work lights on cab (on request)
Hazard light
F12 15A
2nd hazard light (if present)
F13 15A Fitted for front work lights on cab (on request)
Car-radio fitting
F14 10A
Cab light
F15 20A Cab air circulation electro-fan
F16 10A Direction indicator flasher power supply
Roof wiper (upon request)
F17 10A Front and rear wiper
Direct accessory power (BD)
F18 10A Power supply UPD
F19 40A Power supply UCM
Position Type Description
RELAYS AND

I1 Direction lights blinker, emergency lights

BLINKING

LBR Flat battery restoring

RL 5-9 70A Starter motor
RL 19-11 70A UAE signal and Output UCM power supply
RL 3-10 70A Air conditioning compressor

10 - 3
 10 - ELECTRICAL SYSTEM

• FUSES IN ENGINE COMPARTMENT

The fuses and relays located in the engine compartment are protected by cover
(A). Remove cover (A) by unscrewing screws “V” with the hex wrench indicated.

DEUTZ 74 kW (100CV) ENGINE

1) Glow plug relay

2) Fuel pump relay
3) Fuel pump fuse (20A)
4) Engine ECU fuse (30A)
5) Air conditioning fuse (40A)
6) General system fuse (80A)

KUBOTA 55.4 kW (75 CV) ENGINE

1) Glow plug relay

2) Glowplugs fuse (40A)

KUBOTA 55.4 kW (75 CV) ENGINE

1) Glowplug relay
2) Glowplugs fuse (80A)

END OF SECTION

PUBLICATION DATE OF THIS MANUAL: September 2014

10 - 4
 Perkins 2300 Series
Model 2306C-E14

WORKSHOP MANUAL

6 cylinder turbocharged diesel engines for industrial

applications

Publication TSD3455E, Issue 1

© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in September 2002 by Technical Publications,
Perkins Engines Company Limited, Shrewsbury SY1 3NX, England

This document has been printed from SPI². Not for Resale
Chapters

1 General information

2 Specifications

3 Cylinder head assembly

4 Piston and connecting rod assemblies

5 Crankshaft assembly

6 Gear case and drive assembly

7 Crankcase and cylinder liners

8 Engine timing and electronic controls

9 Aspiration system

10 Lubrication system

11 Fuel system

12 Cooling system

13 Flywheel and housing

14 Electrical equipment

15 Auxiliary equipment

16 Special tools
The pages which follow contain a detailed table of contents

ii

This document has been printed from SPI². Not for Resale
 2300

Contents

1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1

Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2

Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4

Welding .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4

Environmental protection ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4

Engine views . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5

Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6

Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6

2 Specifications
Basic engine data - 2306 engine .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7

Basic engine data - 2806 engine .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7

Rocker assemblies ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8

Valves . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9

Valve guides .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 10

Valve springs . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 10

Valve seat inserts .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11

Workshop Manual, TSD3455E, Issue 1 iii

This document has been printed from SPI². Not for Resale
 2300
Cylinder head . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12

Camshaft and bearings . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12

Pistons and connecting rods - 2306 engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13

Pistons and connecting rods - 2806 engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14

Crankshaft, main bearings and flywheel . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15

Crankshaft damper ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15

Crankcase and cylinder liners .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16

Lubricating oil pump . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18

Coolant pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19

Recommended torque figures .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20

3 Cylinder head assembly

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27

Rocker cover
Operation 3-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28

Rocker lever and rocker shaft assemblies

Operation 3-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
Operation 3-3 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
Operation 3-4 How to check/adjust the tappet clearances ... ... ... ... ... ... ... ... ... ... ... 32

Cylinder head assembly

Operation 3-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35

Valve springs
Operation 3-6 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39

Valves
Operation 3-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41

Valve seals
Operation 3-8 To renew . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42

Valve guides
Operation 3-9 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43

Camshaft

iv Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300
Operation 3-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 45
Operation 3-11 How to set the backlash for the camshaft gear ... ... ... ... ... ... ... ... ... . 50

Electronic injector units

Operation 3-12 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 51
Operation 3-13 To check and to adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 53

Injector sleeves
Operation 3-14 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 54

4 Pistons and connecting rod assemblies

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 57

Pistons and connecting rod assemblies

Operation 4-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 58
Operation 4-2 To dismantle and assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 60

Piston cooling jets

Operation 4-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 62

5 Crankshaft assembly
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 63

Crankshaft
Operation 5-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 64

Crankshaft front seal and wear sleeve

Operation 5-2 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 66

Crankshaft rear seal and wear sleeve

Operation 5-3 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 68

Crankshaft vibration damper

Operation 5-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 70

6 Gear case and drive assembly

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 73

Gear case cover

Operation 6-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 74
Workshop Manual, TSD3455E, Issue 1 v

This document has been printed from SPI². Not for Resale
 2300
Timing gears
Operation 6-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 75
Operation 6-3 How to check the position of the timing gears ... ... ... ... ... ... ... ... ... ... 78

Gear case
Operation 6-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79

7 Crankcase and cylinder liners

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81

Front engine support

Operation 7-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 82

Cylinder liners
Operation 7-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Operation 7-3 To check and to adjust the protrusion of the cylinder liners ... ... ... ... ... 84

8 Engine timing and electronic controls

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87

Electronic control module

Operation 8-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88

Engine timing
Operation 8-2 To check . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 89

9 Aspiration system
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 91

Exhaust manifold
Operation 9-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 92

Turbocharger
Operation 9-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 93
Operation 9-3 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 94

vi Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

10 Lubrication system
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 95

Oil filter and oil filter header

Operation 10-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 96

Oil filter header

Operation 10-2 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 98

Sump
Operation 10-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 99

Oil pump
Operation 10-4 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 101
Operation 10-5 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 102

11 Fuel system
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 103

Fuel priming pump

Operation 11-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 104

Fuel transfer pump

Operation 11-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 105
Operation 11-3 To test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 106

Drive for the fuel transfer pump

Operation 11-4 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 107

Fuel filter header

Operation 11-5 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 108

Low pressure fuel system

Operation 11-6 How to eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... 109

12 Cooling system
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 111

Cooling system
Operation 12-1 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 112
Operation 12-2 Leakage test . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 113

Workshop Manual, TSD3455E, Issue 1 vii

This document has been printed from SPI². Not for Resale
 2300
Coolant filler cap
Operation 12-3 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 114

Radiator
Operation 12-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 115

Fan
Operation 12-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 116

Fan drive assembly

Operation 12-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 117

Fan drive belts

Operation 12-7 To check and to adjust the tension ... ... ... ... ... ... ... ... ... ... ... ... ... .. 118
Operation 12-8 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 119

Engine oil cooler

Operation 12-9 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 120

Thermostats and thermostat housing

Operation 12-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 121
Operation 12-11 To test the thermostats ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 123

Coolant temperature sensor

Operation 12-12 To test . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 124

Coolant pump
Operation 12-13 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 125
Operation 12-14 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 126
Operation 12-15 To test the pressure of the coolant pump ... ... ... ... ... ... ... ... ... ... .. 128

13 Flywheel and housing

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 129

Flywheel
Operation 13-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 130

Flywheel housing
Operation 13-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 131

viii Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

14 Electrical equipment
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 133

Starter motor
Operation 14-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 134

Alternator
Operation 14-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 135
Operation 14-3 To check and to adjust the tension of the alternator belt .. ... ... ... ... ... 136
Operation 14-4 To renew the alternator belt . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 137

15 Auxiliary equipment
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 139

Oil sample valve ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 139

16 Special tools
List of special tools .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 141

Workshop Manual, TSD3455E, Issue 1 ix

This document has been printed from SPI². Not for Resale
 2300

x Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

1
General information 1

Introduction
The 2300 and 2800 Series engines are from Perkins Engines Company Limited, a world leader in the design
and manufacture of high-performance diesel engines.
Perkins approved assembly and quality standards, together with the latest technology, have been applied to
the manufacture of your engine to give you reliable and economic power.
This Workshop Manual has been designed to provide assistance in the service and the overhaul of Perkins
2300 and 2800 Series engines. Most of the general information, which is included in the User’s Handbook
(Chapters 1 to 6), has not been repeated in this Workshop Manual and the two publications should be used
together.
To ensure that you use the relevant information for your specific engine type, refer to "Engine identification"
on page 6.
When reference is made to the "left" or "right" side of the engine, this is as seen from the flywheel end of the
engine.
Special tools have been made available and a list of these is given in Chapter 16, Special tools. Reference to
the relevant special tools is also made at the beginning of each operation.
Data and dimensions are included in Chapter 2, Specifications.
Read the "Safety precautions" on page 2 and remember them. They are given for your protection and must be
applied at all times.
In addition to the general safety precautions, danger to both operator and engine are highlighted by the
following conventions:
Warning! This indicates that there is a possible danger to the person (or the person and engine).
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.

Workshop Manual, TSD3455E, Issue 1 1

This document has been printed from SPI². Not for Resale
1 2300
Safety precautions
These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only apply to specific applications.
l Always refer to the text of this handbook for specific warnings and cautions.
l Only use these engines in the type of application for which they have been designed.
l Do not change the specification of the engine.
l Do not make adjustments that you do not understand.
l Do not allow the engine to stand on its sump.
l Do not smoke when you put fuel in the tank.
l Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
l Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
l Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme caution must be used to prevent injury).
l Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
l Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
l Do not permit loose clothing or long hair near moving parts.
Warning! Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly
while the engine runs.
l Do not operate the engine if a safety guard has been removed.
l Do not remove the filler cap or any component of the coolant system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
l Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
l Disconnect the battery terminals before a repair is made to the electrical system. Always disconnect the
negative terminal first.
l Only one person must control the engine.
l Ensure that the engine is operated only from the control panel or from the operator’s position.
l If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
l Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
l Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets.
l Discard used lubricating oil and coolant in accordance with local regulations to prevent contamination.
l The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
Continued

2 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 1
l Always use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.
l Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
l Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
l Some components are not waterproof and should not be washed with a high-pressure water jet or steam.
l Fit only genuine Perkins parts.

Workshop Manual, TSD3455E, Issue 1 3

This document has been printed from SPI². Not for Resale
1 2300
Viton seals
Some seals used in engines and in components fitted to engines are made from Viton (fluorocarbon).
Viton is used by many manufacturers and is a safe material under normal conditions of operation.
If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this
burnt material to come into contact with the skin or with the eyes.
If it is necessary to come into contact with components which have been burnt, ensure that the precautions
which follow are used:
l Ensure that the components have cooled.
l Use Neoprene gloves and discard the gloves safely after use.
l Wash the area with a calcium hydroxide solution and then with clean water.
l Disposal of gloves and components which are contaminated, must be in accordance with local regulations.
If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or
with a calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

Welding
Welding can cause damage to the electronic components fitted to the engine. If welding is necessary, the
precautions which follow must be undertaken before and during the welding operation.

Cautions:
l Switch off the engine.
l Disconnect the cable from the negative terminal of the battery. If the machine is fitted with a battery
disconnect the switch then open the switch.
l If welding to the engine, remove the ECM (electronic control module).
l If welding onto the machine chassis, ensure that the earth clamp is attached as close to the welding point
as possible and NOT near to the ECM.
l If it is necessary to weld near to the ECM, remove the ECM from the engine.

Environmental protection
There is legislation to protect the environment from the incorrect disposal of used lubricating oil. To ensure that
the environment is protected, consult your Local Authority who can give advice.

4 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 1
Engine views

Workshop Manual, TSD3455E, Issue 1 5

This document has been printed from SPI². Not for Resale
1 2300
Engine identification
If you need parts, service or information for your engine, you must give the complete engine number. The
engine number is stamped on a data plate which is fastened to the right side of the engine.
A typical engine number is: HGA060125U 1103H, which consists of these codes:
H Code for engine capacity
G Engine application
A Engine type
06 Number of engine cylinders
0125 Engine specification number
U The country of manufacture
1103 Build line number
H Year of manufacture

Engine lift equipment

A dry engine weighs approximately 1551 kg (3,419 lb). Ensure that the lift equipment used is suitable. An
adjustable lifting beam should be used and the chains or cables must be parallel to each other during use.
Before the engine is lifted:
l Always use lift equipment of the approved type and of the correct capacity to lift the engine. Never use a
single lift bracket to raise an engine.
l Check the engine lift brackets for damage and security before the engine is lifted.
Use suitable lift equipment or obtain assistance to lift heavy engine components such as the cylinder block,
cylinder head, damper unit, flywheel housing, crankshaft and flywheel.
Warning! The lifting eyes which are fitted to the engine must be used for lifting only the engine. Do NOT use
them to lift the engine if it is still attached to its driven unit.

6 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

2
Specifications 2

Basic engine data - 2306 engine

Number of cylinders. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
Cylinder arrangement .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .In line
Cycle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Four stroke
Induction system.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Turbocharged
Combustion system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Direct injection
Nominal bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 137 mm (5.394 in)
Nominal stroke. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 165 mm (6.496 in)
Compression ratio ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15.9:1
Cubic capacity . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14,6 litres (893 in3)
Firing order .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1, 5, 3, 6, 2, 4
Direction of rotation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Anti-clockwise viewed on flywheel
Lubricating oil capacity:
Total system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..68 litres (120 UK pints)
Sump maximum... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..60 litres (106 UK pints)
Sump minimum ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45 litres (79 UK pints)
Lubricating oil pressure:
At rated speed . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4,5 bar
Typical coolant capacity of engine... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20,8 litres (4.6 UK gallons)
Typical coolant capacity of engine and radiator .. ... ... ... ... ... ... ... ... ... ... ... ... ... .47 litres (10.3 UK gallons)

Basic engine data - 2806 engine

Number of cylinders. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
Cylinder arrangement .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .In line
Cycle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Four stroke
Induction system.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Turbocharged
Combustion system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Direct injection
Nominal bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 140 mm (5.512 in)
Nominal stroke. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 171 mm (6.732 in)
Compression ratio ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15.9:1
Cubic capacity . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...15,8 litres (964.18 in3)
Firing order .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1, 5, 3, 6, 2, 4
Direction of rotation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Anti-clockwise viewed on flywheel
Lubricating oil capacity:
Total system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..68 litres (120 UK pints)
Sump maximum... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..60 litres (106 UK pints)
Sump minimum ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45 litres (79 UK pints)
Lubricating oil pressure:
At rated speed . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4,5 bar
Typical coolant capacity of engine... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20,8 litres (4.6 UK gallons)
Typical coolant capacity of engine and radiator .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50 litres (11 UK gallons)

Workshop Manual, TSD3455E, Issue 1 7

This document has been printed from SPI². Not for Resale
2 2300

Rocker assemblies
Rocker shaft diameter (A2) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40,000 +/- 0,010 mm (1.5748 +/- 0.0004 in)
Valve rocker lever bore (A1) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40,065 +/- 0,015 mm (1.5774 +/- 0.0006 in)
Bearing clearance between valve rocker lever and shaft .. ... ... ... ... 0,040 to 0,090 mm (0.0016 to 0.0035 in)
Unit injector rocker lever bore (A3) ... ... ... ... ... ... ... ... ... ... ... ... 43,000 +/- 0,020 mm (1.6929 +/- 0.0008 in)
If a new bearing is fitted to the unit injector rocker lever, the oil hole in the bearing must be aligned with the oil
passage in the rocker lever within 2,4 mm (0.09 in). The bearing must not extend beyond either face of the
rocker lever.
Bore in the rocker lever bearing (A4) . ... ... ... ... ... ... ... ... ... ... ... . 40,065 +/- 0,15 mm (1.5774 +/- 0.0006 in)
Maximum permissible worn dimension .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...40,193 (1.5824 in)

8 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 2
Valves
Diameter of valve stem (B1) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9,441 +/- 0,010 mm (0.3717 +/- 0.0004 in)
Permissible worn dimension ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9,408 mm (0.3704 in)
Diameter of valve head (B3):
Inlet valve ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 47,00 +/- 0,13 mm (1.850 +/- 0.005 in)
Exhaust valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 41,81 +/- 0,13 mm (1.646 +/- 0.005 in)
Angle of face of valve (B2):
Inlet valve ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29 1/4 +/- 1/4 degrees
Exhaust valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44 1/4 +/- 1/4 degrees
Minimum thickness of valve lip (B4):
Inlet valve ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,75 mm (0.108 in)
Exhaust valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,05 mm (0.081 in)
Length of valve:
Inlet.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 202,00 +/- 0,45 mm (7.953 +/- 0.018 in)
Exhaust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 202,06 +/- 0,45 mm (7.955 +/- 0.018 in)

Workshop Manual, TSD3455E, Issue 1 9

This document has been printed from SPI². Not for Resale
2 2300
Valve guides
Bore of valve guide when installed ... ... ... ... ... ... ... ... ... ... ... ... ... 9,487 +/- 0,025 mm (0.3735 +/- 0.010 in)
Maximum permissible dimension... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..9,538 mm (0.3755 in)
Do not use a combination of a valve and valve guide which have a difference of 0,13 mm (0.005 in) or more.
Height from cylinder head to top of valve guide (C1). ... ... ... ... ... ... ... 35,00 +/- 0,50 mm (1.378 +/- 0.020 in)

Valve springs
Inner
Assembled length .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 60,14 mm (2.368 in)
Load at assembled length.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..118 +/- 12 N (27 +/- 3 lb)
Minimum operating length.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44,02 mm (1.733 in)
Load at minimum operating length. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..356 +/- 18 N (80 +/- 4 lb)
Free length after test.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 71,03 mm (2.797 in)
Outside diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25,20 mm (0.992 in)
Outer
Assembled length .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 67,12 mm (2.643 in)
Load at assembled length.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..248 +/- 25 N (56 +/- 6 lb)
Minimum operating length.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51,00 mm (2.008 in)
Load at minimum operating length. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 756 +/- 35 N (165 +/- 8 lb)
Free length after test.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77,88 mm (3.066 in)
Outside diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36,30 mm (1.429 in)

10 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 2
Valve seat inserts
Depth of bore in cylinder head for valve seat insert (D5):
Inlet valve ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14,00 +/- 0,10 mm (0.551 +/- 0.004 in)
Exhaust valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13,90 +/- 0,10 mm (0.547 +/- 0.004 in)
Diameter of valve seat insert (D2):
Inlet valve ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48,025 +/- 0,13 mm (1.8907 +/- 0.0005 in)
Exhaust valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42,840 +/- 0,13 mm (1.6866 +/- 0.0005 in)
Bore in cylinder head for valve seat insert (D2):
Inlet valve ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 47,950 +/- 0,025 mm (1.8878 +/- 0.0010 in)
Exhaust valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 42,774 +/- 0,025 mm (1.6840 +/- 0.0010 in)
Angle of face of valve seat insert (D1):
Inlet valve insert... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30 1/4 +/- 1/2 degrees
Exhaust valve insert ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45 1/4 +/- 1/2 degrees
Valve recess (D4):
Inlet valve (new parts) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2,20 to 2,80 mm (0.087 to 0.110 in)
Exhaust valve (new parts) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1,20 to 1,80 mm (0.047 to 0.071 in)
Inlet valve (reconditioned parts) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2,20 to 3,29 mm (0.087 to 0.129 in)
Exhaust valve (reconditioned parts) ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1,20 to 2,29 mm (0.047 to 0.090 in)
Minimum recommended width of valve seat (D3):
Inlet.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,00 mm (0.079 in)
Exhaust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,25 mm (0.049 in)

Workshop Manual, TSD3455E, Issue 1 11

This document has been printed from SPI². Not for Resale
2 2300
Cylinder head
Thickness of cylinder head (new) .. ... ... ... ... ... ... ... ... ... ... ... ... ... . 120,00 +/- 0,15 mm (4.724 +/- 0.006 in)
Minimum thickness for a used cylinder head . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..119,50 mm (4.705 in)
Flatness of cylinder head: The cylinder head must be flat to within a total of 0,13 mm (0.005 in). Additionally,
the cylinder head must be flat within a maximum of 0,03 mm (0.001 in) across any 76,2 mm (3.00 in) span.

Camshaft and bearings

Diameter of camshaft journal (E3) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84,85 +/- 0,02 mm (3.341+/- 0.001 in)
Exhaust lobe lift.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..8,515 mm (0.3352 in)
Inlet lobe lift ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..9,431 mm (0.3713 in)
Injector lobe lift... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10,451 mm (0.4114 in)
Maximum permissible difference between the actual lobe lift (E7)
and the specified dimension .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,0 mm (0.0394 in)
To obtain the lobe lift (E7) proceed as follows: Measure the lobe height (E5) and measure the base circle (E6).
Subtract the base circle from the lobe height to give the lobe lift.

12 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 2
Pistons and connecting rods - 2306 engine
Piston ring gaps measured with the ring fitted in a new liner with a bore size 137.16 mm (5.400 in):
Top piston ring (F4) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,55 +/- 0,15 mm (0.022 +/- 0.006 in)
Intermediate ring (F3) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,83 +/- 0,15 mm (0.033 +/- 0.006 in)
Oil control ring (F2).. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,550 +/- 0,15 mm (0.022 +/- 0.0059 in)
Width of groove for oil control ring in new piston. ... ... ... ... ... ... ... ... . 4,03 +/- 0,01 mm (0.159 +/- 0.0004 in)
Thickness of a new oil control ring .. ... ... ... ... ... ... ... ... ... ... ... ... ... 3,98 +/- 0,01 mm (0.1567 +/- 0.0004 in)
Clearance between piston ring groove and new oil control ring .. ... ... . 0,05 +/- 0,02 mm (0.002 +/- 0.0008 in)
Maximum permissible clearance between piston
ring groove and a used oil control ring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,15 mm (0.006 in)
Bore of piston crown bearing (F1) ... ... ... ... ... ... ... ... ... ... ... . 55,0355 +/- 0,0055 mm (2.1667 +/- 0.0002 in)
Bore of piston skirt bearing (F1) .. ... ... ... ... ... ... ... ... ... ... ... ... . 55,020 +/- 0,005 mm (2.1661 +/- 0.0002 in)
Gudgeon pin diameter (F1) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 55,000 +/- 0,005 mm (2.1654 +/- 0.0002 in)
Length of gudgeon pin. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 113,20 +/- 0,15 mm (4.457 +/- 0.006 in)
Bore in connecting rod for small end bearing (F7) .. ... ... ... ... ... . 59,640 +/- 0,013 mm (2.3480 +/- 0.0005 in)
Bore of connecting rod small end bearing (F6) ... ... ... ... ... ... ... . 55,035 +/- 0,008 mm (2.1667 +/- 0.0003 in)
Bore in connecting rod for big end bearing shells (F5) ... ... ... ... . 96,200 +/- 0,013 mm (3.7874 +/- 0.0005 in)
Distance between centres of big and small end bearings (F8) ... ... . 261,62 +/- 0,05 mm (10.300 +/- 0.002 in)

Workshop Manual, TSD3455E, Issue 1 13

This document has been printed from SPI². Not for Resale
2 2300
Pistons and connecting rods - 2806 engine
Piston ring gaps measured with the ring fitted in a new liner with a bore size 139,66 mm (5.498 in):
Top piston ring (F4) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 0,50 +/- 0,10 mm (0.020 +/- 0.004 in)
Intermediate ring (F3) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 0,83 +/- 0,15 mm (0.033 +/- 0.006 in)
Oil control ring (F2) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 0,450 +/- 0,150 mm (0.0177 +/- 0.0059 in)
Width of groove for oil control ring in new piston ... ... ... ... ... ... ... . 4,033 +/- 0,013 mm (0.1588 +/- 0.0005 in)
Thickness of a new oil control ring. ... ... ... ... ... ... ... ... ... ... ... ... . 3,980 +/- 0,010 mm (0.1567 +/- 0.0004 in)
Clearance between piston ring groove and new oil control ring ... . 0,053 +/- 0,023 mm (0.0021 +/- 0.0009 in)
Maximum permissible clearance between piston
ring groove and a used oil control ring... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,15 mm (0.006 in)
Bore of piston crown bearing (F1).. ... ... ... ... ... ... ... ... ... ... ... 55,0355 +/- 0,0055 mm (2.1667 +/- 0.0002 in)
Bore of piston skirt bearing (F1). ... ... ... ... ... ... ... ... ... ... ... ... ... 55,020 +/- 0,005 mm (2.1661 +/- 0.0002 in)
Gudgeon pin diameter (F1) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 55,000 +/- 0,005 mm (2.1654 +/- 0.0002 in)
Length of gudgeon pin ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 113,20 +/- 0,15 mm (4.457 +/- 0.006 in)
Bore in connecting rod for small end bearing (F7). ... ... ... ... ... ... 59,640 +/- 0,013 mm (2.3480 +/- 0.0005 in)
Bore of connecting rod small end bearing (F6).. ... ... ... ... ... ... ... 55,035 +/- 0,008 mm (2.1667 +/- 0.0003 in)
Bore in connecting rod for big end bearing shells (F5) .. ... ... ... ... 96,200 +/- 0,013 mm (3.7874 +/- 0.0005 in)
Distance between centres of big and small end bearings (F8) .. ... ... 261,62 +/- 0,05 mm (10.300 +/- 0.002 in)

14 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 2
Crankshaft, main bearings and flywheel
Diameter of main bearing journal (G2) ... ... ... ... ... ... ... ... ... ... 120,650 +/- 0,020 mm (4.7500 +/- 0.0008 in)
Journal undersize by 0,63 mm (0.025 in) ... ... ... ... ... ... ... ... ... ... .. 120,015 +/- 0,020 (4.7250 +/- 0.0008 in)
Journal undersize by 1,27 mm (0.050 in) ... ... ... ... ... ... ... ... ... 119,380 +/- 0,020 mm (4.7000 +/- 0.0008 in)
Clearance between a new bearing and the journal (G3) . ... ... ... ... .. 0,091 to 0,186 mm (0.0036 to 0.0073 in)
Maximum permissible clearance between the
bearing and journal.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,25 mm (0.010 in)
Diameter of main bearing bore ... ... ... ... ... ... ... ... ... ... ... ... ... 129,891 +/- 0,013 mm (5.1138 +/- 0.0005 in)
Diameter of main bearing bore, oversize by 0,63 mm (0.025 in). 130,526 +/- 0,013 mm (5.1388 +/- 0.0005 in)
Diameter of connecting rod journal (G4) . ... ... ... ... ... ... ... ... ... . 90,000 +/- 0,020 mm (3.5433 +/- 0.0008 in)
Journal undersize by 0,63 mm (0.025 in) ... ... ... ... ... ... ... ... ... ... ... 89,370 +/- 0,020 (3.5185 +/- 0.0008 in)
Journal undersize by 1,27 mm (0.050 in) ... ... ... ... ... ... ... ... ... . 88,730 +/- 0,020 mm (3.4933 +/- 0.0008 in)
Clearance between a new bearing and the journal . ... ... ... ... ... ... .. 0,062 to 0,160 mm (0.0024 to 0.0063 in)
Maximum permissible clearance between the
bearing and journal.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,20 mm (0.008 in)
End-float of crankshaft. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 0,15 to 0,55 mm (0.006 to 0.022 in)
Maximum permissible end-float (with used bearings) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,89 mm (0.035 in)
Maximum protrusion of dowel (G1) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6,4 mm (0.25 in)

Crankshaft damper
Maximum permissible run-out of face of damper ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,03 mm (0.080 in)

Workshop Manual, TSD3455E, Issue 1 15

This document has been printed from SPI². Not for Resale
2 2300
Crankcase and cylinder liners
Thickness of spacer plate (H3) .. ... ... ... ... ... ... ... ... ... ... ... ... ... . 8,585 +/- 0,025 mm (0.3380 +/- 0.0010 in)
Thickness of gasket fitted between spacer plate and crankcase... . 0,238 +/- 0,032 mm (0.0094 +/- 0.0013 in)
Cylinder liner protrusion (H5) above the spacer plate ... ... ... ... ... ... 0,025 to 0,152 mm (0.0010 to 0.0060 in)
Maximum variation in each cylinder liner ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,051 mm (0.0020 in)
Maximum average variation between adjacent cylinder liners... ... ... ... ... ... ... ... ... ... ..0,051 mm (0.0020 in)
Maximum variation between all cylinder liners... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,102 mm (0.0040 in)
Refer to Operation 7-3 for further cylinder liner information.
Protrusion of front cylinder head dowel (H6) above top face of crankcase ... 16,0 +/- 0,5 mm (0.63 +/- 0.02 in)
Protrusion of rear cylinder head dowel (H4) above top face of crankcase ... 18,5 +/- 0,5 mm (0.73 +/- 0.02 in)
Protrusion of oil transfer tube (H7) above top face of crankcase... ... ... ... ... 20,0 +/- 0,5 mm (0.79 +/- 0.02 in)
Protrusion of flywheel housing dowels (H1) from rear face of crankcase .. ... 19,1 +/- 0,5 mm (0.75 +/- 0.02 in)
Protrusion of gear case dowels (H8) from front face of crankcase ... ... ... ... 19,1 +/- 0,5 mm (0.75 +/- 0.02 in)
Plug (H2) must be tightened to a torque of ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 70 +/- 10 Nm (52 +/- 7 lbf ft)
The total flatness of the top face of the crankcase must be within 0,10 mm (0.004 in). The flatness must also
be within 0,05 mm (0.002 in) for any 177,5 mm (6.99 in) section of the surface.

Continued

16 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 2
Distance from top of crankcase to centre of main
bearing bore (J1) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 425,45 +/- 0,15 mm (16.750 +/- 0.006 in)
Minimum permissible (J1) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 425,02 mm (16.733 in)
Distance from bottom of crankcase to centre of main
bearing bore (J2) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 165,10 +/- 0,10 mm (6.500 +/- 0.004 in)
Bore in new cylinder liner - 2306 engine (K1).. ... ... ... ... ... ... ... 137,185 +/- 0,025 mm (5.4010 +/- 0.0010 in)
Bore in new cylinder liner - 2806 engine (K1).. ... ... ... ... ... ... ... 139,685 +/- 0,025 mm (5.4994 +/- 0.0010 in)
Thickness of liner flange (K2) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8,890 +/- 0,020 mm (0.3500 +/- 0.0008 in)
Minimum thickness permissible (K2) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8,870 mm (0.3492 in)

Workshop Manual, TSD3455E, Issue 1 17

This document has been printed from SPI². Not for Resale
2 2300
Lubricating oil pump
Diameter of shafts (L1) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22,217 +/- 0,005 mm (0.8747 +/- 0.0002 in)
Diameter of bores in cover for shafts . ... ... ... ... ... ... ... ... ... ... ... 22,258 +/- 0,008 mm (0.8763 +/- 0.0003 in)
Length of gears (L3)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79,375 +/- 0,025 mm (3.1250 +/- 0.0010 in)
Depth of bores for gears (L3). ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79,502 +/- 0,020 mm (3.1300 +/- 0.0008 in)
Spring (L2):
Test force ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 150 +/- 8 Nm (110 +/- 6 lbf ft)
Length under test force .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..117,9 mm (4.64 in)
Free length after test.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..152,9 mm (6.02 in)
Outside diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .27 mm (1.063 in)

18 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 2
Coolant pump
Shaft diameter at the position of the coolant seal (M1) ... ... ... ... ... . 19,10 +/- 0,01 mm (0.7520 +/- 0.0004 in)

Workshop Manual, TSD3455E, Issue 1 19

This document has been printed from SPI². Not for Resale
2 2300
Recommended torque figures
Exceptions to these torque figures are given in the Workshop Manual where necessary.
Before any components are fitted to the engine, ensure that they are in a new or close to new condition. Bolts
or threads must not be worn or damaged. Components must be free from rust or other corrosion. Clean with
a non-corrosive cleaner if necessary. Do not lubricate the threads of fasteners. Rust preventative which has
been applied by the component supplier for shipping and storage is acceptable. Certain components may
require an application of a particular lubricant, details are given in the Workshop Manual where relevant.

Standard torque figures for metric fasteners

Metric nuts and bolts

Thread size
Standard torque
metric
M6 12 +/- 3 Nm (9 +/- 2 lbf ft)
M8 28 +/- 7 Nm (21 +/- 5 lbf ft)
M10 55 +/- 10 Nm (41 +/- 7 lbf ft)
M12 100 +/- 20 Nm (75 +/- 15 lbf ft)
M14 160 +/- 30 Nm (120 +/- 22 lbf ft)
M16 240 +/- 40 Nm (175 +/- 30 lbf ft)
M20 460 +/- 60 Nm (340 +/- 44 lbf ft)
M24 800 +/- 100 Nm (590 +/- 75 lbf ft)
M30 1600 +/- 200 Nm (1180 +/- 150 lbf ft)
M36 2700 +/- 300 Nm (2000 +/- 220 lbf ft)

Metric taperlock studs

Thread size
Standard torque
metric
M6 8 +/- 3 Nm (6 +/- 2 lbf ft)
M8 17 +/- 5 Nm (13 +/- 4 lbf ft)
M10 35 +/- 5 Nm (26 +/- 4 lbf ft)
M12 65 +/- 10 Nm (48 +/- 7 lbf ft)
M16 110 +/- 20 Nm (80 +/- 15 lbf ft)
M20 170 +/- 30 Nm (125 +/- 22 lbf ft)
M24 400 +/- 60 Nm (300 +/- 44 lbf ft)
M30 750 +/- 80 Nm (550 +/- 60 lbf ft)
M36 1200 +/- 150 Nm (880 +/- 110 lbf ft)

20 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 2
Standard torque figures for imperial fasteners

Imperial nuts and bolts

Thread size
Standard torque
inches
1/4 12 +/- 3 Nm (9 +/- 2 lbf ft)
5/16 25 +/- 6 Nm (18 +/- 4 lbf ft)
3/8 47 +/- 9 Nm (35 +/- 7 lbf ft)
7/16 70 +/- 15 Nm (50 +/- 11 lbf ft)
1/2 105 +/- 20 Nm (75 +/- 15 lbf ft)
9/16 160 +/- 30 Nm (120 +/- 22 lbf ft)
5/8 215 +/- 40 Nm (160 +/- 30 lbf ft)
3/4 370 +/- 50 Nm (275 +/- 37 lbf ft)
7/8 620 +/- 80 Nm (460 +/- 60 lbf ft)
1 900 +/- 100 Nm (660 +/- 75 lbf ft)
1 1/8 1300 +/- 150 Nm (960 +/- 110 lbf ft)
1 1/4 1800 +/- 200 Nm (1320 +/- 150 lbf ft)
1 3/8 2400 +/- 300 Nm (1780 +/- 220 lbf ft)
1 1/2 3100 +/- 350 Nm (2280 +/- 260 lbf ft)

Imperial taperlock studs

Thread size
Standard torque
inches
1/4 8 +/- 3 Nm (6 +/- 2 lbf ft)
5/16 17 +/- 5 Nm (13 +/- 4 lbf ft)
3/8 35 +/- 5 Nm (26 +/- 4 lbf ft)
7/16 45 +/- 10 Nm (33 +/- 7 lbf ft)
1/2 65 +/- 10 Nm (48 +/- 7 lbf ft)
5/8 110 +/- 20 Nm (80 +/- 15 lbf ft)
3/4 170 +/- 30 Nm (125 +/- 22 lbf ft)
7/8 260 +/- 40 Nm (190 +/- 30 lbf ft)
1 400 +/- 60 Nm (300 +/- 44 lbf ft)
1 1/8 525 +/- 60 Nm (390 +/- 44 lbf ft)
1 1/4 750 +/- 80 Nm (550 +/- 60 lbf ft)
1 3/8 950 +/- 125 Nm (700 +/- 90 lbf ft)
1 1/2 1200 +/- 150 Nm (880 +/- 110 lbf ft)

Workshop Manual, TSD3455E, Issue 1 21

This document has been printed from SPI². Not for Resale
2 2300
Standard torque figures for ‘O’ ring face seal fittings and 37 degree flared fittings

Torque figures for ferrous straight thread ‘O’ ring fittings when connected to ferrous materials
Thread size Standard
Outside diameter of nominal tube
Inches torque
3,18 mm 5,0 +/- 1,5 Nm
5/16 - 24
(0.125 in) (4 +/- 1 lbf ft)
4,76 mm 12 +/- 2 Nm
3/8 - 24
(0.188 in) (9 +/- 1 lbf ft)
6,35 mm 22 +/- 2 Nm
7/16 - 20
(0.250 in) (16 +/- 1 lbf ft)
7,94 mm 30 +/- 3 Nm
1/2 - 20
(0.312 in) (22 +/- 2 lbf ft)
9,52 mm 48 +/- 5 Nm
9/16 - 18
(0.375 in) (35 +/- 4 lbf ft)
12,70 mm 82 +/- 8 Nm
3/4 - 16
(0.500 in) (60 +/- 6 lbf ft)
15,88 mm 143 +/- 15 Nm
7/8 - 14
(0.625 in) (105 +/- 11 lbf ft)
19,05 mm 190 +/- 20 Nm
1 1/16 - 12
(0.750 in) (140 +/- 15 lbf ft)
22,22 mm 250 +/- 25 Nm
1 3/16 - 12
(0.875 in) (185 +/- 18 lbf ft)
25,40 mm 300 +/- 30 Nm
1 5/16 - 12
(1.000 in) (220 +/- 22 lbf ft)
31,75 mm 350 +/- 30 Nm
1 5/8 - 12
(1.250 in) (260 +/- 22 lbf ft)
38,10 mm 430 +/- 40 Nm
1 7/8 - 12
(1.500 in) (320 +/- 30 lbf ft)
50,80 mm 450 +/- 45 Nm
2 1/2 - 12
(2.000 in) (330 +/- 33 lbf ft)

Note: For the table above, use 50 percent of the torque figure when the fitting, the plug or the port material is
nonferrous.
Examples of relevant fittings are shown (A): ‘O’ ring face seal (A1), 37 degree flare (A2) and plug with a
hexagon or socket-type head (A3).

22 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 2
‘O’ ring face seal fittings

Torque figures for ferrous straight thread ‘O’ ring fittings (B)
Thread size
Standards torque
inches
1/4 8 +/- 3 Nm (6 +/- 2 lbf ft)
5/16 17 +/- 5 Nm (13 +/- 4 lbf ft)
3/8 35 +/- 5 Nm (26 +/- 4 lbf ft)
7/16 45 +/- 10 Nm (33 +/- 7 lbf ft)
1/2 65 +/- 10 Nm (48 +/- 7 lbf ft)
5/8 110 +/- 20 Nm (80 +/- 15 lbf ft)
3/4 170 +/- 30 Nm (125 +/- 22 lbf ft)
7/8 260 +/- 40 Nm (190 +/- 30 lbf ft)
1 400 +/- 60 Nm (300 +/- 44 lbf ft)
1 1/8 525 +/- 60 Nm (390 +/- 44 lbf ft)
1 1/4 750 +/- 80 Nm (550 +/- 60 lbf ft)
1 3/8 950 +/- 125 Nm (700 +/- 90 lbf ft)
1 1/2 1200 +/- 150 Nm (880 +/- 110 lbf ft)

Workshop Manual, TSD3455E, Issue 1 23

This document has been printed from SPI². Not for Resale
2 2300
Torque figures for flared and ‘O’ ring fittings
The torque figures given in the table below and the table given on page 17 should be applied to the nut of the
fittings which follow: 37 degree flared fittings (C1), 45 degree flared fittings (C3), inverted flared fittings (C2),
‘O’ ring fittings for a recessed drive, ‘O’ ring fittings for air conditioning and swivel nuts (C2). The figures should
be used for applications which allow these working pressures: 7750 to 34450 kPa (1125 to 5000 lb/in²). The
torque figure depends on the size and type of fitting.
Nuts for 37 degree flared fittings
Thread size Standard
Outside diameter of nominal tube
Inches torque
3,18 mm 5,0 +/- 1,5 Nm
5/16
(0.125 in) (4 +/- 1 lbf ft)
4,76 mm 11 +/- 2 Nm
3/8
(0.188 in) (8 +/- 1 lbf ft)
6,35 mm 16 +/- 4 Nm
7/16
(0.250 in) (12 +/- 3 lbf ft)
7,94 mm 20 +/- 5 Nm
1/2
(0.312 in) (15 +/- 4 lbf ft)
9,52 mm 25 +/- 5 Nm
9/16
(0.375 in) (18 +/- 4 lbf ft)
9,52 mm 35 +/- 5 Nm
5/8
(0.375 in) (26 +/- 4 lbf ft)
12,70 mm 50 +/- 7 Nm
3/4
(0.500 in) (37 +/- 5 lbf ft)
15,88 mm 65 +/- 7 Nm
7/8
(0.625 in) (48 +/- 5 lbf ft)
19,05 mm 100 +/- 10 Nm
1 1/16
(0.750 in) (75 +/- 7 lbf ft)
22,22 mm 120 +/- 10 Nm
1 3/16
(0.875 in) (90 +/- 7 lbf ft)
25,40 mm 135 +/- 15 Nm
1 5/16
(1.000 in) (100 +/- 11 lbf ft)
31,75 mm 180 +/- 15 Nm
1 5/8
(1.250 in) (135 +/- 11 lbf ft)
38,10 mm 225 +/- 15 Nm
1 7/8
(1.500 in) (165 +/- 11 lbf ft)
50,80 mm 320 +/- 30 Nm
2 1/2
(2.000 in) (240 +/- 22 lbf ft)

Note: For the table above, use 50 percent of the torque figure when the fitting, the plug or the port material is
nonferrous.

24 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 2
45 degree flared and 45 degree inverted flare fittings

45 degree flared and 45 degree inverted flare fittings

Thread size Standard
Outside diameter of nominal tube
Inches torque
3,18 mm 5,0 +/- 1,5 Nm
5/16
(0.125 in) (4 +/- 1 lbf ft)
4,76 mm 8 +/- 1,5 Nm
3/8
(0.188 in) (6 +/- 1 lbf ft)
6,35 mm 11 +/- 2 Nm
7/16
(0.250 in) (8 +/- 1 lbf ft)
7,94 mm 17 +/- 3 Nm
1/2
(0.312 in) (13 +/- 2 lbf ft)
9,52 mm 30 +/- 3 Nm
5/8
(0.375 in) (22 +/- 2 lbf ft)
11,11 mm 30 +/- 3 Nm
11/16
(0.438 in) (22 +/- 2 lbf ft)
12,70 mm 38 +/- 4 Nm
3/4
(0.500 in) (28 +/- 3 lbf ft)
15,88 mm 50 +/- 5 Nm
7/8
(0.625 in) (37 +/- 4 lbf ft)
19,05 mm 90 +/- 8 Nm
1 1/16
(0.750 in) (65 +/- 6 lbf ft)
22,22 mm 100 +/- 10 Nm
1 1/4
(0.875 in) (75 +/- 7 lbf ft)

Tapered pipe thread fittings

Tapered pipe thread fittings

Standard torque
Thread size
Inches Threads with pipe sealant
Threads without pipe sealant
(CV60891)
1/16 - 27 10 Nm (7 lbf ft) 10 Nm (7 lbf ft)
1/8 - 27 16 Nm (12 lbf ft) 16 Nm (12 lbf ft)
1/4 - 18 20 Nm (15 lbf ft) 25 Nm (18 lbf ft)
3/8 - 18 35 Nm (26 lbf ft) 45 Nm (33 lbf ft)
1/2 - 14 45 Nm (33 lbf ft) 60 Nm (44 lbf ft)
3/4 - 14 60 Nm (44 lbf ft) 75 Nm (55 lbf ft)
1 - 11 1/2 75 Nm (55 lbf ft) 90 Nm (65 lbf ft)
1 1/4 - 11 1/2 90 Nm (65 lbf ft) 110 Nm (80 lbf ft)
1 1/2 - 11 1/2 110 Nm (80 lbf ft) 130 Nm (95 lbf ft)
2 - 11 1/2 130 Nm (95 lbf ft) 160 Nm (120 lbf ft)

Note: For the table above, use 50 percent of the torque figure when the fitting, the plug or the port material is
nonferrous.

Workshop Manual, TSD3455E, Issue 1 25

This document has been printed from SPI². Not for Resale
2 2300
Torque figures for standard hose clamps of the worm drive band type

Torque figure for initial

Width of clamp
installation on a new hose
7,9 mm (0.31 in) 0,9 +/- 0,2 Nm (8 +/- 2 lbf in)
13,5 mm (0.53 in) 4,5 +/- 0,5 Nm (40 +/- 4 lbf in)
15,9 mm (0.63 in) 7,5 +/- 0,5 Nm (65 +/- 4 lbf in)
Width of clamp Torque figure for used clamp
7,9 mm (0.31 in) 0,7 +/- 0,2 Nm (6 +/- 2 lbf in)
13,5 mm (0.53 in) 3,0 +/- 0,5 Nm (27 +/- 4 lbf in)
15,9 mm (0.63 in) 4,5 +/- 0,5 Nm (40 +/- 4 lbf in)

Torque figures for constant torque hose clamps

Use a torque wrench for the correct installation of a constant torque hose clamp. For a constant torque hose
clamp to be installed correctly, these conditions must exist:
The screw tip (D1) must extend by 6,35 mm (0.250 in) beyond the housing (D2).
The belleville washers must be collapsed almost flat after the screw (D3) has been tightened to a torque of
11 +/- 1 Nm (98 +/- 9 lb in).

26 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

3
Cylinder head assembly 3

General information
The cylinder head is a single-piece cast iron component. The camshaft is mounted in the cylinder head and
runs in shell bearings. The bearings are pressed into each journal and are lubricated under pressure. Bridge
piece guides have been eliminated as floating valve bridges have been utilised.
Special thermal sleeves manufactured from stainless steel are fitted to the exhaust ports. These reduce the
amount of heat transferred to the cooling system and direct the thermal energy to the turbocharger.
The electronic unit injectors are mounted in stainless steel sleeves which have been pressed into the injector
bores of the cylinder head.
The operations to remove and to fit valve seat inserts and to remove and to fit camshaft bearings are not
included as specialist equipment is required. It is recommended that operators take advantage of the Perkins
service exchange scheme if these procedures become necessary.

Workshop Manual, TSD3455E, Issue 1 27

This document has been printed from SPI². Not for Resale
3 2300

Rocker cover

To remove and to fit Operation 3-1

To remove
Warning! The electrical circuit for the fuel injector units operates on 110 volts. Do NOT work on the fuel injector
units unless the power supply to the ECM has been disconnected.
1 Disconnect the wiring harness at the socket on the rocker cover (A1).
2 Disconnect and remove the engine breather pipe (A2).
3 Loosen fully the bolts which retain the rocker cover, but do not remove the bolts from the assembly; allow
them to be retained by the seal.
4 Remove the rocker cover.
To fit
1 Inspect the seal of the rocker cover and renew if worn of damaged.
2 Fit the rocker cover, complete with seal and bolts. Tighten the bolts to a torque of 20 Nm (15 lbf ft); use the
sequence shown (B).
3 Fit the engine breather pipe (A2).
4 Connect the wiring harness. Ensure that the wiring harness is fully engaged with the connector.

28 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
Rocker lever and rocker shaft assemblies

To remove and to fit Operation 3-2

To remove
1 Remove the rocker cover, Operation 3-1.
2 The valve rocker levers (A1) and the unit injector rocker levers (A2) can move on the shaft (A6) after the four
bolts (A5) have been removed. The shaft (A6) should be kept level when removed from the cylinder head. To
avoid possible personal injury, keep fingers clear of the rocker levers (A1 and A2) during removal of the
assembly from the cylinder head.
3 Remove the four bolts (A5).
4 Remove the shaft (A6), valve rocker levers (A1) and unit injector rocker levers (A2) as a unit.
5 Repeat steps 1 and 2 for the rocker shaft assemblies which remain.
To fit
1 Loosen the adjustment screws (A3 and A4) of each of the rocker levers which have been removed. Install
the rocker shaft assembly in the reverse order to removal.
2 Set the tappet clearances, Operation 3-4.
3 Check/adjust the unit injectors, Operation 3-13.
4 Fit the rocker cover, Operation 3-1.

Workshop Manual, TSD3455E, Issue 1 29

This document has been printed from SPI². Not for Resale
3 2300

To dismantle and to assemble Operation 3-3

To dismantle
Note: Check the condition of all components and renew any which are worn or damaged.
1 Slide the valve rocker levers (A3) and the unit injector rocker levers (A4) from the shaft (A7).
Note: Fit a new ‘O’ ring seal to any rocker lever adjuster if its button (A1) has been removed from the
adjustment screw (A2).
2 Remove the button (A1) from the adjustment screw (A2) in the valve rocker lever (A3).
3 Remove the button (A6) from the adjustment screw (A5) in the unit injector rocker lever (A4).
4 Repeat steps 1 to 3 for the rocker lever assemblies which remain.

30 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
To assemble
1 Install new ‘O’ ring seals in the buttons (A1).
2 Install new ‘O’ ring seals in the buttons (A6).
3 To fit the ‘O’ ring seals and buttons to the valve rocker levers, proceed as follows:
a. Support the valve rocker lever (A3) in a vice which has soft jaws.
b. Put the ‘O’ ring seal and button (A1) on the round end of the adjustment screw (A2).
c. Use a soft hammer to seat the button on the adjustment screw.
4 To fit the ‘O’ ring seals and buttons to the unit injector rocker levers, proceed as follows:
a. Support the unit injector rocker lever (A4) in a vice which has soft jaws.
b. Put the ‘O’ ring seal and button (A6) over the end of adjustment screw (A5).
c. Use a soft hammer to seat the button on the adjustment screw.
5 Repeat steps 3 and 4 for the rocker levers which remain.
6 Fit the assembled rocker levers to the shafts (A7). Ensure that they are fitted to their original positions.

Workshop Manual, TSD3455E, Issue 1 31

This document has been printed from SPI². Not for Resale
3 2300

How to check/adjust the tappet clearances Operation 3-4

Special requirements
Special tools Tappet clearances
Description Part number Inlet Exhaust
Engine turning tool CH11148 0,38 mm (0.015 in) 0,76 mm (0.030 in)

The tappet clearance is measured between the rocker levers and the top of the valve bridge pieces. The
operation must be done with the engine cold and stopped. Refer also to Operation 3-13, How to check/adjust
the electronic unit injectors.
1 Remove the rocker cover, Operation 3-1.
2 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt.
Caution: If a customer-fitted speed sensor is fitted to the flywheel housing, it must be removed before the
engine turning tool can be inserted.
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing bolt.
Note: There are two locations for the timing bolt, one at each side of the flywheel housing. Use the location
that is the most convenient.
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind the cover
(A2). Use a 1/2 inch drive ratchet with the turning tool to rotate the engine flywheel in the normal direction of
rotation (anti-clockwise when viewed on the flywheel) until the timing bolt engages with the threaded hole in
the flywheel. The piston of number 1 cylinder is now at TDC (top dead centre).
Caution: If the flywheel is turned past the threaded hole, the flywheel must be turned in the opposite direction
for approximately 45 degrees and then back in the normal direction of rotation until the timing bolt engages
with the threaded hole. This is to eliminate backlash.

Continued

32 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
5 Check the inlet and exhaust valves of the number 1 cylinder. If they are fully closed the piston is on its
compression stroke and the rocker levers can be moved by hand. If the rocker levers can not be moved
because the valves are slightly open, the piston is on its exhaust stroke. If it is on its exhaust stroke, withdraw
the timing bolt and turn the flywheel a further 360 degrees in the normal direction of rotation so that the number
1 cylinder is set to TDC on its compression stroke, then insert again the timing bolt.
6 Before each set of tappet clearances is adjusted, ensure that the roller of the rocker lever is fully against the
camshaft lobe.
7 Use a set of feeler gauges, inserted at the position shown (B3) between the valve bridge piece and the rocker
lever button, to check the tappet clearances for the inlet valves (C1) on cylinders 1, 2 and 4. Adjust the
clearances if necessary. Check the tappet clearance for the exhaust valves (C2) on cylinders 1, 3 and 5, and
adjust the clearances if necessary.

Continued

Workshop Manual, TSD3455E, Issue 1 33

This document has been printed from SPI². Not for Resale
3 2300

Notes:
l Move each valve bridge piece before the feeler gauge is inserted to reduce the effect of the oil film.
l During the procedure, ensure that the feeler gauge is fully inserted
8 After each unit has been adjusted, tighten the lock nut (B2) of the adjustment screw (B1) to a torque of 30 +/
- 4 Nm (22 +/- 3 lbf ft).
9 Withdraw the timing bolt and rotate the flywheel by 360 degrees so that the number 6 piston is at TDC on
its compression stroke. Insert again the timing bolt into the threaded hole.
10 Check the tappet clearances for the inlet valves (C1) on cylinders 3, 5 and 6. Adjust the clearances if
necessary. Check the tappet clearances for the exhaust valves (C2) on cylinders 2, 4 and 6, and adjust the
clearances if necessary.
11 After each unit has been adjusted, tighten the lock nut of the adjustment screw to a torque of 30 +/- 4 Nm
(22 +/- 3 lbf ft).
12 Check again the tappet clearances for all six cylinders.
13 Fit the rocker cover. Remove the engine turning tool and the timing bolt and fit the cover to the flywheel
housing. Fit the plug to the timing bolt location.

34 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
Cylinder head assembly

To remove and to fit Operation 3-5

Special requirements
Special tools Consumable products
Description Part number Description Part number
Guide bolt, camshaft gear GE50019 Special lubricant CV60895
Socket, cylinder head bolt GE50020
Retaining compound 21820 638
Lifting bracket VP12712

To remove
1 Remove the thermostat housing, Operation 12-10.
2 Remove the exhaust manifold, Operation 9-1.
3 Remove the rocker lever and rocker shaft assemblies, Operation 3-2.
4 Remove the electronic unit injectors, Operation 3-12.
5 Remove the gear case cover, Operation 6-1.
6 Disconnect the cable and remove the timing sensor from the cylinder head.
7 Remove the support bracket which is fitted between the gear case and the cylinder head.
8 Remove one bolt from the camshaft gear and install the guide stud, GE50019. Remove the five bolts which
remain and withdraw carefully the camshaft gear. Remove the guide stud.
9 Disconnect the fuel lines from the front and rear of the cylinder head. Fit temporary covers to the fuel lines
and also to the ports on the cylinder head.
10 Remove the cylinder head bolts; use the special socket, GE50020.
11 Fit the lifting bracket (A1), VP12712, to the cylinder head and attach a suitable hoist. Remove the cylinder
head. The cylinder head weighs approximately 148 kg (325 lb).

Continued

Workshop Manual, TSD3455E, Issue 1 35

This document has been printed from SPI². Not for Resale
3 2300
12 Remove the cylinder head gasket (B4).
13 Remove the ‘O’ ring seal from the oil transfer tube (B6) and remove the 24 coolant seals (B3).
14 Remove the seal (B2).
15 Remove the spacer plate (B5) and discard the spacer plate gasket.
16 Remove the second ‘O’ ring seal from the oil transfer tube (B6).

36 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
To fit
1 If the oil transfer tube (B6) has been removed, apply retaining compound, 21820 638, and insert it in the
crankcase. It must protrude from the top face of the crankcase by 20,0 +/- 0,5 mm (0.79 +/- 0.02 in). Remove
any excess compound and ensure that the bore of the oil transfer tube is clean.
2 If the rear dowel has been removed, apply retaining compound, 21820 638, and insert it in the crankcase.
It must protrude from the top face of the crankcase by 18,5 +/- 0,5 mm (0.73 +/- 0.02 in).
3 If the front dowel, close to the oil transfer tube, has been removed, it must be fitted in a dry condition. It must
protrude from the top face of the crankcase by 16,0 +/- 0,5 mm (0.63 +/- 0.02 in).
Note: Ensure that the spacer plate and the machined surface of the cylinder block are clean and free from dirt
and gasket material. Both surfaces of the spacer plate gasket and the top of the cylinder block must be clean.
Do NOT use a gasket adhesive on the surfaces.
4 Fit suitable guide studs (B1) to the cylinder block. Fit a new spacer plate gasket over the dowels in the
cylinder block.
Note: Apply a small amount of clean engine oil to the seals and ‘O’ ring seals before installation.
5 Fit a new ‘O’ ring seal to the oil transfer tube (B6).
6 Fit the spacer plate (B5) and fit the second ‘O’ ring seal to the oil transfer tube (B6). Fit the 24 coolant seals
(B3) and a new seal (B2) to the oil drain passage.
7 Check, and if necessary adjust, the protrusion of the cylinder liners, Operation 7-3.
8 Fit a new cylinder head gasket (B4) to the spacer plate.

Continued

Workshop Manual, TSD3455E, Issue 1 37

This document has been printed from SPI². Not for Resale
3 2300
9 Fasten a hoist to the cylinder head, use the lifting bracket VP12712, and lower the cylinder head onto the
spacer plate.
10 Apply special lubricant, CV60895, to the washers, the threads and under the heads of the bolts and fit the
cylinder head bolts and washers. The long bolts must be fitted at the positions shown in the black circles (C).
Use the special socket, GE50020, and the procedure which follows to tighten the bolts correctly:
a. Tighten the cylinder head bolts in the sequence given (C) to a torque of 270 +/- 15 Nm (200 +/- 11 lbf ft).
b. Tighten the cylinder head bolts in the sequence given (C) to a torque of 450 +/- 20 Nm (333 +/- 15 lbf ft).
c. Again, tighten the cylinder head bolts in the sequence given (C) to a torque of 450 +/- 20 Nm (333 +/-
15 lbf ft).
Caution: After the cylinder head assembly has been removed and fitted, it is necessary to check the backlash
between the camshaft and the idler gears. Incorrect adjustment can cause damage to components.
11 Fit the camshaft gear. Check and, if necessary, adjust the backlash between the camshaft gear and the
idler gear, Operation 3-11.
12 Fit the gear case cover, Operation 6-1.
13 Fit the support bracket between the cylinder head and the gear case.
14 Fit the electronic unit injectors, Operation 3-12.
15 Fit the rocker lever and shaft assemblies, Operation 3-2.
16 Fit the exhaust manifold, Operation 9-1.
17 Fit the thermostat housing, Operation 12-10.
18 Remove the covers from the fuel lines and from the fuel line ports on the cylinder head. Connect the fuel
lines to the cylinder head and attach any relevant clamps.
19 Fit the timing sensor and connect the cable.

38 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
Valve springs

To remove and to fit Operation 3-6

Special requirements
Special tools
Description Part number
Valve spring compressor GE50026

To remove
Note: The valve springs can be removed with the cylinder head either fitted to or removed from the engine.
The procedure given here is for use when the cylinder head is fitted to the engine. Before any components are
removed, ensure that the relevant piston is set to the top of its compression stroke. If the piston is not at this
position, the valves can fall into the cylinder liner.
Caution: If a valve falls into the cylinder liner, the cylinder head must be removed.
1 Remove the rocker lever and rocker shaft assemblies, Operation 3-2.
2 Remove the electronic unit injectors, Operation 3-12.
3 Set the piston for the relevant valve spring assembly to the top of its compression stroke.
4 Use the hold-down clamp from the electronic unit injector to secure the valve spring compressor, GE50026,
to the cylinder head.
5 Insert the stud and base of the valve spring compressor into the bore of the injector sleeve. Use the bolt and
clamp from the electronic unit injector to secure the stud and base to the cylinder head. Fit the compressor
plate (A1) over the stud and fit the thrust bearing, the washer and the nut (A2)
6 Tighten the nut until the collets are loose on the valves.
7 Remove two collets from each valve.
8 Loosen slowly, then remove the nut, washer, thrust bearing and plate.
9 Remove the rotocoils, valve springs and washers from each valve.
10 Inspect the valve springs, refer to Chapter 2, Specifications for the correct dimensions and spring force.
11 Repeat steps 3 to 10 for the other valve spring assemblies which are to be removed.

Workshop Manual, TSD3455E, Issue 1 39

This document has been printed from SPI². Not for Resale
3 2300
To fit
1 Apply clean engine oil to the relevant valve stems.
2 Fit the washer, valve spring and rotocoil to each valve.
3 Use the valve spring compressor, GE50026, to compress the valve springs.
Note: The collets are tapered. When fitted, the large (thick) diameter must be uppermost.
4 Fit two collets to each valve.
Caution: The collets can be dislodged from the valve stem during the removal of the valve spring compressor.
Ensure that the collets are seated correctly during this procedure.
5 Loosen slowly and then remove the nut (A2) and plate (A1) of the valve spring compressor. Remove the
other parts of the valve spring compressor tool and ensure that the collets are fitted correctly to the valve
stems.
6 Tap lightly each valve with a soft hammer to ensure that the collets are seated correctly.
7 Fit the electronic unit injectors, Operation 3-12.
8 Fit the rocker lever and rocker shaft assemblies, Operation 3-2.

40 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
Valves

To remove and to fit Operation 3-7

Special requirements
Special tools
Description Part number
Valve spring compressor GE50026

To remove
1 Remove the cylinder head, Operation 3-5.
Note: If more than one valve is to be removed, make a note of the position of the valves as they are removed
from the cylinder head.
2 Put the cylinder head, flame face down, on a bench with a soft surface and release the valves by use of the
valve spring compressor, GE50026. Use the procedure given in Operation 3-6.
3 Withdraw the valves from the cylinder head.
4 Repeat the procedure for all valves which are to be removed.
To fit
1 Apply clean engine oil to the stems of the valves. Fit the valves to their original positions in the cylinder head.
2 Use the special tool, GE50026, and the procedure given in Operation 3-6, to install the valve springs.
3 Fit the cylinder head, Operation 3-5.

Workshop Manual, TSD3455E, Issue 1 41

This document has been printed from SPI². Not for Resale
3 2300
Valve seals

To renew Operation 3-8

Special requirements
Special tools
Description Part number
Insertion tool, valve seal GE50027

Note: The valve seals can be removed with the cylinder head either fitted to or removed from the engine.
1 Remove the relevant valve spring assembly, Operation 3-6.
2 Remove the valve seal from the valve and valve guide.
3 Apply a thin film of clean engine oil to the new valve seal and slide the seal over the valve stem.
4 If the valve seal is to be fitted to a valve guide with the valve removed, fit the seal to the special tool,
GE50027. Insert the seal pin (part of the special tool GE50027) through the insertion tool, then enter the seal
pin into the bore of the valve guide.
5 Use the special tool, GE50027, and hand pressure only to push the valve seal into its position in the valve
guide.
6 Withdraw the tool and fit the valve spring assembly, Operation 3-6.

42 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
Valve guides

To remove and to fit Operation 3-9

Special requirements
Special tools
Description Part number
Removal/installation tool GE50043
Sleeve GE50044

To remove
1 Remove the cylinder head, Operation 3-5.
2 Remove the valves, Operation 3-7.
3 Use the special tool (A1), GE50043, and a hammer to drive the valve guide (A2) from the cylinder head.

Workshop Manual, TSD3455E, Issue 1 43

This document has been printed from SPI². Not for Resale
3 2300
To fit
1 Apply clean engine oil to the outside diameter of the new valve guides.
2 Use the special tool (B1), GE50043, together with the sleeve (B2), GE50044, to install the valve guide. The
guide must protrude from the cylinder head, as shown (C1), by 35,0 +/- 0,5 mm (1.38 +/- 0.02 in).
Refer to Chapter 2, Specifications for the correct dimensions for the inside diameter of new and used valve
guides.
3 When a new valve guide has been fitted, check that there is full contact between the valve and the valve
seat. If necessary, lap the valve to the seat.
4 Fit the valves, Operation 3-7.
5 Fit the cylinder head, Operation 3-5.

44 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
Camshaft

To remove and to fit Operation 3-10

Special requirements
Special tools Consumable products
Description Part number Description Part number
Engine turning tool CH11148 Thread lock compound (10 ml) 21820 117
Guide stud GE50019
Cradle tool GE50018
Camshaft guide GE50017
Pilot GE50015
Lifting hooks GE50025
Alignment sleeve GE50016

To remove
1 Remove the radiator, Operation 12-4.
2 Remove the fan, Operation 12-5.
3 Remove the gear case cover, Operation 6-1.
4 Remove the rocker cover, Operation 3-1.
5 Remove the rocker lever and shaft assemblies, Operation 3-2.
6 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt.
7 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing bolt.
Note: There are two locations for the timing bolt, one at each side of the flywheel housing. Use the location
which is the most convenient.

Continued

Workshop Manual, TSD3455E, Issue 1 45

This document has been printed from SPI². Not for Resale
3 2300
8 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind the cover
(A2). Use a 1/2 inch drive ratchet with the turning tool to rotate the engine flywheel in the normal direction of
rotation (anti-clockwise when viewed on the flywheel) until the timing bolt engages with the threaded hole in
the flywheel. The piston of number 1 cylinder is now at TDC (top dead centre). When the number one piston
is at top dead centre on its compression stroke, the mark on the camshaft gear is be aligned with the mark on
the gear case. If the mark is not aligned, withdraw the timing bolt, rotate the crankshaft a further 360 degrees
in the normal direction of rotation and insert the timing bolt again.

Cautions:
l If the flywheel is turned past the threaded hole, the flywheel must be turned in the opposite direction for
approximately 45 degrees and then back in the normal direction of rotation until the timing bolt engages
with the threaded hole. This is to eliminate backlash.
l Do not rotate the crankshaft with the camshaft gear or any of the idler gears removed and the rocker shaft
assemblies installed. Damage can be caused to the pistons and valves, or to both.
9 Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case.
10 Remove one bolt from the camshaft gear and install the guide stud, GE50019. Remove the five bolts which
remain.
11 Attach a hoist to the camshaft gear and withdraw the gear from the camshaft. Remove the guide stud.
12 Remove three bolts and withdraw the thrust plate, the adaptor plate and the seal assembly.
Note: Take care during removal of the camshaft to ensure that the surfaces of both the camshaft and the
camshaft bearings are not damaged. Use the procedure which follows, together with the relevant special tools,
to avoid damage to the engine and components.
13 Use the bolts of the rocker shaft to retain the cradle tool (B1), GE50018, at the position shown (B).

Continued

46 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
14 Remove the rear cover (C1), complete with seal (C3).
15 Fit the camshaft guide (D1), GE50017, to the gear case. Do not tighten the bolts for the guide at this stage.
Note: It is necessary to install two pilots, GE50015, on the rear end of the camshaft. The second pilot will
support the rear of the camshaft as it is moved from the cylinder head and into the guide, GE50017.
16 Install a pilot tool, GE50015, into the threaded hole at the rear end of the camshaft. Then attach the second
pilot tool, GE50015, to the first.
17 Withdraw the camshaft until it enters the bore of the camshaft guide. Tighten the bolts which retain the
guide on the gear case.
18 Use the lifting hooks, GE50025, to move the camshaft toward the front of the engine.
Caution: During use of the lifting hooks do not raise the camshaft; the camshaft should be supported by the
cradle, GE50018. If the camshaft is raised, damage to the camshaft bearings can occur.
19 Withdraw the camshaft from the cylinder head just enough for a strap and hoist to be attached. Attach a
suitable strap and hoist to support the camshaft, ensure that the camshaft is kept level and withdraw it from
the cylinder head. The camshaft weighs approximately 39 kg (85 lb).

Workshop Manual, TSD3455E, Issue 1 47

This document has been printed from SPI². Not for Resale
3 2300
To fit
1 Fit the two pilot tools, GE50015, to the rear end of the camshaft. Ensure that the camshaft and camshaft
bearings have been cleaned thoroughly. Apply clean engine oil to the lobes and journals of the camshaft. Apply
a thin coat of clean engine oil to the camshaft bearings.
2 Fit the camshaft guide (E1), GE50017, to the gear case cover, but do not tighten the bolts fully.
3 Insert the alignment sleeve (E2), GE50016, through the camshaft guide (E1) and into the camshaft bearings
to align the camshaft guide correctly. Tighten the bolts which retain the camshaft guide, GE50017, on the gear
case. Remove the alignment sleeve; the sleeve should move freely from the bore of the camshaft guide,
GE50017.
4 Fit the cradle tool (F1), GE50018, at the position shown (F).
Note: Rotate the camshaft in both directions during installation to prevent binding.
5 Use a suitable strap and hoist to support the camshaft. Insert the camshaft through the guide and into the
cylinder head. Move the camshaft into the head as far as the strap and hoist will allow.
6 Remove the strap and hoist. Rotate the camshaft during installation. Do not allow the end of the camshaft
to drop during removal of the hoist as the bearings can be damaged. Use the lifting hooks, GE50025, to
support the camshaft during installation.
7 Remove the pilot tools and push the camshaft fully into its bore.
8 Inspect the seal (G3) and renew if necessary. Fit the rear cover (G1), complete with seal (G3).

Continued

48 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
9 Remove the cradle tool and the camshaft guide.
10 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubricating oil to the
‘O’ ring seal on the outside of the plate. Fit the seal plate with the face seal against the cylinder head. Insert
the adapter plate and fit the thrust plate. Apply thread lock compound, 21820 117, to the three bolts, fit the
bolts and tighten.
Note: Camshaft timing is very important. During installation of the camshaft assembly, ensure that the timing
marks on the camshaft gear and the gear case cover are aligned when number one cylinder is at top centre
(TDC).
11 Fit the guide stud, GE50019, to the camshaft.
12 Fit the camshaft gear; align the hole in the gear with the dowel pin on the adapter plate. If the timing mark
on gear does not align with the pointer at the top of the gear case, remove the gear and rotate the camshaft
until the gear can be installed with the marks aligned.
13 Fit the bolts which retain the gear, remove the guide stud and fit the bolt which remains. Tighten the bolts
to a torque of 240 +/- 40 Nm (177 +/- 30 lbf ft).
14 Fit the camshaft timing sensor to its location behind the top of the gear case and connect the lead.
15 Fit the gear case cover, Operation 6-1.
16 Remove the timing bolt from the flywheel and fit the cover and plug.
17 Install the rocker lever and shaft assemblies, Operation 3-2.

Workshop Manual, TSD3455E, Issue 1 49

This document has been printed from SPI². Not for Resale
3 2300

How to set the backlash for the camshaft gear Operation 3-11

If the cylinder head or the camshaft is removed, the backlash between the camshaft gear (A1) and the
adjustable idler gear (A2) must be checked and, if necessary, adjusted. The backlash between the camshaft
gear and the adjustable idler gear, and also between the adjustable idler gear (A2) and the main idler gear
(A3), must be 0,25 +/- 0,08 mm (0.010 +/- 0.003 in).
Note: This procedure must be performed before the rocker lever and shaft assemblies are fitted.
1 Remove the main idler gear (A3). Hold the camshaft gear stationary and use a dial test indicator (DTI),
mounted on the gear case, to check the backlash of the adjustable idler gear.
2 Fit the main idler gear (A3), hold the main idler gear stationary and measure the backlash on the adjustable
idler gear.
3 To adjust the backlash, remove the three bolts and thrust plate which retain the adjustable idler gear (A2)
and remove the gear. Loosen the five nuts (B3) and the bolt (B1) which retain the stub axle (B2) and move the
stub axle by the relevant amount. Tighten the nuts and bolt to a torque of 47 +/- 9 Nm (35 +/- 7 lbf ft).
4 Fit the idler gear. Retain with the thrust plate and three bolts. Check again the backlash between the
adjustable idler gear and the camshaft gear, and also between the adjustable idler gear (A2) and the main idler
gear (A3), as given in steps 1 and 2. Repeat the procedure if necessary until the correct backlash settings have
been obtained.
5 When the correct backlash settings have been obtained, remove the adjustable idler gear and proceed as
follows: Remove one of the nuts which retains the idler axle, apply a small amount of Loctite 542 to the threads
of the stud, fit the nut and tighten to a torque of 47 +/- 9 Nm (35 +/- 7 lbf ft). Repeat this procedure for the other
four nuts and the bolt; work on one nut or bolt at a time so that the position of the stub axle is not affected.

50 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
Electronic injector units

To remove and to fit Operation 3-12

Special requirements
Special tools
Description Part number Description Part number
Injector installer/removal GE50021 Brush GE50022
Vacuum pump GE50028 Brush GE50023
Tube GE50030
Brush GE50024
Bottle GE50029

To remove
Warning! The electrical circuit for the fuel injector units operates on 110 volts. Do NOT work on the fuel injector
units unless the power supply to the ECM has been disconnected.
1 Remove the relevant rocker shaft assembly, Operation 3-2.
2 Loosen the two nuts and remove the electrical connector from the injector unit.
3 Mark the valve bridge pieces to assist during assembly, then remove them.
4 Remove the bolt (A2) from the spacer and clamp which retain the injector unit and use the special tool,
GE50021, to release the injector unit from the cylinder head.
Caution: If more than one injector unit is to be removed, make a note of the trim code (A1), a four-digit number
adjacent to the bar code, and also the cylinder to which the unit is fitted.
5 Remove the injector unit, together with the spacer and clamp.
6 Use the vacuum pump, GE50028, together with the tube, GE50030, and bottle, GE50029, to extract any
fuel which has spilled into the combustion chamber during removal of the injector.

Workshop Manual, TSD3455E, Issue 1 51

This document has been printed from SPI². Not for Resale
3 2300
To fit
1 Clean thoroughly the bore of the injector sleeve and cylinder head. Use the special brushes (GE50022,
GE50023 and GE50024) to remove carbon or dirt.
2 Check the condition of the ‘O’ ring seals (B1 and B2); renew the seals if they are worn or damaged. Lubricate
the ‘O’ ring seals with clean engine oil before the injector unit is installed in the cylinder head.
Caution: Injector units MUST be fitted to their original positions or the information in the ECM will need to be
updated.
3 Fit the injector unit to the cylinder head. Fit the clamp, spacer and retaining bolt. Tighten the bolt (A2) to a
torque of 47 +/- 9 Nm (35 +/- 7 lbf ft).
4 Fit the bridge pieces.
5 Attach the electrical connector to the injector unit and retain with the two nuts. Tighten the nuts to a torque
of 2,5 Nm (22 lbf in).
6 Fit the rocker shaft assembly, Operation 3-2.

52 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
To check and to adjust Operation 3-13

Special requirements
Special tools
Description Part number
Injector height gauge CH11149

This operation should be performed at the same time as the operation to check the valve tappet clearances.
Warning! The electrical circuit for the fuel injector units operates on 110 volts. Do NOT work on the fuel injector
units unless the power supply to the ECM has been disconnected.
1 With the rocker covers removed, set the number 1 piston to TDC (top dead centre) on its compression
stroke. Check/adjust the height dimensions for the fuel injectors of cylinders 3, 5 and 6.
2 Use the fuel injector setting gauge, CH11149, to obtain the correct height for the fuel injector. The dimension
to be measured is from the top of the unit injector (A1) to the machined ledge on the fuel injector body (A2).
This dimension should be 78,0 +/- 0,2 mm (3.07 +/- 0.01 in). Slacken the lock nut and use the adjustment screw
of the rocker lever to obtain the correct dimension. Tighten the lock nut to a torque of 55 +/- 10 Nm (41 +/-
7 lbf ft).
3 Remove the timing bolt from the flywheel housing and rotate the flywheel by 360 degrees in the normal
direction of engine rotation until the timing bolt can be inserted into the threaded hole. This will put the number
1 piston at TDC in its exhaust stroke.
4 Check/adjust the height dimensions for the fuel injectors of cylinders 1, 2 and 4 as given in step 2.
When all adjustments have been made, remove the timing bolt, fit the cover to the flywheel housing, fit the plug
to the timing bolt position and fit the rocker covers.

Workshop Manual, TSD3455E, Issue 1 53

This document has been printed from SPI². Not for Resale
3 2300
Injector sleeves

To remove and to fit Operation 3-14

Special requirements
Special tools
Description Part number Description Part number
Injector installer/removal GE50021 Brush GE50022
Vacuum pump GE50028 Brush GE50023
Tube GE50030
Brush GE50024
Bottle GE50029

To remove
1 Remove the rocker shaft assemblies, Operation 3-2.
2 Remove the electronic injector units, Operation 3-12.
3 Mark the bridge pieces and make a note of their position to assist during assembly, then remove the bridge
pieces.
4 Fit the puller stud from the special tool, GE50021, into the injector sleeve as shown (A). Fit the bridge, thrust
bearing, washer and nut, from the special tool, over the stud as shown. Tighten the nut (A1) of the special tool
until the sleeve is drawn from the cylinder head. Remove the special tool from the sleeve.
5 Remove the ‘O’ ring seals from the injector sleeve. Check the condition of the injector sleeve and renew if
necessary.
6 Repeat steps 1 to 5 for the injector sleeves which remain.

54 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 3
To fit
Caution: Before installation ensure that the injector sleeve and its bore in the cylinder head are clean and free
from oil, dirt and sealant.
1 Use the brushes, special tool numbers: GE50023, GE50024 and GE50022, to clean thoroughly the bore for
the injector sleeve.
Caution: Ensure that the fuel passage in the cylinder head is clean.
2 Fit new ‘O’ ring seals to the injector sleeve.
3 Fit the stud from the special tool into the threads of the injector sleeve.
Caution: Do not apply retaining and anti-seize compounds to the cylinder head surfaces. These compounds
must ONLY be applied to the injector sleeve.
4 Apply CV60889 anti-seize compound to the ‘O’ ring seals and to the large diameter (B1) off the injector
sleeve.
5 Apply CV60893 retaining compound to the small diameter (B2) off the injector sleeve.
6 Using the stud, insert the injector sleeve into its bore in the cylinder head. Take care to prevent damage to
the ‘O’ ring seals. Use that only hand force is used to push the injector sleeve into the cylinder head.
7 Fit the driver tool over the stud and tap lightly with a hammer to ensure that the injector sleeve is fully seated
in the cylinder head. The tool and sleeve will "ring" when the sleeve is in full contact with the base of the bore.
8 Use a clean cloth to remove any retaining or anti-seize compound from the bores of the cylinder and injector
sleeve.
9 Fit the electronic injector units, Operation 3-12.
10 Fit the rocker shaft assemblies, Operation 3-2.

Workshop Manual, TSD3455E, Issue 1 55

This document has been printed from SPI². Not for Resale
 This page is intentionally blank

This document has been printed from SPI². Not for Resale
 2300

4
Pistons and connecting rod assemblies 4

General information
The pistons fitted to the 2300 and 2800 Series engines consist of two parts: a forged steel crown (A1) and a
cast aluminium skirt (A2). The two parts are retained on the connecting rod by the gudgeon pin (A4). The
pistons each have three rings fitted to grooves in the crown. The top ring is keystone shaped and its face is
plasma coated. The second ring has a tapered face which has a chrome finish. The third ring is an oil control
ring and also has a chrome finish on its face. The oil control ring contains a coil spring which expands the ring.
Small holes in the piston groove allow oil from the oil control ring to drain back to the sump.
The connecting rods are of a conventional design. The small end is wedge shaped and the big end bearing
cap is retained by two special bolts. A split type shell bearing is fitted at the big end and a single piece bearing
is pressed into the small end.
Piston squirter jets provide a supply of oil to cool the piston crown. On 2806 engines, an oil cooling chamber
is formed by the lip at the top of the piston skirt and the cavity behind the ring grooves in the piston crown. The
oil returns to the sump through the clearance gap between the crown and the skirt. For pistons fitted to the
2306 engine, the oil cooling chamber is formed between the cavity behind the ring grooves and two flat plates
fitted in the piston crown. There is a hole in each plate; the oil supply is squirted through one hole, flows around
the cooling chamber and returns to the sump through the hole at the opposite side.

Workshop Manual, TSD3455E, Issue 1 57

This document has been printed from SPI². Not for Resale
4 2300

Pistons and connecting rod assemblies

To remove and to fit Operation 4-1

Special requirements
Special tools Consumable products
Description Part number Description Part number
Installer, piston (2806 engine) GE50003
Anti-seize compound CV60890
Installer, piston (2306 engine) GE50045

To remove
1 Remove the cylinder head assembly, Operation 3-5.
2 Remove the oil pump, Operation 10-4.
3 Remove the stiffener plate from the base of the crankcase.
4 Remove the carbon ridge from the top inside surface of the cylinder liners.
5 Turn the crankshaft until two pistons are at bottom centre.
6 Remove the bolts (A1) and the bearing caps. Push the connecting rods and pistons up until the rings are
free from the cylinder liners.
7 Withdraw carefully the pistons and connecting rods from the cylinder liners. Store the bearing caps with their
relevant connecting rods.
8 Repeat steps 3 to 6 for the remainder of the pistons and connecting rods.

58 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 4
To fit
1 Apply clean engine oil to the piston rings, the connecting rod bearings and the cylinder liners.
2 Ensure that the piston ring gaps are set at 120 degree intervals to each other.
3 Use the special tool (B1), GE50003 for 2806 engines or GE50045 for 2306 engines, to install the piston and
the connecting rod in the cylinder liner (B2). The connecting rod must be fitted with tab groove side of the big
end bearing at the opposite side to the camshaft. Proceed with care to ensure that the piston rings are not
damaged during the operation.
Caution: Bearing caps must be fitted to their original connecting rods,
4 Fit the bearing cap to the connecting rod. The cap must be fitted with its number on the same side as that
on the connecting rod and the number must be the same.
5 Apply anti-seize compound, CV60890, to the bolt threads. Install the bolts and bearing cap. Tighten each
bolt in the bearing cap to a torque of 90 +/- 8 Nm (66 +/- 6 lbf ft). Make a temporary mark on each bolt and the
bearing cap, then tighten each bolt by an additional 90 +/- 5 degrees.
6 Repeat steps 1 to 4 for the remainder of the pistons and connecting rods.
7 Fit the stiffener plate to the base of the crankcase.
8 Fit the oil pump, Operation 10-4.
9 Fit the cylinder head assembly, Operation 3-5.

Workshop Manual, TSD3455E, Issue 1 59

This document has been printed from SPI². Not for Resale
4 2300

To dismantle and assemble Operation 4-2

To dismantle
1 Remove the pistons and connecting rod assemblies, Operation 4-1.
2 Remove the big-end bearing shells (A5) from the connecting rod (A4) and connecting rod cap. If the bearings
are to be used again, make a note of the position where they were fitted.
3 Remove the circlips (A1).
4 Remove the gudgeon pin (A2) and separate the connecting rod and the piston crown from the piston.
5 Remove carefully the piston rings (A3) from the piston crown and clean the piston ring grooves with a
suitable cleaning tool.
Special equipment is required to renew the small end bearing. If this operation becomes necessary, contact
your Perkins dealer.

60 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 4
To assemble
1 Check the gaps between the ends of the piston rings when the rings are inserted in a new liner. The rings
can also be checked by insertion in an unworn part of a used liner.
For the correct dimensions refer to Chapter 2, Specifications.
2 Fit the spring of the oil control ring to its groove in the piston crown.
Note: The oil control ring must be fitted over the spring with the gap of the oil control ring at 180 degrees from
the joint of the spring.
3 Use a suitable piston ring expander to fit the oil control ring to its groove in the piston crown.
4 Fit the second (intermediate) piston ring with the side that has the identification "UP-2" toward the top of the
piston. Use a suitable piston ring expander.
5 Fit the first (top) piston ring with the side that has the identification "UP-1" toward the top of the piston. Use
a suitable piston ring expander.
6 When all three piston rings have been fitted, adjust the position of the piston ring gaps so that they are
120 degrees apart.
7 Fit the piston crown into the piston skirt and insert the connecting rod. Apply clean engine oil to the gudgeon
pin (A2) and install the pin. Fit the circlips (A1). Ensure that the circlips are located fully in the grooves of the
piston.
8 Fit the big-end bearings to the connecting rod (A4) and connecting rod cap. If the original bearings are to be
used, ensure that they are fitted to their original positions.
Note: The tabs at back of the bearings must be located correctly in the tab slots of the connecting rod and
connecting rod cap.
9 Fit the pistons and connecting rod assemblies, Operation 4-1.

Workshop Manual, TSD3455E, Issue 1 61

This document has been printed from SPI². Not for Resale
4 2300
Piston cooling jets

To remove and to fit Operation 4-3

Special requirements
Special tools
Description Part number
Engine turning tool CH11148
Jet alignment tool GE50004

To remove
1 Remove oil pump, Operation 10-4.
2 Use the engine turning tool, CH11148, to turn the crankshaft in a clockwise direction (as seen from the front
of the engine) to obtain access to the relevant piston cooling jet.
3 Remove the bolt which retains the cooling jet and remove the cooling jet from the engine.
4 Repeat steps 2 and 3 for the cooling jets which remain.
To fit
1 Before a piston cooling jet is fitted to the engine, use the jet alignment tool, GE50004, to ensure that the
direction of the nozzles is correct.
Caution: If, when fitted to the alignment tool, a nozzle does not align correctly with the relevant dowel, discard
the cooling jet; do NOT fit a damaged or distorted cooling jet to the engine.
2 Carefully fit the piston cooling jets to the engine, ensure that the nozzles of the cooling jets are not damaged
or distorted during the operation. Turn the crankshaft clockwise (as seen from the front of the engine) as
necessary to obtain access to the relevant positions.
3 Fit the oil pump, Operation 10-4.

62 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

5
Crankshaft assembly 5

General information
The crankshaft fitted to the 2300 and 2800 Series engines has 13 bearing surfaces, which consists of seven
main journals and six crank pins. Each crank pin holds two connecting rods.
Eight counterweights are included within the crankshaft forging and a vibration damper is fitted at the front end
to reduce torsional vibrations.
A gear at the front end of the crankshaft provides the drive for the engine timing gears, the coolant pump and
the lubricating oil pump.
To seal the crankcase, crankshaft seals are fitted in the gear case and the flywheel housing.

Workshop Manual, TSD3455E, Issue 1 63

This document has been printed from SPI². Not for Resale
5 2300

Crankshaft

To remove and to fit Operation 5-1

Special requirements
Consumable products
Description Part number
Anti-seize compound CV60890

To remove
1 Remove the gear case cover, Operation 6-1.
2 Remove the flywheel housing, Operation 13-2.
3 Remove the pistons and connecting rod assemblies, Operation 4-1.
4 Remove the crankshaft rear seal and wear sleeve, Operation 5-3.
5 Remove the crankshaft front seal and wear sleeve, Operation 5-2.
Note: Make a note of the number on the bearing caps for assembly purposes. If a number cannot be seen, put
a number on the left side of the crankcase with a corresponding number on the bearing cap.
6 Remove the bolts (A1) which retain the main bearing caps in the crankcase and remove the bearing caps.
7 Fit one of the bolts from the front pulley to each end of the crankshaft. Fasten a hoist to the crankshaft and
lift the crankshaft from the crankcase. The weight of the crankshaft is approximately 159 kg (350 lb).
Note: If new main bearings are not to be installed, make a note of the position of the used bearings. Used
bearings must be fitted to their original positions.

64 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 5
To fit
1 Clean the crankcase and the main bearing caps thoroughly. Apply clean engine oil to the main bearings and
fit the upper halves of the main bearings into the crankcase.
2 Install one of the bolts from the front pulley in each end of the crankshaft, fasten a suitable hoist and fit the
crankshaft into the crankcase. Ensure that the line mark on the crankshaft gear is in alignment with the line on
the idler gear.
3 Fit the thrust bearings for the centre main bearing. Ensure that the bearings are fitted with the side
identification "BLOCK SIDE" against the crankcase.
4 Fit the main bearings to the bearing caps.
5 Ensure that the tabs on the back of the bearing shells fit into the tab slots of the bearing caps and crankcase.
Caution: Ensure that the main bearing caps are fitted to the correct positions. The numbers on the side of the
crankcase must be the same as the numbers on the bearing caps, and the arrows on the bearing caps must
be directed toward the front of the crankcase.
6 Apply anti-seize compound, CV60890, to the bolts and install the main bearing caps and bolts.
7 Begin at the tab end of the bearing cap first, tighten each bearing cap bolt to a torque of 260 +/- 14 Nm
(190 +/- 10 lbf ft). Make a temporary mark on each bolt and bearing cap. Start with the bolt opposite the tab
end of the bearing cap and again tighten each bolt by an additional 120 +/- 5 degrees.
8 Use a dial test indicator (DTI) to check the end-float of the crankshaft. Ensure that the pointer of the DTI is
against a machined surface. The end-float is controlled by the thrust bearings of the centre main bearing. The
end-float with new bearings must be between 0,15 and 0,51 mm (0.006 and 0.020 in). The maximum
permissible end-float with used bearings is 0,89 mm (0.035 in).
9 Fit the crankshaft front seal and wear sleeve, Operation 5-2.
10 Fit the crankshaft rear seal and wear sleeve, Operation 5-3.
11 Fit the pistons and connecting rod assemblies, Operation 4-1.
12 Fit the flywheel housing, Operation 13-2.
13 Fit the gear case cover, Operation 6-1.

Workshop Manual, TSD3455E, Issue 1 65

This document has been printed from SPI². Not for Resale
5 2300
Crankshaft front seal and wear sleeve

To renew Operation 5-2

Special requirements
Special tools Consumable products
Description Part number Description Part number
Locator assembly GE50008
Bolt GE50009 Quick cure primer CV60892
Distorter protection ring GE50010
Distorter tool GE50011
Installer GE50012 Retaining compound CV60893
Nut GE50014

To remove
1 Remove the vibration damper, Operation 5-4.
Note: The crankshaft front seal and wear sleeve are supplied as a set and must be installed as a set. If a seal
is renewed, the wear sleeve must also be renewed.
2 Drill three holes (A2) at an equal distance around the circumference of the seal. Fit self-tapping screws (A1),
complete with washers if necessary, to the holes and use a screwdriver as a lever to remove the seal from the
crankcase. Ensure that the gear case does not become damaged during this operation.
3 Fit the distorter protection ring (B1), GE50010, to the seal bore and at the same depth as the wear sleeve.
The distorter ring is fitted to protect the seal bore in the crankcase during the removal of the wear sleeve.
4 Insert the distorter tool (B2), GE50011, between the protection ring and the wear sleeve. With the sharp
edge of the tool against the wear sleeve, use a socket and spanner to rotate the distorter and cause a crease
to form in the wear sleeve. Repeat this procedure in three or more places until the wear sleeve becomes loose
on the crankshaft.
5 Remove the distorter tool, the protection ring and the wear sleeve.

66 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 5
To fit
Note: Before the new seal and wear sleeve are installed, read carefully the special instruction which is supplied
with each seal and wear sleeve.
1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure primer,
CV60892. Apply some retaining compound, CV60893, to the crankshaft outside diameter before the wear
sleeve is installed on the crankshaft. Do not allow any quick cure primer or retaining compound to touch the
lip of the seal.
2 Use the bolts (C3), GE50009, to install the guide, GE50008, on the crankshaft.

Notes:
l The seal and the wear sleeve must be installed in a dry condition.
l Ensure that the seal is fitted with the part number and the crankshaft rotation arrows toward the outside.
Caution: The front and rear seals and wear sleeves have different spiral grooves. The seal will not function if
it is installed at the wrong end of the engine.
3 Fit the wear sleeve and seal (C4) as a unit onto the locator, GE50008.
4 Fit the installer (C2), GE50012, onto the locator.
5 Apply clean engine oil to the face of the nut (C1), GE50014, and to its contact area on the installer, GE50012.
6 Fit the nut to the locator and tighten the nut until the inside surface of the installer is in contact with the
locator.
7 Remove all of the tools from the crankshaft.
8 Fit the vibration damper, Operation 5-4.

Workshop Manual, TSD3455E, Issue 1 67

This document has been printed from SPI². Not for Resale
5 2300
Crankshaft rear seal and wear sleeve

To renew Operation 5-3

Special requirements
Special tools Consumable products
Description Part number Description Part number
Locator assembly GE50008
Bolt GE50009 Quick cure primer CV60892
Distorter protection ring GE50010
Distorter tool GE50011
Installer GE50013 Retaining compound CV60893
Nut GE50014

To remove
1 Remove the flywheel, Operation 13-1.
Note: The crankshaft front seal and wear sleeve are supplied as a set and must be installed as a set. If a seal
is renewed, the wear sleeve must also be renewed.
2 Drill three holes (A2) at an equal distance around the circumference of the seal. Fit self-tapping screws (A1),
complete with washers if necessary, to the holes and use a screwdriver as a lever to remove the seal from the
crankcase. Ensure that the flywheel housing does not become damaged during this operation.
3 Fit the distorter protection ring (B1), GE50010, to the seal bore and at the same depth as the wear sleeve.
The distorter ring is fitted to protect the seal bore in the crankcase during the removal of the wear sleeve.
4 Insert the distorter tool (B2), GE50011, between the protection ring and the wear sleeve. With the sharp
edge of the tool against the wear sleeve, use a socket and spanner to rotate the distorter and cause a crease
to form in the wear sleeve. Repeat this procedure in three or more places until the wear sleeve becomes loose
on the crankshaft.
5 Remove the distorter tool, the protection ring and the wear sleeve.

68 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 5
To fit
Note: Before the new seal and wear sleeve are installed, read carefully the special instruction which is supplied
with each seal and wear sleeve.
1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure primer,
CV60892. Apply some retaining compound, CV60893, to the crankshaft outside diameter before the wear
sleeve is installed on the crankshaft. Do not allow any quick cure primer or retaining compound to touch the
lip of the seal.
2 Use the bolts (C4), GE50009, to install the guide, GE50008, on the crankshaft.

Notes:
l The seal and the wear sleeve must be installed in a dry condition.
l Ensure that the seal is fitted with the part number and the crankshaft rotation arrows toward the outside.
Caution: The front and rear seals and wear sleeves have different spiral grooves. The seal will not function if
it is installed at the wrong end of the engine.
3 Fit the wear sleeve and seal (C3) as a unit onto the locator, GE50008.
4 Fit the installer (C2), GE50012, onto the locator.
5 Apply clean engine oil to the face of the nut (C1), GE50014, and to its contact area on the installer, GE50012.
6 Fit the nut to the locator and tighten the nut until the inside surface of the installer is in contact with the
locator.
7 Remove all of the tools from the crankshaft.
8 Fit the flywheel, Operation 13-1.

Workshop Manual, TSD3455E, Issue 1 69

This document has been printed from SPI². Not for Resale
5 2300
Crankshaft vibration damper

To remove and to fit Operation 5-4

To remove
1 Remove the fan guards.
2 Slacken the tension on the fan drive belts, then remove the belts from the crankshaft pulley (A1).
3 Attach a strap and a suitable lifting device to the vibration damper (A2). Remove the six bolts and washers
which retain the vibration damper and the adapter (A3) to the crankshaft.
4 Remove damper and adapter. The weight of the vibration damper is approximately 25 kg (55 lb).
Note: The dash marks at the front of the damper assembly must be in alignment with each other. If the dash
marks are not in alignment, renew the damper assembly.

70 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 5
To fit
1 Attach a strap and a suitable lifting device to the vibration damper (A2). Use a 5/8 -18 x 6 in (152 mm) long
guide stud, and fit the vibration damper (A2) and adapter (A3) to the crankshaft. The weight of the vibration
damper is approximately 25 kg (55 lb).
2 Fit the crankshaft pulley (A1). Apply clean engine oil to the threads of the bolts and install five of the six bolts
and washers which retain the pulley, the damper and the adapter.
3 Remove the guide stud and install the final bolt and washer. Tighten the bolts to a torque of 215 Nm
(158 lbf ft).
4 Fit the fan belts and adjust the tension as given in Operation 12-7.
5 Fit the fan guards.

Workshop Manual, TSD3455E, Issue 1 71

This document has been printed from SPI². Not for Resale
 This page is intentionally blank

This document has been printed from SPI². Not for Resale
 2300

6
Gear case and drive assembly 6

General information
The cast iron gear case contains the timing gears for the engine and the gears which drive the coolant pump
(A4), the lubricating oil pump (A1) and the fuel transfer pump (A8). All of the gears are spur gears.
An adjustable idler gear (A6) provides the backlash between the main idler (A7) and the camshaft gear (A5).
If the cylinder head and head gasket are removed, the tolerances may change and the position of the
adjustable idler gear can be adjusted to obtain the correct backlash settings.
The camshaft drive gear (A5) is fitted with pendulum rollers. These are designed to counteract the injector
pulses and eliminate vibration and noise.
For correct engine timing, a line is provided on the large gear (A3) of the compound idler which aligns with a
‘V’ on the crankshaft gear (A2), and a mark on the camshaft drive gear aligns with a line at the top of the gear
case.

Workshop Manual, TSD3455E, Issue 1 73

This document has been printed from SPI². Not for Resale
6 2300

Gear case cover

To remove and to fit Operation 6-1

To remove
1 Remove the radiator, Operation 12-4.
2 Remove the fan, Operation 12-5.
3 Loosen the bolts which retain the gear case cover. Do not remove the bolts from the assembly, allow them
to be retained by the seal.
4 Remove the gear case cover.
To fit
Note: Ensure that all contact surfaces of the seal and the gear case are clean and free from oil, paint, burrs or
debris.
1 Examine the seal and renew if necessary, clean the contact surfaces of the seal and the gear case.
2 Fit the gear case cover and tighten the bolts, in the sequence shown (A), to a torque of 20 Nm (15 lbf ft).
3 Fit the fan, Operation 12-5.
4 Fit the radiator, Operation 12-4.

74 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 6
Timing gears

To remove and to fit Operation 6-2

Special requirements
Special tools Consumable products
Description Part number Description Part number
Engine turning tool CH11148
Thread lock compound (10 ml) 21820 117
Guide stud GE50019

To remove
1 Remove the gear case cover, Operation 6-1, and set the engine to the correct timing position for number
one cylinder as follows:
2 Remove the top bolt (A1) from the cover (A2) on the flywheel housing and loosen the other cover bolt to
allow the cover to open. The top bolt (A1) is the timing bolt.
Caution: If a customer-fitted speed sensor is fitted to the flywheel housing, it must be removed before the
engine turning tool can be inserted.
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing bolt.
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind the cover
(A2). Use a 1/2 inch drive ratchet with the turning tool to rotate the engine flywheel in the normal direction of
rotation (anti-clockwise when viewed on the flywheel) until the timing bolt engages with the threaded hole in
the flywheel. When the number one piston is at top dead centre on its compression stroke, the mark on the
camshaft gear is be aligned with the mark on the gear case (B1). If the mark is not aligned, withdraw the timing
bolt, rotate the crankshaft a further 360 degrees in the normal direction of rotation and insert the timing bolt
again.
Caution: If the flywheel is turned past the threaded hole, the flywheel must be turned in the opposite direction
for approximately 45 degrees and then back in the normal direction of rotation until the timing bolt engages
with the threaded hole. This is to eliminate backlash.

Continued

Workshop Manual, TSD3455E, Issue 1 75

This document has been printed from SPI². Not for Resale
6 2300
5 Remove the rocker lever and rocker shaft assemblies, Operation 3-2. If the camshaft gear (C2) is to be
removed, slacken the six retaining bolts before the removal of the rocker lever and rocker shaft assemblies.
6 Remove the camshaft gear (C2), if relevant. Use the guide stud, GE50019. If the gear case is to be removed,
the camshaft gear should be removed at this stage.
Caution: Do not rotate the crankshaft with the camshaft gear or any of the idler gears removed and the rocker
shaft assemblies installed. Damage can be caused to the pistons and valves, or to both.
7 Remove the three bolts and the thrust plate (C3) and remove the adjustable idler. Discard the bolts.
8 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged.
9 Remove the three bolts and the thrust plate (C4) and remove the main idler. Discard the bolts.
10 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged.
11 Remove the four bolts and the thrust plate (C1) and withdraw the compound idler. Discard the bolts.
12 Check the condition of the bearing in the gear. Renew the bearing if it is worn or damaged.
Note: If the nuts for the adjustable idler axle are loosened, the backlash for the camshaft gear and main idler
gear will have to be adjusted during the assembly operation. Refer to Operation 3-11.
13 Check the condition of the shaft for the adjustable idler. If the bearing diameter of the shaft is worn or
damaged, remove the nuts and bolt and renew the assembly. Apply thread lock compound, 21820 117, to the
bolt and five studs, fit the bolt and nuts and tighten to a torque of 50 +/- 10 Nm (37 +/- 7 lbf ft).
14 Check the condition of the shaft for the main idler. If the bearing diameter of the shaft is worn or damaged,
remove the nuts and bolt and renew the assembly. Apply thread lock compound, 21820 117, to the bolt and
five studs, fit the bolt and nuts and tighten to a torque of 50 +/- 10 Nm (37 +/- 7 lbf ft).
15 Check the condition of the shaft for the compound idler. Renew the shaft if the bearing diameter is worn or
damaged. If the shaft is removed, renew the five bolts which retain the shaft. Apply thread lock compound,
21820 117, to the bolts and tighten to a torque of 50 +/- 10 Nm (37 +/- 7 lbf ft).

76 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 6
To fit
1 Fit the assembly of the compound idler to its shaft, ensure that the "V" timing mark on the crankshaft is
aligned with the marks on the large gear of the compound idler. Fit the thrust plate and fit new bolts. Tighten
the bolts to a torque of 28 +/- 7 Nm (21 +/- 5 lbf ft).
2 Fit the main idler gear to the shaft assembly. Fit the thrust plate and fit new bolts. Apply thread lock
compound, 21820 117, to the bolts and tighten to a torque of 28 +/- 7 Nm (21 +/- 5 lbf ft).
3 Fit the adjustable idler gear to the shaft assembly. Fit the thrust plate and fit new bolts. Apply thread lock
compound, 21820 117, to the bolts and tighten to a torque of 28 +/- 7 Nm (21 +/- 5 lbf ft).
4 Fit the camshaft gear, if it was removed: align the hole in the gear with the dowel pin on the adapter plate.
If the timing mark on the gear does not align with the pointer at the top of the gear case, remove the gear and
rotate the camshaft until the gear can be installed with the marks aligned. Ensure that the timing marks on the
crankshaft gear and compound idler are aligned.
5 Fit the bolts which retain the gear, remove the guide stud and fit the bolt which remains. Tighten the bolts to
a torque of 240 +/- 40 Nm (177 +/- 30 lbf ft).
6 Fit the gear case cover, Operation 6-1.
7 Remove the timing bolt from the flywheel and fit the cover and plug.
8 Install the rocker lever and shaft assemblies, Operation 3-2.

Workshop Manual, TSD3455E, Issue 1 77

This document has been printed from SPI². Not for Resale
6 2300

How to check the position of the timing gears Operation 6-3

Fuel injection timing and the operation of the rocker valves depends on the correct alignment of the timing
gears. When the timing mark on the camshaft gear (A1) is aligned with the mark on the gear case, the ‘V’ on
the crankshaft must also be aligned exactly with the line (A2) on the idler gear. At this position the piston of
cylinder number 1 is at top dead centre (TDC). This can be confirmed by the insertion of the timing bolt into
the flywheel as described in Timing gears - To remove and to fit, Operation 6-2.

78 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 6
Gear case

To remove and to fit Operation 6-4

Special requirements
Consumable products
Description Part number
Thread lock compound (10 ml) 21820 117

To remove
1 Remove the gear case cover, Operation 6-1.
2 Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case.
3 Disconnect the lead and remove crankshaft timing sensor from behind the bottom of the gear case.
4 Remove the fan drive assembly, Operation 12-6.
5 Remove the coolant pump, Operation 12-13.
6 Remove the crankshaft vibration damper, Operation 5-4.
7 Remove the front engine support, Operation 7-1.
8 Remove the sump, Operation 10-3.
9 Remove the fuel transfer pump, Operation 11-2. If necessary, remove the drive for the fuel transfer pump,
Operation 11-4.
10 Remove the timing gears and the camshaft drive gear, Operation 6-2.
11 Remove the bolt and five nuts which retain the axle for the adjustable idler.
12 Remove the bolt and five nuts which retain the axle for the main idler.
13 Remove the three bolts which retain the camshaft front seal assembly. Remove the thrust plate, the
adaptor plate and the seal plate. Discard the seals from the seal plate.
14 Attach a suitable hoist to the gear case and remove the mounting bolts.
15 Remove the gear case from the dowels in the crankcase. The weight of the gear case is approximately
62 kg (137 lb).

Workshop Manual, TSD3455E, Issue 1 79

This document has been printed from SPI². Not for Resale
6 2300
To fit
1 Clean thoroughly the contact surfaces of the crankcase and gear case.
2 Fit the two dowels, if they have been removed, and ensure that they protrude from the crankcase by 19,1 +/
- 0,5 mm (0.75 +/- 0.02 in).
3 Ensure that the front surface of the crankcase is clean and fit a new joint to the crankcase.
4 Ensure that the rear face of the gear case is clean and fit the gear case onto the crankcase. Fit the retaining
bolts and tighten to a torque of 50 +/- 10 Nm (37 +/- 7 lbf ft).
5 Check the condition of the shaft for the adjustable idler. If the bearing diameter of the shaft is worn or
damaged, renew the assembly. Apply thread lock compound, 21820 117, to the bolt and five studs, fit the bolt
and nuts and tighten to a torque of 50 +/- 10 Nm (37 +/- 7 lbf ft).
6 Check the condition of the shaft for the main idler. If the bearing diameter of the shaft is worn or damaged,
renew the assembly. Apply thread lock compound, 21820 117, to the bolt and five studs, fit the bolt and nuts
and tighten to a torque of 50 +/- 10 Nm (37 +/- 7 lbf ft).
7 Check the condition of the shaft for the compound idler. Renew the shaft if the bearing diameter is worn or
damaged. Renew the five bolts which retain the shaft. Apply thread lock compound, 21820 117, to the bolts
and tighten to a torque of 50 +/- 10 Nm (37 +/- 7 lbf ft).
8 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubricating oil to the
‘O’ ring seal on the outside of the plate. Fit the seal plate with the face seal against the cylinder head. Insert
the adapter plate and fit the thrust plate. Apply thread lock compound, 21820 117, to the three bolts, fit the
bolts and tighten.
9 Fit the timing gears, Operation 6-2.
10 Fit the sump, Operation 10-3.
11 Fit a new crankshaft front seal and wear sleeve, Operation 5-2.
12 Fit the front engine support, Operation 7-1.
13 Fit the crankshaft vibration damper, Operation 5-4.
14 Fit the coolant pump, Operation 12-13.
15 Fit the camshaft timing sensor to its location behind the top of the gear case and connect the lead.
16 Fit the crankshaft timing sensor to its location behind the bottom of the gear case and connect the lead.
17 Fit the gear case cover, Operation 6-1.

80 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

7
Crankcase and cylinder liners 7

General information
The crankcase is a single unit casting made from high quality cast iron and comprises the crank chamber and
the cylinder block. The crank chamber extends below the centre of the crankshaft to ensure rigidity. The
crankshaft is supported in seven bearings secured by removable caps and fitted with thrust washers at the
centre bearing. The cylinder block contains a row of six cylinders arranged vertically. Wet-type cylinder liners
are used, these are manufactured from cast iron and are induction hardened. A steel spacer plate is fitted to
the top face of the crankcase. This improves the strength and durability when compared with conventional
designs.

Workshop Manual, TSD3455E, Issue 1 81

This document has been printed from SPI². Not for Resale
7 2300

Front engine support

To remove and to fit Operation 7-1

To remove
1 Remove the radiator, Operation 12-4.
2 Use a suitable hoist, attached to the front lifting bracket, to support the engine and remove the bolts (A2).
which retain the front mounting support (A3) to the base frame.
3 Remove the eight bolts and washers (A1) and remove the engine support.
To fit
1 Fit the front engine support to the engine and retain with eight bolts and washers (A1).
2 Attach the engine support to the base frame with the relevant bolts (A2), remove the hoist from the lifting
bracket and tighten the bolts.
3 Fit the radiator, Operation 12-4.

82 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 7
Cylinder liners

To remove and to fit Operation 7-2

Special requirements
Special tools Consumable products
Description Part number Description Part number
Cylinder liner remover GE50001 Anti-seize compound CV60890
Cylinder liner installer GE50000 Anti-seize compound CV60890

To remove
1 Remove the pistons and connecting rod assemblies, Operation 4-1.
2 Fit covers over the journals of the crankshaft for protection from dirt or water.
3 Use the special tool (A1), GE50001, to remove the cylinder liners (A2). Make a note of the bore position to
which each liner is fitted.
To fit
1 Clean the cylinder liners and the liner bores in the crankcase.
2 Install the cylinder liners in the cylinder block without the ‘O’ ring seals or the filler band. Ensure that the
cylinder liners are fitted to their original positions.
3 Check the protrusion of the cylinder liners, Operation 7-3.
4 Remove the liners and fit new ‘O’ ring seals.
Note: Apply liquid soap and/or clean engine oil immediately before assembly. Do not apply the liquid soap and/
or clean engine oil to the seals too early as the seals may swell and become pinched by the liners during
installation.
5 When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upper filler band
must be lubricated before installation. If the lower ‘O’ ring seals are black in colour, apply liquid soap to them
and to the cylinder block, and immerse the upper filler band in clean engine oil. If the lower ‘O’ rings are brown
in colour, apply engine oil to them, to the cylinder block and immerse the upper filler band in clean engine oil.
6 After the engine oil or liquid soap has been applied, immerse the filler band in clean engine oil, then
immediately fit the filler band to the groove in the cylinder liner below the liner flange. Immediately install the
cylinder liner in the crankcase before expansion of the band occurs. Use the special tool (B1), GE50000, to
install the liners (B2). Ensure that the liners are fitted to the correct positions.
7 Fit the pistons and connecting rod assemblies, Operation 4-1.

Workshop Manual, TSD3455E, Issue 1 83

This document has been printed from SPI². Not for Resale
7 2300

To check and to adjust the protrusion of the cylinder liners Operation 7-3

Special requirements
Special tools
Description Part number Description Part number
Clamp bolt GE50005 Fibre washer GE50007
Clamp washer GE50006 Cylinder liner projection tool GE50002

Note: Cylinder liner protrusion is measured from the top of the cylinder liner to the top of the spacer plate.
1 Ensure that the top face of the cylinder block (A4) is clean. Fit a new spacer plate gasket and fit a clean
spacer plate (A3).
2 Fit the cylinder liners to the cylinder block without seals or bands. Ensure that the cylinder liners are fitted
to their original positions.
3 Install all of the bolts (A6), GE50005, or the six bolts around the liner (A5) to be checked. A plain washer
(A1), GE50006, and a fabric washer (A2), GE50007, must be fitted to each bolt. Tighten the bolts to a torque
of 95 Nm (70 lbf ft).
4 Use the special tool, GE50002, to measure the liner protrusion at the four positions shown (B1, B2, B3 and
B4) and record the measurements for each cylinder.
5 Add the four readings for each cylinder and divide the sum of the readings by four to obtain the average
reading for each cylinder.
The correct specifications for cylinder liner protrusion are:
Liner protrusion: 0,025 to 0,152 mm (0.001 to 0.006 in)
Maximum variation in each liner: 0,051 mm (0.0020 in)
Maximum average variation between adjacent liners: 0,051 mm (0.0020 in)
Maximum variation between all liners: 0,102 mm (0.0040 in)
Note: If the liner protrusion changes around the liner, turn the liner to a new position within the bore. If the liner
protrusion is not within the specifications, move the liner to a different bore. Inspect the top face of the cylinder
block.

Continued

84 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 7
6 If the liner protrusions are all below the specifications or low in the range, 0,025 mm (0.001 in) or 0,051 mm
(0.002 in), try a thinner spacer plate, available from your Perkins dealer. These plates are 0,076 mm (0.003 in)
thinner than the original plate and will increase the liner protrusion. Use these spacer plates to compensate for
low liner protrusions which are less than the 0,076 mm (0.003 in). Use these spacer plates if inspection of the
top face of the cylinder block reveals no measurable damage directly under the liner flanges but the average
liner protrusion is less than 0,076 mm (0.003 in).
Caution: Do not exceed the maximum liner protrusion of 0,152 mm (0.006 in). Excessive liner protrusion will
cause the liner flange to crack.
7 When the liner protrusion is correct, add a temporary mark to the liner and to the spacer plate to assist with
the assembly procedure. Remove the bolts and washers, and withdraw the cylinder liners.
8 When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upper filler band
must be lubricated before installation. If the lower ‘O’ ring seals are black in colour, apply liquid soap to them
and to the cylinder block. Immerse the upper filler band in clean engine oil. If the lower ‘O’ rings are brown in
colour, apply engine oil to them and to the cylinder block. Immerse the upper filler band in clean engine oil.
Note: Apply liquid soap and/or clean engine oil immediately before assembly. Do not apply the liquid soap and/
or clean engine oil to the seals too early as the seals may swell and become pinched by the liners during
installation.

Workshop Manual, TSD3455E, Issue 1 85

This document has been printed from SPI². Not for Resale
 This page is intentionally blank

This document has been printed from SPI². Not for Resale
 2300

8
Engine timing and electronic controls 8

General information
The electronic control system, used on the 2300 and 2800 Series engines, consists of the Electronic Control
Module (ECM) and engine sensors. The ECM, mounted on the left side of the engine, is the computer which
controls the engine operating parameters. The software stores the operating maps which define power, engine
speed, etc. Electronic unit injectors are fitted to each cylinder. A solenoid on each injector controls the amount
of fuel delivered by the injector. The ECM sends a signal to each injector solenoid to provide complete control
of the engine. The ECM compares the ‘desired speed’ with the actual engine speed, obtained from sensors on
the crankshaft and camshaft drives, and calculates how much fuel to inject to achieve the desired speed.
The timing of the fuel injection is determined by the ECM after it has received information from the coolant
temperature sensor, the air temperature sensor of the inlet manifold and the turbocharger boost pressure
sensor. From a signal provided by the engine speed/timing sensor, the ECM determines where top dead centre
on cylinder number one is located. The ECM decides when injection should occur relative to top dead centre
and provides a signal to the injector at the desired time. The ECM adjusts timing for the best engine
performance, fuel economy and white smoke control. Actual or desired timing can be viewed with the service
tool.
The ECM controls the amount of fuel injected by varying signals to the injectors. The ECM sends a high voltage
signal to energise the solenoids of the fuel injectors. The injectors will pump fuel ONLY if the injector solenoid
is energised.
Warning! The electrical circuit for the fuel injector units operates on 110 volts. Do NOT work on the fuel injector
units unless the power supply to the ECM has been disconnected.
The software inside the ECM sets limits on the amount of fuel that can be injected dependent on the selected
rating and the engine operating parameters. The parameters which follow are monitored by the ECM: High
coolant temperature, low lubricating oil pressure, overspeed condition, inlet manifold air temperature, fuel
temperature and boost pressure.
The electronic system has some ability to diagnose itself. When a diagnostic code is generated, the
‘Diagnostics’ lamp is illuminated and the exact fault should be determined by use of the service tool. Full
information on fault finding the system is given in the relevant Diagnostic Manual.
The ECM communicates with the service tool through the Perkins Data Link (PDL); a connector is normally
fitted to the wiring harness to enable the service tool to be connected. A J1939 data link is also available in
addition to the Perkins Data Link.

Workshop Manual, TSD3455E, Issue 1 87

This document has been printed from SPI². Not for Resale
8 2300

Electronic control module

To remove and to fit Operation 8-1

To remove
1 Switch off the engine and disconnect the electrical power supply.
2 Loosen fully the Allen screws from the J1 and J2 connectors (A1 and A4).
3 Remove the two nuts which retain the bar (A6) and the control module (A3), release the ground strap and
withdraw the bar and connectors from the control module.
4 Support the control module, remove the two remaining nuts (A2 and A5) and remove the electronic control
module from the engine.
To fit
1 Fit the electronic control module. Retain with four nuts, ensure that the ground strap is fitted correctly.
Note: To avoid damage to the components, use the Allen screws to pull the mating parts of the connectors
(A1 and A4) and control module (A3) together. Ensure that the connectors are aligned correctly and are fitted
to the correct positions before the Allen screws are tightened.
2 Fit the connectors (A1 and A4) and retain with Allen screws. Tighten the screws to a torque of 3 Nm
(2.2 lbf ft). Do NOT overtighten the screws.
3 Connect the electrical power supply.

88 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 8
Engine timing

To check Operation 8-2

Special requirements
Special tools
Description Part number
Engine turning tool CH11148

If it becomes necessary to check the valve/ignition timing position of the engine, use this procedure:
1 With the engine switched off and electrically isolated, remove the rocker cover, Operation 3-1.
2 Remove the cover (A2) from the flywheel housing. The top bolt (A1) is the timing bolt.
Caution: If a customer-fitted speed sensor is fitted to the flywheel housing, it must be removed before the
engine turning tool can be inserted.
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing bolt.
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind the cover
(A2). Use a 1/2 inch drive ratchet with the turning tool to rotate the engine flywheel in the normal direction of
rotation (anti-clockwise when viewed on the flywheel) until the timing bolt engages with the threaded hole in
the flywheel. The piston of number 1 cylinder is now at TDC (top dead centre).

Continued

Workshop Manual, TSD3455E, Issue 1 89

This document has been printed from SPI². Not for Resale
8 2300
When the number one piston is at TDC on its compression stroke, the valves of number one cylinder will be
fully closed, if not, remove the timing bolt, rotate the engine by a further 360 degrees and insert again the timing
bolt. The piston of number 1 cylinder is now at TDC on its compression stroke. Withdraw the timing bolt from
the flywheel and rotate the engine backwards until the follower of the number one injector rocker lever is in
contact with the back of the cam lobe.
5 Attach a plunger clock and set the plunger on the top face of the rocker lever of the number one injector at
the position shown (B1). Set the clock to zero.
6 Rotate the engine in the normal direction of rotation until the timing bolt can again enter the hole in the
flywheel and check the reading on the plunger clock. The cam lift at this point should be 2,92 +/- 0,25 mm
(0.115 +/- 0.010 in).
7 Repeat step 6 to ensure that a consistent reading is obtained.
8 If the reading is not within the limits, adjust the position of the adjustable idler gear to advance or retard the
camshaft as necessary. Refer to Operation 3-11.

90 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

9
Aspiration system 9

General information
The induction system of the engine is supplied with air under pressure by a turbocharger. The turbocharger is
driven by the energy of the exhaust gas.
Special thermal sleeves manufactured from stainless steel are fitted to the exhaust ports. These reduce the
amount of heat transferred to the cooling system and direct the thermal energy to the turbocharger.
The exhaust gas passes through the exhaust manifold and enters the turbine housing of the turbocharger. The
pressure of the exhaust gas causes the turbine rotor to rotate, the gas then leaves the engine through the
exhaust pipes. Exhaust pipes and exhaust silencers are fitted in accordance with the requirements of the
installation. An impeller at the other end of the turbine shaft supplies clean air to the engine at more than
atmospheric pressure. The air is drawn through the air cleaner and into the compressor housing which
contains the impeller. From the compressor housing the air is forced through the air-to-air charge cooler which
is integral with the radiator. The air is cooled as it flows through the charge cooler, this improves the
combustion efficiency. From the charge cooler the air is directed through ducts to the cylinder head and enters
the cylinders of the engine.
A restriction indicator is fitted next to the casing of the air filter to give a visual indication when the filter element
is dirty. The air filter needs no special maintenance, except for the procedures given in the User’s Handbook.
The engine breather is an integral part of the rocker cover. If the breather becomes blocked or damaged, the
assembly of the rocker cover should be renewed, refer to Operation 3-1.

Workshop Manual, TSD3455E, Issue 1 91

This document has been printed from SPI². Not for Resale
9 2300

Exhaust manifold

To remove and to fit Operation 9-1

Special requirements
Special tools Consumable products
Description Part number Description Part number
Pressurizing pump GE50031 Anti-seize compound CV60889

To remove
1 Remove the turbocharger, Operation 9-2.
2 Remove the thermostat housing, Operation 12-10.
3 Remove the exhaust shield.
4 Remove the nuts and spacers which retain the exhaust manifold and remove the manifold.
5 Withdraw the sleeves from the cylinder head.
6 Remove the gaskets from the cylinder head.
To fit
1 Check the condition of all sleeves, studs and nuts. Renew the components if worn or damaged. Apply anti-
seize compound, CV60889, to the studs.
2 Fit new gaskets over the studs and install the sleeves. Fit the exhaust manifold, fit the spacers and the nuts.
Tighten the nuts in the sequence shown (A) to a torque of 52 +/- 7 Nm (38 +/- 5 lbf ft).
3 Fit the thermostat housing, Operation 12-10.
4 Fit the turbocharger, Operation 9-2.

92 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 9
Turbocharger

To remove and to fit Operation 9-2

To remove
1 Disconnect the exhaust pipe from the turbocharger.
2 Remove the air duct from between the turbocharger and the air cleaner.
3 Disconnect the air duct from between the turbocharger and the charge air cooler.
4 Disconnect the oil feed (A2) and oil drain (A1) pipes.
5 Use a strap and hoist to support the turbocharger, remove the four bolts which retain the turbocharger on
the exhaust manifold and remove the turbocharger. Note that the turbocharger weighs approximately 26.5 kg
(58 lb).
To fit
1 Fit the turbocharger to the exhaust manifold. Apply CV60889 anti-seize compound to the bolts. Fit the bolts
and tighten them to a torque of 55 +/- 5 Nm (40 +/- 4 lbf ft).
2 Connect the oil feed and oil drain pipes (A2 and A1).
3 Fit the air duct between the turbocharger and the air cleaner.
4 Connect the air duct between the turbocharger and the charge air cooler.
5 Connect the exhaust pipe.

Workshop Manual, TSD3455E, Issue 1 93

This document has been printed from SPI². Not for Resale
9 2300

To dismantle and to assemble Operation 9-3

To dismantle
1 Remove turbocharger, Operation 9-2.
2 Add temporary alignment marks between the bearing housing and both the compressor housing and the
turbine housing to ensure that the parts can be correctly aligned during the assembly operation.
3 Loosen the nuts on the clamps and separate the compressor housing and the turbine housing from the
bearing housing.
Caution: Do not attempt to dismantle the turbocharger bearing housing. Do not remove the compressor wheel.
The bearing housing is not serviceable and must be renewed only as a unit.
4 Check the condition of all components. Renew any worn or damaged components.
To assemble
1 Fit the compressor housing and the turbine housing to the bearing housing and retain with the relevant
clamps.
2 Adjust the position of both the compressor and turbine housings until the temporary marks are aligned with
those on the bearing housing. Tighten the clamp nuts.
3 Fit the turbocharger, Operation 9-2.

94 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

10
Lubrication system 10

General information
A wet sump type of lubrication system is used on the engine.
The engine is fitted with a lubricating oil pump, of the spur gear type. The drive gear of the lubricating oil pump
is driven by a gear on the front of the crankshaft. The oil pump draws oil from the sump through a suction
strainer. A pressure relief valve, integral with the oil pump, ensures that a constant pressure is maintained.
Oil leaves the oil pump and is delivered to the main oil gallery in the crankcase. When the engine is warm, the
oil passes through the oil cooler and oil filter before it enters the main oil gallery. When the engine is cool, the
high viscosity of the oil causes the by-pass valves to open and provide oil directly to the oil filter. To protect the
engine, the by-pass valves will also open if there is a restriction in the oil cooler or the oil filter.
A supply of oil is directed to the turbocharger from the oil filter. After lubricating the turbocharger bearings, the
oil drains into the crankcase and returns to the sump.
The main oil gallery is parallel to the crankshaft and supplies oil to each of the main bearings and through the
main bearings to the crankshaft. The oil in the crankshaft then lubricates the connecting rod bearings. A supply
of oil from the main oil gallery is directed to the piston cooling jets which cool the pistons.
An oil passage at the front end of the main oil gallery delivers oil to the cylinder head gallery and has passages
which supply the bearings of the drive gears. The teeth of the drive gears are lubricated by spill oil as it returns
to the sump.
Small holes in the cylinder head gallery direct oil to the camshaft bearing journals and also to the pedestals for
the rocker shafts. From the pedestals the oil passes through the rocker shafts to lubricate the bearings of the
valve and unit injector rocker levers. Oil flows through drilled passages in the rocker levers to lubricate the
rollers, the valve bridges and the contact surfaces of the actuators for the unit injectors. Other components of
the valve assembly are lubricated by splash oil. An aperture at the front of the cylinder head allows oil to drain
to the sump.
The full length sump is manufactured from a composite material.
Some engines are fitted with an oil sample valve which enables a small quantity of oil to be drained for testing.
Information about the oil sample valve is given in Chapter 15, Auxiliary equipment.

Workshop Manual, TSD3455E, Issue 1 95

This document has been printed from SPI². Not for Resale
10 2300

Oil filter and oil filter header

To remove and to fit Operation 10-1

To remove
1 Remove the plug (A5) and drain the oil from the oil filter housing.
2 Remove the oil filter housing (A3), and remove the oil filter element.
Warning! Discard the used filter element and used engine oil in a safe place and in accordance with local
regulations.
3 Remove the four bolts (A1) which connect the oil filter header to the oil cooler.
4 Remove the two bolts (A2) which retain the oil filter header on the crankcase.
5 Disconnect the turbocharger oil supply pipe from the elbow behind the oil cooler.
6 Remove the four bolts which retain the assembly of the elbow and oil filter header on the crankcase and
withdraw the assembly.
7 Remove the four bolts to separate the oil filter header from the elbow. Renew the ‘O’ ring seals if they are
worn or damaged.

96 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 10
To fit
1 Ensure that the ‘O’ ring seals are fitted to the elbow. Assemble the elbow and oil filter header and retain with
four bolts.
2 Ensure that the used gasket material has been removed from the mating faces. Fit the assembly to the
crankcase, complete with new gaskets, and retain with four short bolts through the elbow and two long bolts
(A2) through the oil filter header.
3 Fit the four bolts (A1) which retain the oil filter header to the oil cooler
4 Connect the turbocharger oil supply pipe and tighten securely.
5 Clean the filter housing (A3) and clean the contact face of the filter head. Clean the drain plug (A2) and fit it
to the housing.
Note: If a degreasing agent has been used to clean the housing, a special lubricant, CV60896, must be applied
to the threads before the housing is fitted.
6 Fit a new element into the filter housing, ensure that it engages fully with the guide in the base of the housing.
Fit a new ‘O’ ring seal around the top of the housing.
Caution: It is important that only genuine Perkins parts are used. The use of incorrect parts could damage the
engine.
7 Fit the housing (A3) onto the filter head and tighten by use of a socket and torque wrench on the hexagon
(A1). Tighten the housing to a torque of 90 Nm (66 lbf ft). Do NOT overtighten. Ensure that the drain plug is
tightened securely.
8 Check the amount of engine oil in the sump. If necessary, add more oil of the correct grade and specification.
Refer to the User’s Handbook.
9 Run the engine and check for leaks. Check again the amount of engine oil in the sump. If necessary, add
more oil of the correct grade and specification.

Workshop Manual, TSD3455E, Issue 1 97

This document has been printed from SPI². Not for Resale
10 2300
Oil filter header

To dismantle and to assemble Operation 10-2

To dismantle
1 Remove the two plugs (A5 and A6) which retain the by-pass valves in the oil filter header (A1).
2 Remove the spring (A3) and the plunger (A2) for the oil cooler by-pass valve. Remove the spring (A8) and
plunger (A9) for the oil filter by-pass valve. Add temporary marks to the two springs and plungers to assist
during assembly.
3 Remove the two small plugs and the adaptor.
To assemble
Inspect the ‘O’ ring seals fitted to all plugs and renew them if necessary.
Note: Ensure that the plungers and springs are fitted to their original locations.
1 Fit the plunger (A9) and spring (A8) to the oil filter header.
2 Fit the plunger (A2) and spring (A3) to the oil filter header.
3 Fit the plugs (A5 and A6). Tighten each plug to 100 +/- 15 Nm (74 +/- 11 lbf ft).
4 Fit the adaptor and the two small plugs. Tighten each of them to 25 +/- 5 Nm (18 +/- 4 lbf ft).

98 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 10
Sump

To remove and to fit Operation 10-3

Special requirements
Consumable products
Description Part number
RTV silicone sealant CV60888

To remove
Warning! Hot oil and components can cause personal injury. Do not allow hot oil or components to contact
the skin.
1 Drain the oil from the sump (A2).
2 Loosen the bolts which retain the sump on the engine. Do not remove the bolts fully, allow them to be
retained by the seal (A1).
3 Remove the sump.

Workshop Manual, TSD3455E, Issue 1 99

This document has been printed from SPI². Not for Resale
10 2300
To fit
1 Examine the sump seal and renew if necessary. Ensure that the machined surface of the sump is clean
before a new seal is fitted.
2 Clean the bottom face of the crankcase and also the bottom faces of the flywheel housing and the gear case.
3 Apply a bead of RTV silicone sealant, CV60888, at the four positions where the edge of the flywheel housing
and gear case joints will be in contact with the sump seal. The bead must cover completely the exposed edge
of the joints.
4 Fit the sump and tighten the bolts to a torque of 30 Nm (22 lbf ft); use the sequence shown (B).
5 Fill the engine to the correct level with oil of the correct grade and specification. Refer to the User’s
Handbook.

100 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 10
Oil pump

To remove and to fit Operation 10-4

To remove
1 Remove the sump, Operation 10-3.
2 Remove the oil supply tube (A3) and the strainer and tube (A2).
3 Remove the bolts and remove the oil pump (A4).
Note: If the oil pump is to be dismantled, slacken the bolt which retains the drive gear (A1) before the pump is
removed from the engine.
To fit
1 Fit the oil pump to the crankcase.
2 Apply clean engine oil to the ‘O’ ring seals of the tubes.
3 Install oil supply tube (A3) and strainer and tube (A2).
4 Fit the sump, Operation 10-3.

Workshop Manual, TSD3455E, Issue 1 101

This document has been printed from SPI². Not for Resale
10 2300

To dismantle and to assemble Operation 10-5

To dismantle
1 Remove the bolt and washer which retain the gear on the shaft.
2 Use a suitable gear puller to remove drive gear (A1) from the shaft. Remove the key from the shaft.
3 Remove retainer (A5) for the by-pass valve.
4 Remove the spring (A4) and the by-pass valve (A3).
5 Remove the cover (A6) from the pump body (A2).
6 Remove the idler gear and drive gear from pump body.
To assemble
1 Apply clean engine oil to the idler gear and drive gear and install the gears in the oil pump body.
2 Fit the by-pass valve, the spring and the retainer to the pump body (A2).
3 Fit the key to the shaft.
4 Fit the drive gear (A1) to the shaft. Install the washer and bolt which retain the gear. Tighten the bolt to a
torque of 55 +/- 10 Nm (41 +/- 7 lbf ft). Ensure that the oil pump turns freely after assembly.

102 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

11
Fuel system 11

General information
The fuel supply circuit used on the 2300 and 2800 Series engines is a conventional design for engines fitted
with unit injectors. A fuel transfer pump, driven by the timing gears of the engine, is fitted behind the gear case
on the left side of the engine. The fuel transfer pump draws fuel from the fuel tank. The fuel is filtered by the
primary fuel filter before it enters the transfer pump. From the transfer pump, the fuel is filtered by the
secondary fuel filter and is then supplied to the fuel gallery in the cylinder head. The fuel injectors draw fuel
from the gallery and return the spill fuel to the same gallery. A pressure relief valve ensures that the pressure
in the gallery is maintained and any excess fuel is returned to the fuel tank.
Each unit injector is operated, through a rocker lever, by a lobe of the camshaft. This provides the force
required to pressurize the fuel in the injector. The camshaft has three lobes for each cylinder, the other two
lobes operate the inlet and exhaust valves. The unit injectors are fitted with a solenoid (A1) which is
electronically controlled by the ECM (engine control module).
Low pressure fuel circulates through the body of the unit injector and excess fuel is returned to the fuel gallery
through a spill port. When the solenoid of the unit injector is activated by a signal from the ECM, it closes the
escape route for the fuel and the pressure increases in the injector tip (A4).
Injection begins when the pressure in the tip reaches 34464 kPa (5,000 lb/in2). At this pressure the force
applied by the spring (A3) is not sufficient to keep the nozzle closed. As the plunger (A2) moves through its full
stroke, the pressure increases. When the correct amount of fuel has been injected, the ECM de-energises the
solenoid. This opens the spill port and the reduction in pressure allows the spring (A3) to close the injector
nozzle. The high-pressure fuel which passes through the spill port returns to the fuel gallery.
During maintenance of the fuel system, clean thoroughly each component before it is removed or dismantled
and fit suitable caps and plugs to all unions immediately after they have been disconnected.
Operations for the unit injectors and the injector sleeves are given in Chapter 3 Cylinder head assembly.

Workshop Manual, TSD3455E, Issue 1 103

This document has been printed from SPI². Not for Resale
11 2300

Fuel priming pump

To remove and to fit Operation 11-1

To remove‘
1 Remove two bolts (A2) and remove fuel priming pump (A1).
To fit
1 Inspect the gasket of the fuel priming pump; fit a new gasket if necessary.
2 Fit the fuel priming pump (A1) and retain with the two bolts (A2).

104 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 11
Fuel transfer pump

To remove and to fit Operation 11-2

To remove
1 Disconnect the fuel pipes from the fuel transfer pump (A2).
2 Use plugs or caps to seal temporarily all openings to prevent contamination of the fuel system.
3 Remove the bolts (A1) and withdraw the fuel transfer pump.
To fit
1 Check the condition of the ‘O’ ring seal on the fuel transfer pump, renew the seal if it is worn or damaged.
2 Ensure that the ‘O’ ring seal is fitted correctly to the fuel transfer pump. Apply a small amount of clean engine
oil to the seal.
3 Fit the fuel transfer pump (A2) and retain with two bolts (A1).
4 Remove the plugs or caps from the fuel pipe openings and connect the fuel pipes.
5 Eliminate air from the fuel system, Operation 11-6.

Workshop Manual, TSD3455E, Issue 1 105

This document has been printed from SPI². Not for Resale
11 2300

To test Operation 11-3

Use a suitable test rig and diesel fuel to test the fuel transfer pump.
1 Run the pump at 2940 rev/min. The flow at 650 kPa (94 lb/in2) must be 4,5 litres/min (1.0 UK gall/min).
2 Run the pump at 840 rev/min. The flow at 550 kPa (80 lb/in2) must be 3,0 litres/min (0.66 UK gall/min).
3 Run the pump at 100 rev/min with the inlet to the atmosphere for 10 seconds. The pump must maintain a
vacuum of 60 kPa (9 lb/in2) for 30 seconds when the inlet is blocked.
If the pump cannot achieve the figures given above, it must be renewed.

106 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 11
Drive for the fuel transfer pump

To remove and to fit Operation 11-4

To remove
1 Remove the fuel transfer pump (A2), Operation 11-2.
2 Remove four bolts and washers (A1) and withdraw the assembly of the pump drive and housing (A3) from
the gear case.
3 Remove the three bolts from the housing (B1) and remove the assembly of the bearings and gear (B2) from
the housing.
4 Remove the ‘O’ ring seal (B3) from the housing.
5 Inspect all components, renew any which are worn or damaged.
To fit
1 Fit the assembly of the bearings and gear (B2) into the pump drive housing (B1).
2 Retain the gear and bearings in the housing with the three bolts.
3 Fit a new ‘O’ ring seal (B3) to the housing.
4 Insert carefully the assembly of the pump drive and pump drive housing into the gear case. Retain with four
bolts and washers.
5 Fit the fuel transfer pump, Operation 11-2.

Workshop Manual, TSD3455E, Issue 1 107

This document has been printed from SPI². Not for Resale
11 2300
Fuel filter header

To remove and to fit Operation 11-5

To remove
1 Remove the fuel priming pump (A2), Operation 11-1.
2 Disconnect the fuel pipes (A1, A3, A4 and A5). Fit plugs or caps to all openings to prevent contamination of
the fuel system.
3 Remove the filter housings and elements from the fuel filter header.
Warning! Discard the used filter elements and ‘O’ ring seals in a safe place and in accordance with local
regulations.
4 Remove the bolts which retain the filter header on the crankcase.
To fit
1 Fit the filter header to the crankcase.
2 Remove any plugs or caps and connect the fuel pipes (A1, A3, A4 and A5).
3 Renew the fuel filter elements in the primary and secondary fuel filter canisters. Use the procedures given
in the User’s Handbook, TSD3449E.
4 Fit the fuel priming pump, Operation 11-1.
5 Eliminate air from the fuel system, Operation 11-6.

108 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 11
Low pressure fuel system

How to eliminate air from the fuel system Operation 11-6

This procedure is used normally when the engine runs out of fuel.
1 Loosen the union of the fuel return pipe (A1). Unlock and operate the hand priming pump (A2) until fuel, free
from air, flows from the union; this procedure will require many strokes of the pump. Use a cloth or a container
to collect the excess fuel.
2 Tighten the union (A1). Operate the hand priming pump until a strong pressure is felt on the pump. Push the
priming pump plunger inward. Tighten the plunger by hand and continue immediately with the next stage.
3 Start the engine.
Caution: Do not crank the engine continuously for more than 30 seconds. Allow the starter motor to cool for
two minutes before the engine is cranked again.
4 If the engine will not start, allow the starter motor to cool for 2 minutes. Repeat steps 1 and 2 to start the
engine. Continue to eliminate air from the fuel system if:
l The engine starts, but runs unevenly.
l The engine starts, but continues to misfire or smoke.
5 Run the engine with no load until it runs smoothly.

Workshop Manual, TSD3455E, Issue 1 109

This document has been printed from SPI². Not for Resale
 This page is intentionally blank

This document has been printed from SPI². Not for Resale
 2300

12
Cooling system 12

General information
A pressurised coolant system is used on the engine. This allows the system to operate at a temperature higher
than the boiling point of water and prevents cavitation in the coolant pump.
In normal operation, the coolant pump directs most of the coolant through the oil cooler and into the cylinder
block. The coolant circulates around the cylinder liners and is then directed into the cylinder head where it flows
around the valves and passages for the exhaust gases. The coolant leaves the cylinder head at the front end
and enters the thermostat housing.
When the engine is cold, the thermostats are closed and the coolant flow is directed back to the coolant pump.
When the engine is at normal operating temperature, the thermostats open and the flow is directed to the top
of the radiator. The coolant flows from the top to the bottom of the radiator and then returns to the coolant
pump.
Only the approved coolant mixture should be used in the engine. Refer to the User’s Handbook.

Workshop Manual, TSD3455E, Issue 1 111

This document has been printed from SPI². Not for Resale
12 2300

Cooling system

To inspect Operation 12-1

Inspect visually the cooling system before any tests are performed.

Notes:
l Inspect the coolant pump seals. A small amount of leakage of coolant across the surface of the face seal
in the water pump is normal. Its purpose is to provide lubrication for the seal.
l There is a hole in the water pump body to allow coolant to drain. Small amounts of coolant might be seen
to leak intermittently from the drain hole during the engine operation cycle.
l Signs of a small leakage through the drain hole are not an indication that the pump is faulty. Coolant stains
or intermittent drops of coolant from the hole, indicate normal operation of the pump.
1 Check the coolant level in the cooling system.
Warning! On a hot engine release the filler cap carefully as the system will be under pressure.
2 Check for leaks in the system.
3 Ensure that the air flow through the radiator is not restricted. Check for bent fins in the radiator and also for
large deposits of dirt or debris.
4 Inspect the drive belts for the fan.
5 Check for damage to the fan blades.
6 Check for air or combustion gas in the cooling system.
7 Inspect the filler cap and check the surface which the filler cap seals against. This surface must be clean.

112 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 12
Leakage test Operation 12-2

Special requirements
Special tools
Description Part number
Pressurizing pump GE50031

Use the procedure which follows to check for leakage of the cooling system.
Warning! On a hot engine release the filler cap carefully as the system will be under pressure. Cooling system
conditioner contains alkali. Avoid contact with skin and eyes.
1 When the engine is cool, loosen the filler cap slowly to relieve any pressure, then remove the filler cap from
the radiator.
2 Ensure that the coolant is at the correct level.
3 Attach the pressurizing pump, GE50031, to the radiator and apply pressure until the reading on the gauge
is 20 kPa (3 lb/in2) more than the pressure given on the filler cap.
4 Check the radiator for leakage.
5 Check all connection points and hoses for leakage.
The cooling system is free from leaks if you do NOT see any external leakage and the reading remains
constant for at least five minutes. If the reading on the gauge goes down and there is no external leakage, the
cooling system must be leaking internally. Make repairs as necessary.

Workshop Manual, TSD3455E, Issue 1 113

This document has been printed from SPI². Not for Resale
12 2300
Coolant filler cap

To test Operation 12-3

Special requirements
Special tools
Description Part number
Pressurizing pump GE50031

Use the procedure which follows to check the operation of the coolant filler cap.
Warning! On a hot engine release the filler cap carefully as the system will be under pressure. Cooling system
conditioner contains alkali. Avoid contact with skin and eyes.
1 When the engine is cool, loosen the filler cap slowly to relieve any pressure, then remove the filler cap from
the radiator.
2 Carefully inspect the filler cap. Check for damage to the seals and to the sealing surface. Examine the filler
cap, the seal and the surface for seal, ensure that they are free from deposits. Any deposits or other material
that is found on these items must be removed.
3 Check the opening pressure for the filler cap as follows: fit the filler cap to the pressurizing pump, GE50031.
4 Apply pressure and check the gauge for the exact pressure which opens the filler cap.
5 Compare the reading on the gauge with the correct pressure which should open the filler cap, this figure is
given on the filler cap.
6 Renew the filler cap if it is defective.

114 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 12
Radiator

To remove and to fit Operation 12-4

To remove
1 Drain the coolant into a suitable container.
2 Remove the air duct from between the charge air cooler and the air inlet elbow.
3 Remove the coolant pipe from between the thermostat housing and the top of the radiator.
4 Remove the fan guards.
5 Remove the air duct from between the turbocharger and the base of the charge air cooler.
6 Remove the coolant pipe from between the coolant pump elbow and the radiator.
7 Remove fasteners which retain the radiator to its base frame.
To fit
1 Fit the radiator to its base frame.
2 Fit the coolant pipe between the coolant pump elbow and the radiator.
3 Fit the air duct between the turbocharger and the base of the charge air cooler.
4 Fit the fan guards.
5 Fit the coolant pipe between the thermostat housing and the top of the radiator.
6 Fit the air duct between the charge air cooler and the air inlet elbow.
7 Fill the radiator with the correct coolant mixture. Refer to the User’s Handbook.
8 Run the engine until it reaches the normal temperature of operation and check for leaks.

Workshop Manual, TSD3455E, Issue 1 115

This document has been printed from SPI². Not for Resale
12 2300
Fan

To remove and to fit Operation 12-5

To remove
1 Switch off the engine and disconnect the electrical power supply.
2 Remove the fan guards.
Caution: Take care during the removal of the fan; ensure that the radiator does not become damaged.
3 Remove the bolts which retain the fan on the hub and remove the fan.
To fit
1 Fit the fan to the hub and retain with the six bolts.
2 Fit the fan guards.
3 Connect the electrical power supply.

116 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 12
Fan drive assembly

To remove and to fit Operation 12-6

To remove
1 Remove the fan, Operation 12-5.
2 Remove the hub (A1).
3 Loosen the adjustment bolts to release the tension on the alternator belt. Remove the belt and the alternator
(A3).
4 Release the tension on the fan drive belts and remove the belts.
5 Remove the two bolts and cap which retain the pulley (A2) and withdraw the pulley complete with bearing.
6 Remove the two nuts and two bolts which retain the fan bearing housing (A4) and remove the housing.
To fit
1 Fit the fan bearing housing (A4).
2 Fit the pulley (A2) and retain with the cap and two bolts. Tighten the bolts to a torque of 24 +/- 6 Nm (18 +/
- 4 lbf ft).
3 Fit the fan drive belts and adjust the tension as given in Operation 12-7.
4 Fit the alternator (A3), fit the alternator belt and adjust the tension as given in Operation 14-3.
5 Fit the hub (A1).
6 Fit the fan, Operation 12-5.

Workshop Manual, TSD3455E, Issue 1 117

This document has been printed from SPI². Not for Resale
12 2300
Fan drive belts

To check and to adjust the tension Operation 12-7

1 Remove the fan guards.

2 Use a Borroughs belt tension gauge to check the tension at the position shown (A1). It should be 800 N,
which is equivalent to 4,0 mm of movement when a force of 33 N is applied. To adjust the tension, proceed as
follows:
3 Loosen the lock nuts on the adjustment bolt (A2), loosen the large lock nut on the belt tensioner and turn
the adjustment bolt (A2) until the correct tension is obtained. Tighten the large lock nut and check the tension
of the belts again. If the tension is correct, slacken the adjustment bolt (A2) just enough to release its tension,
then tighten its lock nuts.
4 Fit the fan guards and run the engine for 15 minutes. Remove the guards and check again the tension.
5 For new fan belts, set the tension to 868 N, which is equivalent to 4,0 mm of movement when a force of
35,7 N is applied. After the engine has been run for 15 minutes, check the tension and adjust it to 800 N;
equivalent to 4,0 mm of movement when a force of 33 N is applied.
6 When the correct tension is obtained, fit the fan guards.

118 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 12
To renew Operation 12-8

1 Remove the fan, Operation 12-5.

2 Loosen the belt tensioner and remove the old belts. Ensure that the grooves of the pulley are free from
grease and dirt and fit a new set of belts.
3 Fit the fan and tighten the bolts securely. Adjust the fan belts to the correct tension, as given in Operation
12-7.

Workshop Manual, TSD3455E, Issue 1 119

This document has been printed from SPI². Not for Resale
12 2300
Engine oil cooler

To remove and to fit Operation 12-9

To remove
1 Drain the coolant from the engine.
2 Use a tray to collect any oil which may spill from the oil cooler during its removal.
3 Make temporary marks on the coolant duct (A2) and the oil cooler (A1) for correct alignment during
assembly. Remove the four bolts (A3) which retain the coolant duct (A2) and carefully separate the duct from
the oil cooler.
4 Remove the four bolts which retain the oil cooler (B1) on the oil filter header (B3).
5 Withdrawn the oil cooler from the elbow (B2), take care not to damage the seal.
6 Remove the ‘O’ ring seal from the elbow (B2).
Note: The matrix is not removable from the housing.
To fit
1 Clean the core tubes of the oil cooler with a 3,81 mm (0.150 in) diameter rod.
2 Check the condition of the ‘O’ ring seals used on the oil cooler and the oil filter header. Renew any ‘O’ ring
seal which appears to be worn or damaged. Apply clean engine oil to the seals before they are fitted.
3 Ensure that the ‘O’ ring seals are fitted to the oil filter header.
4 Fit the ‘O’ ring seal over the elbow (B2). Apply clean engine oil on the seal.
5 Align the oil cooler with the elbow and slide the oil cooler over the elbow. Fit the four bolts which retain the
oil cooler on the oil filter header.
6 Fit an ‘O’ ring seal to the coolant duct (A2) and fit the duct to the oil cooler. Fit the four bolts.
7 Fill the cooling system with the correct coolant mixture. Refer to the User’s Handbook.
8 Check the amount of lubricating oil in the sump. Add lubricating oil of the correct grade, if necessary. Refer
to the User’s Handbook.
9 Clean away any oil or coolant which has been spilled.

120 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 12
Thermostats and thermostat housing

To remove and to fit Operation 12-10

To remove
1 Drain the coolant until the level is below the thermostat housing (A1).
2 Disconnect the cable (A3) from the coolant temperature sensor.
3 Release the hose clips (A2) and disconnect the pipe and hose from the top of the unit.
4 If the thermostats are to be removed, loosen all five bolts of the thermostat housing; then remove fully the
three bolts (A4) which retain the thermostat housing on the cylinder head. If the thermostat housing is to be
removed without access to the thermostats, do not loosen the five bolts; remove only the three retaining bolts
(A4).
5 Lift carefully the assembly to separate it from the coolant bobbin (A5) at its base.
Note: If relevant, remove the two short bolts which remain, separate the two halves of the assembly and
remove the thermostats.

Workshop Manual, TSD3455E, Issue 1 121

This document has been printed from SPI². Not for Resale
12 2300
To fit
Note: If the thermostat housing has not been dismantled, continue from step 3.
1 Clean thoroughly both parts of the assembly and check the condition of the lip-type seals. Renew the seals
if they are worn or damaged.
2 Fit the new thermostats. Ensure that the new thermostats are fitted correctly. Fit a new ‘O’ ring type seal to
the groove in the thermostat housing, assemble the two halves of the unit and retain with the two short bolts.
3 Ensure that the mating face on the cylinder head is clean. Fit new seals to the coolant bobbin (A5) which fits
into the base of the unit and lubricate the seals with a small amount of rubber lubricant. Fit a new ‘O’ ring seal
to the groove in the mating face of the housing and fit the assembly over the coolant bobbin. Fit the three bolts
(A4) which retain the thermostat housing on the cylinder head and tighten all five bolts to a torque of 47 +/-
9 Nm (35 +/- 7 lbf ft).
4 Connect the hose to the top of the housing and tighten the hose clip.
5 Connect the cable (A3) to the coolant temperature sensor.
6 Fill the coolant system to the correct level with the approved coolant mixture.
7 Operate the engine until it reaches the normal temperature of operation and check for leaks. Stop the
engine, check the coolant level and, if necessary, add extra coolant.
Warning! Take care during removal of the filler cap as the coolant system will be under pressure.

122 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 12
To test the thermostats Operation 12-11

1 Remove the thermostats from the engine.

Warning! Use care during this operation to avoid serious injury from the hot water.
2 Heat water in a suitable container until the temperature is 98 °C (208 °F). Stir the water to ensure that the
temperature is consistent within the container.
3 Suspend the thermostat in the container of water. The thermostat must be below the surface of the water
and it must be away from the sides and the bottom of the container.
4 Ensure that the water is maintained at the correct temperature for ten minutes.
5 After ten minutes, remove the thermostat. Immediately check the distance that the thermostat has opened.
It must be a minimum of 10,4 mm (0.41 in). If the distance is less, renew the thermostat.

Workshop Manual, TSD3455E, Issue 1 123

This document has been printed from SPI². Not for Resale
12 2300
Coolant temperature sensor

To test Operation 12-12

Special requirements
Special tools
Description Part number
Thermometer GE50032

Check the accuracy of the coolant temperature sensor (A2) if one of these conditions exist:
The engine runs at a temperature that is too hot, but a normal temperature is indicated. A loss of coolant is
found.
The engine runs at a normal temperature, but a hot temperature is indicated. No loss of coolant is found.
Note: The coolant temperature can be read on the display screen of the electronic service tool.
Warning! On a hot engine release the filler cap carefully as the system will be under pressure.
1 When the engine is cool, release the coolant filler cap to relieve any pressure.
2 Remove one of the two plugs (A1) and install the special thermometer, GE50032. A temperature indicator
of known accuracy can also be used for this test. Tighten again the coolant filler cap.
3 Start the engine and run the engine until the temperature reaches the desired range according to the test
thermometer. If necessary, place a cover over part of the radiator to cause a restriction of the coolant flow. The
reading on the coolant temperature indicator should agree with the test thermometer within the tolerance range
of the coolant temperature indicator.
Pointer Test Test
position thermometer °C thermometer °F
1 65 to 77 150 to 170
2 99 to 103 210 to 218

Caution: If a cover was used over part of the radiator ensure that is removed on completion of the test.
4 If the temperature sensor is renewed, do not attempt to disconnect the leads from the unit. Disconnect the
unit at the connection shown (A3).

124 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 12
Coolant pump

To remove and to fit Operation 12-13

To remove
1 Drain the coolant from the engine into a suitable container for storage or disposal.
2 Remove the thermostat housing, Operation 12-10.
3 Remove the oil cooler, Operation 12-9.
4 Remove four bolts (A1) and the elbow (A2).
5 Check the condition of the ‘O’ ring seal (B1), discard the seal if it is worn or damaged. Remove the bolts
from the gear case cover and the coolant pump and remove the coolant pump.
To fit
1 Fit the coolant pump to the gear case, ensure that the gear engages correctly. Tighten the bolts.
2 If necessary, fit a new ‘O’ ring seal (B1). Fit the elbow (A2) and retain with four bolts (A1).
3 Fit the oil cooler, Operation 12-9.
4 Fit the thermostat housing, Operation 12-10.
5 Fill the coolant system to the correct level with the specified coolant mixture. Refer to the User’s Handbook
for the correct procedure.

Workshop Manual, TSD3455E, Issue 1 125

This document has been printed from SPI². Not for Resale
12 2300

To dismantle and to assemble Operation 12-14

Notes:
l The coolant pump seal can be renewed without removal of the coolant pump from the engine.
l Intermittent leakage of a small amount of coolant from the hole in the coolant pump housing is not an
indication of a coolant pump seal failure. This is required to provide lubrication for the seal. Renew the
coolant pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from
the coolant pump housing.
l Service exchange coolant pumps can be obtained from your Perkins dealer.
To dismantle
1 Remove the bolt (A15) and washer (A14). Use a suitable puller to remove the impeller (A11) from the shaft
(A16). Ensure that the impeller does not become damaged during this operation.
2 Remove the spring and seal (A13) from the shaft.
Note: The coolant pumps of certain engines may not have a spring fitted at this position.
3 Remove the four bolts (A6) from the retainer (A7) and remove the ‘O’ ring seal (A9) from the housing (A10).
4 Remove the gear and shaft assembly (A8). Remove the bolt (A4) and retainers (A3 and A7) from the shaft
assembly.
5 Use a press to remove the shaft (A16) from the gear. Remove the bearing (A1), the spacer if fitted, and
second bearing (A12) from the shaft.
6 Remove the lip-type seal (A12) from the housing.

126 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 12
To assemble
1 Ensure that the shaft and the seal counter bore in the pump housing are clean.
2 Fit the bearing (A1), the spacer if relevant, and the second bearing (A2) to the shaft (A16).
3 Fit the retainer (A7) and gear (A8) to the shaft assembly. Fit the second retainer (A3) and the bolt (A4).
4 Fit a new lip-type seal (A12) into the housing (A10). The seal must be fitted with the lip toward the inside of
the housing. Apply a small amount of clean engine oil to the lip of the seal.
5 Fit a new ‘O’ ring seal (A9) to the housing.
6 Install the gear and shaft assembly in the housing. Fit the bolts (A6) which hold the retainer (A7) to the
housing.
Caution: Do not allow grease or oil to contact the faces of the seal. Do not stretch the seal during installation.
Note: The carbon seal assembly (A13) must rotate with the coolant pump shaft when it is installed. Use clean
water as a lubricant for assistance during installation.
7 Separate the spring from the seal assembly (A13). Use hand pressure to install the seal on the shaft (A16).
Push the seal onto the shaft until the seal faces make light contact. Fit the spring to the shaft.
8 Fit the impeller (A11) to the shaft and retain with the washer (A14) and bolt (A15). Tighten the bolt to a torque
of 39 +/- 3 Nm (28 +/- 2 lbf ft).
9 Fit the coolant pump, Operation 12-13.

Workshop Manual, TSD3455E, Issue 1 127

This document has been printed from SPI². Not for Resale
12 2300

To test the pressure of the coolant pump Operation 12-15

Special requirements
Special tools
Description Part number
Pressure gauge GE50033

1 To check that the coolant pump is operating correctly, the outlet pressure can be measured.
2 Remove the plug (A1) from the coolant manifold and connect the pressure gauge, GE50033, to the port.
3 Start the engine and run the engine until the normal temperature of operation is obtained.
4 Make a note of the reading on the pressure gauge. The pressure supplied by the coolant pump should be
112 +/- 12 kPa (16 +/- 2 lbf/in2).

128 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

13
Flywheel and housing 13

General information
The steel flywheel is fitted with a hardened starter ring. The flywheel is fastened securely to the rear face of
the crankshaft by a clamp ring and 12 bolts.
A dowel ensures that, when the flywheel is fitted, the timing marks on the flywheel are in the correct relationship
to the crankshaft.
The flywheel housing is located on the crankcase by two dowels and is retained by 24 bolts and washers. The
electric starter motor is mounted on the left side of the flywheel housing and a facility is provided on the right
side for setting the engine to the correct timing position for the purposes of checking and adjustment. The cover
(A1) can be removed for the insertion of the engine barring tool and the plug (A3) is removed for insertion of
the timing bolt (A1). The engine barring tool can be used to rotate the engine until the timing bolt can be
inserted in the flywheel. When the timing bolt can be inserted, dependent on the stroke, the piston of either
number one or number six cylinder will be at top dead centre.

Workshop Manual, TSD3455E, Issue 1 129

This document has been printed from SPI². Not for Resale
13 2300

Flywheel

To remove and to fit Operation 13-1

To remove
1 Remove two of the flywheel bolts from horizontally opposite sides of the flywheel and insert two suitable
guide studs.
2 Remove the bolts which remain and withdraw the flywheel from the crankshaft. Fit a suitable sling through
the centre of the flywheel and support the weight with a hoist. The weight of the flywheel is approximately 56 kg
(123 lb).
3 Remove the flywheel and remove the guide studs.
4 Remove the gear ring from the flywheel if necessary.
To fit
1 If the gear ring has been removed, heat the ring in an oven to a maximum temperature of 315 °C (600 °F)
and fit it to the flywheel. Ensure that the gear ring is fully seated on the flywheel.
Note: The gear ring must be fitted with the chamfer on the gear teeth toward the starter motor pinion.
2 Fit suitable guide studs to bolt holes at horizontally opposite sides of the flywheel. Ensure that the dowel is
fitted in the end of the crankshaft.
3 Attach a sling to the flywheel and use a hoist to locate the flywheel on the guide studs. Ensure and that the
flywheel is correctly aligned with the dowel.
4 Remove the sling and slide the flywheel up to the crankshaft.
5 Apply clean engine oil to the threads of the bolts which retain the flywheel and fit 10 of the bolts. Remove
the guide studs and fit the two bolts which remain. Tighten the bolts to a torque of 270 Nm (200 lbf ft).

130 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 13
Flywheel housing

To remove and to fit Operation 13-2

Special requirements
Consumable products
Description Part number
Liquid gasket CH10879

To remove
1 Remove the flywheel, Operation 13-1.
2 Remove the crankshaft rear seal and wear sleeve, Operation 5-3.
3 Remove the starter motor, Operation 14-1.
4 Remove the sump, Operation 10-3.
5 Use a suitable hoist to support the flywheel housing and remove the bolts (A1 to A24) which retain it.
Note: The bolts which retain the flywheel housing are of two different sizes. Make a note of their positions to
ensure that they are fitted correctly.
6 Remove the flywheel housing from the dowels in the crankcase. The weight of the flywheel housing is
approximately 83 kg (183 lb).

Workshop Manual, TSD3455E, Issue 1 131

This document has been printed from SPI². Not for Resale
13 2300
To fit
1 Clean thoroughly the contact surfaces of the crankcase and flywheel housing.
2 Fit the two dowels (B2 and B3) if they have been removed from the crankcase. They must protrude from the
crankcase by 19,1 +/- 0,5 mm (0.75 +/- 0.02 in).
3 Apply a bead of liquid gasket, CH10879, to the area shown (B1).
4 Attach a suitable hoist and fit the flywheel housing to the crankcase. Fit the bolts which retain the housing
but do not tighten at this stage.
5 Tighten the flywheel housing bolts as follows:
a. Tighten bolts A1 to A9, in numerical sequence, to a torque of 100 +/- 20 Nm (74 +/- 15 lbf ft).
b. Tighten bolts A10 to A24, in numerical sequence, to a torque of 40 +/- 10 Nm (30 +/- 7 lbf ft).
c. Tighten bolts A1 to A9, in numerical sequence, to a torque of 135 +/- 20 Nm (100 +/- 15 lbf ft).
d. Tighten bolts A10 to A24, in numerical sequence, to a torque of 55 +/- 10 Nm (40 +/- 7 lbf ft).
6 Fit the sump, Operation 10-3.
7 Fit the starter motor, Operation 14-1.
8 Fit a new crankshaft rear seal and wear sleeve, Operation 5-3.
9 Fit the flywheel, Operation 13-1.

132 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300

14
Electrical equipment 14

General information
This section includes the components which form part of the battery charging circuit and the engine starting
circuit: the alternator and starter motor.
A brush-type alternator is fitted at the front of the engine. The alternator unit is driven by a single belt from the
fan pulley. The output, 24 volts/70 amps, is controlled by an integral regulator.
The 24 volt starter motor is mounted on the flywheel housing and, when operated, rotates the engine flywheel
at a speed that is fast enough to start the engine. When the engine start button is operated, a solenoid,
mounted on the starter motor, engages the starter pinion with the ring gear of the flywheel. The circuit which
operates the starter motor is completed when the pinion is fully engaged. When the circuit between the battery
and the starter motor is complete, the pinion will rotate the engine flywheel. A clutch provides protection for the
starter motor so that the engine cannot turn the starter motor too fast. When the start button is released, the
pinion is withdrawn from the ring gear.

Workshop Manual, TSD3455E, Issue 1 133

This document has been printed from SPI². Not for Resale
14 2300

Starter motor

To remove and to fit Operation 14-1

To remove
Note: To assist with the assembly operation, identify and mark the positions of all wiring before it is
disconnected.
1 Disconnect the batteries before any service work is attempted.
2 Disconnect the wiring loom from the starter motor assembly (A2).
3 Fasten a hoist to the starter motor. Remove the three bolts (A1) which retain the starter motor on the flywheel
housing, then withdraw the starter motor from the housing. The weight of the starter motor is 32 kg (70 lb).
To fit
1 Use a hoist to support the starter motor. Fit the starter motor to the flywheel housing. Retain with three bolts.
2 Connect the wiring loom to the starter motor. If the engine earth strap is connected to the starter motor,
tighten the nut which retains the earth strap to a torque of 30,5 +/- 3,5 Nm (22.5 +/- 2.5 lbf ft).
3 Connect the batteries.

134 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 14
Alternator

To remove and to fit Operation 14-2

To remove
Note: To assist with the assembly operation, identify and mark the positions of all wiring before it is
disconnected.
1 Disconnect the batteries before any service work is attempted.
2 Remove the access panel in the fan guard.
3 Loosen the alternator pivot bolt (A3), the adjustment link bolt which is behind the fan pulley and the
adjustment bolt (A4). Move the alternator to release the drive belt and remove the drive belt from the alternator
pulley.
4 Disconnect the wiring loom from the alternator.
5 Remove the bolts (A3 and A4) and remove the alternator.
To fit
1 Fit the alternator and retain with the pivot bolt (A3) and the adjustment link bolt (A4). Do not tighten the bolts
at this stage.
2 Fit the alternator drive belt over the alternator pulley and set the tension as given in Operation 14-3.
3 Connect the wiring loom to the alternator.
4 Fit the access panel to the fan guard.
5 Connect the batteries.

Workshop Manual, TSD3455E, Issue 1 135

This document has been printed from SPI². Not for Resale
14 2300

To check and to adjust the tension of the alternator belt Operation 14-3

1 Remove the access panel in the fan guard and proceed as follows.
2 Use a Borroughs belt tension gauge to check the tension at the position shown (A5). It should be 267 N,
which is equivalent to 2,5 mm of movement when a force of 11,3 N is applied. To adjust the tension, proceed
as follows.
3 Loosen the alternator pivot bolt (A3), the adjustment link bolt which is behind the fan pulley and the
adjustment bolt (A4). Move the alternator to obtain the correct belt tension and tighten the bolts.
4 Fit the access panel to the fan guard and run the engine for 15 minutes. Remove the access panel and check
again the tension.
5 If a new alternator belt is fitted, set the tension to 400 N, which is equivalent to 2,5 mm of movement when
a force of 16,6 N is applied. After the engine has been run for 15 minutes, check the tension and adjust it to
267 N; equivalent to 2,5 mm of movement when a force of 11,3 N is applied.
6 When the correct tension is obtained, fit the access panel to the fan guard.

136 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 14
To renew the alternator belt Operation 14-4

1 Remove the fan, Operation 12-5.

2 Loosen the adjustment bolts to release the tension on the alternator belt and remove the old belt. Check that
the pulley grooves are clean and fit a new belt.
3 Fit the fan, Operation 12-5.
4 Adjust the alternator belt to the correct tension, Operation 14-3.

Workshop Manual, TSD3455E, Issue 1 137

This document has been printed from SPI². Not for Resale
 This page is intentionally blank

This document has been printed from SPI². Not for Resale
 2300

15
Auxiliary equipment 15

General information
Some engines are fitted with an oil sample valve. The valve enables a small quantity of oil to be drained for
testing. Details about further auxiliary equipment are not available at the time of print.

Oil sample valve

Warning! The ‘O’ ring fitted to the oil sample valve contains ‘VITON’, see the safety precautions for "Viton
seals" on page 4.
Note: Some engines have an oil sample valve (A1) fitted to the oil filter head. The oil sample valve is supplied
with an ‘O’ ring seal already fitted in a recess at the top of the threaded section. If the oil sample valve has
been removed, ensure that the ‘O’ ring is in place. Screw the oil sample valve into its boss on the filter head
and apply a torque of 24 +/- 2 Nm (17 +/-1 lbf ft); ensure that the torque is applied to that part of the sample
valve which is in contact with the oil filter head. Fit the eye of the dust cover strap into the recess close to the
top of the valve, then fit the cover over the valve.

Workshop Manual, TSD3455E, Issue 1 139

This document has been printed from SPI². Not for Resale
 This page is intentionally blank

This document has been printed from SPI². Not for Resale
 2300

16
Special tools 16

List of special tools

Tool number Description Illustration

CH11148 Engine turning tool

CH11149 Setting gauge, fuel injector

GE50000 Installer, cylinder liner

GE50001 Remover, cylinder liner

GE50002 Height tool, cylinder liner projection

Workshop Manual, TSD3455E, Issue 1 141

This document has been printed from SPI². Not for Resale
16 2300

Tool number Description Illustration

GE50003 Piston ring compressor

GE50004 Alignment tool, piston cooling jets

GE50005 Clamp bolt, cylinder liner (26 required)

GE50006 Washer (26 required)

GE50007 Fibre washer (26 required)

GE50008 Locator, crankshaft seal

142 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 16
Tool number Description Illustration

Bolt, crankshaft seal installer

GE50009
(use with GE50008)

Distorter protection ring

GE50010
(use with GE50008)

Distorter tool
GE50011
(use with GE50008)

Installer, front crankshaft seal

GE50012
(use with GE50008)

Installer, rear crankshaft seal

GE50013
(use with GE50008)

Nut
GE50014
(use with GE50008)

Workshop Manual, TSD3455E, Issue 1 143

This document has been printed from SPI². Not for Resale
16 2300
Tool number Description Illustration

GE50015 Pilot, camshaft guide

GE50016 Alignment sleeve, camshaft guide

GE50017 Guide, camshaft

GE50018 Cradle, camshaft

GE50019 Guide stud, camshaft gear

GE50020 Impact socket

144 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 16
Tool number Description Illustration

GE50021 Remover/installer, injector sleeve

GE50022 Brush, large bore

GE50023 Brush, small tapered

GE50024 Brush, small bore

GE50025 Lifting hook, camshaft

GE50026 Compressor, valve spring

Workshop Manual, TSD3455E, Issue 1 145

This document has been printed from SPI². Not for Resale
16 2300
Tool number Description Illustration

GE50027 Installer, valve guide seal

GE50028 Vacuum pump

GE50029 Vacuum pump bottle

GE50030 Vacuum pump tube

GE50031 Pressurising pump, coolant system

GE50032 Thermometer, coolant temperature

146 Workshop Manual, TSD3455E, Issue 1

This document has been printed from SPI². Not for Resale
 2300 16
Tool number Description Illustration

GE50033 Pressure gauge

GE50043 Remover/installer, valve guide

GE50044 Sleeve, valve guide

GE50045 Piston ring compressor

VP12712 Lift bracket, cylinder head

Workshop Manual, TSD3455E, Issue 1 147

This document has been printed from SPI². Not for Resale
 This page is intentionally blank

This document has been printed from SPI². Not for Resale
Perkins 2300 Series
Model 2306C-E14

DIAGNOSTIC MANUAL

6 cylinder turbocharged diesel engine

Publication TSD 3457E, Issue 1.

© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in August 2002 by Technical Publications,
Perkins Engines Company Limited, Tixall Road, Stafford, ST16 3UB, England
Diagnostic Manual, TSD 3453E, Issue 1 i
Chapters

1 General information

2 Electronic system overview

3 Programming parameters

4 Fault diagnosis

5 Special Tools

The following pages contain a detailed table of contents

ii Diagnostic Manual, TSD 3453E, Issue 1

2300 Series

Contents

1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1

Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2

Glossary of terms . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3

2 Electronic system overview

System operation .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9

Electronic controls ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9

Engine governor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9

Timing considerations .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9

Fuel injection . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 10

Engine monitoring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11

Fuel temperature monitoring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11

Self diagnostics ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11

Effect of diagnostic codes on engine performance .. ... ... ... ... ... ... ... ... ... ... ... ... . 12

Current totals stored in the ECM . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12

Programmable parameters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12

Passwords . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13

Diagnostic Manual, TSD 3457E, Issue 1 iii

 2300 Series
Engine component diagram . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14

OEM connection diagram . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15

Sensor and connector location diagram . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16

Engine wiring diagram .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17

Machine wiring diagram (all options) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18

Electrical connectors and functions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19

Colour codes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19

Service tools and diagnostics .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20

3 Programming parameters
Connecting the TIPSS-EST ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21

Passwords .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23

Programming a new ECM . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24

Programming an ECM using flash programming ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27

ECM date/time clock .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28

ECM diagnostic clock ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29

Injector codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29

TIPSS-EST cylinder cut-out test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29

Programming parameters . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29

System configuration parameters ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30

Customer specified parameters ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32

4 Fault diagnosis
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35

Diagnostic procedures without a diagnostic fault code

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36

Diagnostic symptoms
Test 1 - Engine will not crank . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
iv Diagnostic Manual, TSD 3457E, Issue 1
2300 Series
Test 2 - Engine cranks but will not start ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 38
Test 3 - Engine misfires, runs rough or is unstable ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 39
Test 4 - Low power/poor or no response to throttle ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 40
Test 5 - Intermittent engine shutdowns . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 41
Test 6 - Intermittent low power or power cut-outs . ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 42
Test 7 - Electronic service tool will not communicate with the ECM . ... ... ... ... ... ... ... . 43
Test 8 - ECM will not accept factory passwords ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 44
Test 9 - Excessive black smoke ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 45
Test 10 - Excessive white smoke .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 46
Test 11 - Excessive blue smoke ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 47
Test 12 - Engine cannot reach correct rev/min . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 48
Test 13 - Poor acceleration or response ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 49
Test 14 - Poor fuel consumption ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 50
Test 15 - Too much vibration . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 51
Test 16 - Noise coming from cylinder ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 52
Test 17 - Excessive valve clearance . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 53
Test 18 - Valve rotocoil or spring lock is free ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 54
Test 19 - Mechanical noise (knock) in engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 55
Test 20 - Oil in cooling system .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 56
Test 21 - Fuel in cooling system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 57
Test 22 - Coolant in lubricating oil . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 58
Test 23 - Fuel dilution of lubricating oil .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 59
Test 24 - Engine has early wear ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 60
Test 25 - Engine has low oil pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 61
Test 26 - Engine uses too much lubricating oil .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 62
Test 27 - Engine coolant is too hot ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 63
Test 28 - Oil at the exhaust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 64
Test 29 - Engine has a fuel supply problem .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 65
Test 30 - Indicator lamp not functioning correctly .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 66
Test 31 - Inlet air manifold temperature is too high ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 67
Test 32 - Engine has a high fuel temperature ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 68

Diagnostic procedures with an event code

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 69

Event codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 69

Diagnostic tests
Test 33 - High intake manifold pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 70
Test 34 - Low oil pressure . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 71
Test 35 - High coolant temperature ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 72
Test 36 - Engine overspeed .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 73
Test 37 - High fuel temperature . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 74
Test 38 - High intake manifold air temperature . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 75

Diagnostic procedures with a diagnostic fault code

General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 76

Diagnostic codes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 76
Diagnostic Manual, TSD 3457E, Issue 1 v
 2300 Series
Diagnostic terminology . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 78

Connectors . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79

Diagnostic tests
Test 39 - Inspecting electrical connectors .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 82
Test 40 - Electrical power supply to the ECM ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88
Test 41 - Analogue sensor open or short circuit test . ... ... ... ... ... ... ... ... ... ... ... ... ... 91
Test 42 - ECM Status indicator output circuit test .. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 101
Test 43 - +5 V Sensor voltage supply circuit test ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 107
Test 44 - PWM desired speed setting circuit test ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 112
Test 45 - Perkins Data Link circuit test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 118
Test 46 - Engine speed/timing circuit test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 126
Test 47 - Engine speed/timing calibration .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 134
Test 48 - Injector solenoids circuit test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 138
Test 49 - Analogue sensor abnormal test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146

5 Special tools
Required service tools .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 149

Optional service tools ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 150

vi Diagnostic Manual, TSD 3457E, Issue 1

2300 Series

1
General information 1

Introduction
The 2300 and 2800 Series industrial diesel engines are the latest development from Perkins Engines
Company Limited, a world leader in the design and manufacture of high performance diesel engines.
Read and remember the "Safety precautions" on page 2. They are given for your protection and must be
applied at all times.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.
Ensure that all adjustments and repairs are done by personnel who have had the correct training.

Diagnostic Manual, TSD 3457E, Issue 1 1

1 2300 Series
Safety precautions
These safety precautions are important. Reference must also be made to the local regulations in the country
of operation.
l Only use these engines in the type of application for which they have been designed.
l Do not change the specification of the engine.
l Do not smoke when you put fuel in the tank.
l Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
l Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
l Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme caution must be used to prevent injury).
l Do not make adjustments that you do not understand.
l Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
l Other persons must be kept at a safe distance while the engine or equipment is in operation.
l Do not permit loose clothing or long hair near moving parts.
l Keep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
l Do not operate the engine if a safety guard has been removed.
l Do not remove the filler cap of the cooling system while the engine is hot and while the coolant is under
pressure, because dangerous hot coolant can be discharged.
l Do not use salt water or any other coolant which can cause corrosion in the closed coolant circuit.
l Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
l Disconnect the battery terminals before a repair is made to the electrical system. Always disconnect the
negative terminal first.
l Only one person must control the engine.
l Ensure that the engine is operated only from the control panel or from the operator’s position.
l If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
l Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
l Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets.
l Discard used lubricating oil in a safe place to prevent contamination.
l The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
l Fuel and oil pipes MUST be inspected for cracks or damage before they are fitted to the engine.
l Fit only genuine Perkins parts.

2 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 1
Glossary of terms
Active diagnostic code
Describes a condition that is currently present to alert the operator or service technician of an abnormal engine
operation parameter. See also Diagnostic fault code.
Aftermarket device
A device or an accessory that is installed by the customer or OEM after the engine has been delivered.
Alternating current (AC)
The direction of current flow changes (alternates) regularly and constantly in a circuit.
Atmospheric pressure sensor
Analogue sensor generates a signal proportional to atmospheric (barometric) air pressure in the crankcase
and sends a signal to the ECM.
Before top center (BTC)
The 180° of crankshaft rotation before the piston reaches the very top of its travel (normal direction of rotation).
Intake manifold pressure sensor
This sensor measures inlet manifold air pressure (boost pressure) and sends a signal to the ECM.
Bypass circuit
A circuit, usually temporary, to substitute for an existing circuit, typically for test purposes.
Calibration
An electronic adjustment of a sensor signal.
Perkins engine monitoring
The part of the Perkins Electronic Engine Control that monitors coolant temperature, oil pressure, intake
manifold air temperature and coolant level to alert the operator of detected problems. The coolant temperature,
intake manifold air temperature, and oil pressure sensors are supplied by Perkins and monitored by the ECM.
Aftermarket engine monitoring systems do not interface with the Perkins Electronic Engine Control.
Check engine lamp
Sometimes referred to as the diagnostic lamp, it is used to alert the operator of the presence of an active event.
Code
Refer to diagnostic fault code and diagnostic event code.
Cold mode
A mode of engine operation where the timing is retarded for engine protection, reduced smoke emissions and
faster warm up time.

Diagnostic Manual, TSD 3457E, Issue 1 3

1 2300 Series
Component identifier (CID)
The CID is a number that identifies the specific component of the electronic control system that has
experienced a diagnostic code. This is part of the PDL (Perkins Data Link).
Communication adapter
The communication adapter provides a communication link between the ECM and an electronic service tool.
Coolant temperature sensor
This sensor detects the engine coolant temperature for Cold Mode operation and Perkins Engine Monitoring.
Crankshaft position sensor
A sensor that measures the crankshaft position, the direction of rotation, and engine rev/min and sends signals
to the ECM.
Customer specified parameter
A parameter value that can be changed and whose value is set by the customer. These parameters can be
protected by customer passwords.
Desired rev/min
An input to the electronic governor in the ECM. The electronic governor uses inputs from the crankshaft
position sensor and customer parameters to determine ’desired rev/min’.
Diagnostic event code
These codes indicate an event that describes an abnormal engine condition such as a shutdown occurrence.
These codes are not necessarily (or usually) an indication of problems within the electronic system.
Diagnostic fault code
Sometimes referred to as a "fault code". These codes indicate an electronic system malfunction or problem
with the engine electronic system.
Diagnostic lamp
Sometimes referred to as the "engine check lamp", it is used to alert the operator of the presence of an active
diagnostic code.
Direct current (DC)
The type of current where the direction of current flow is consistently in one direction.
Duty cycle
Refer to pulse width modulation.
Engine control module (ECM)
The engine control computer that provides power to the engine electronics. It accepts inputs that monitor and
outputs that control or change to act as a governor to control engine rev/min.
Electronically controlled unit injector
The injection pump which is a mechanically actuated, electronically controlled unit injector, combining the
pumping, electronic fuel metering and injecting elements in a single unit.
Electronic engine control
The complete electronic system that monitors and controls the engine operation under all conditions.
Engine speed/timing sensor
Provides a variable amplitude and pulse width modulated signal to the ECM, which the ECM interprets as
crankshaft position and engine speed.
Estimated dynamic timing
The ECM’s estimation of actual injection timing.

4 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 1
Failure mode identifier (FMI)
Type of failure that has been experienced by the component (adopted from the SAE standard practice of J1587
diagnostics).
Flash programming
A method of programming or updating an ECM with an electronic service tool over the data link instead of
replacing components.
Fuel position
An internal signal within the ECM, from the electronic governor to the fuel injection control. It is based on
desired rev/min, FRC fuel limit, rated fuel limit, and the actual engine rev/min.
Fuel ratio control (FRC)
A limit based on control of the fuel to air ratio and used for emission control purposes. When the ECM senses
a higher intake manifold pressure (more air into cylinder), it increases the FRC fuel limit (allows more fuel into
cylinder).
Fuel temperature sensor
This sensor detects the fuel temperature. The ECM monitors the fuel temperature and adjusts the calculated
fuel rate accordingly.
Full load setting (FLS)
Number representing fuel system adjustment made at the factory to "fine tune" the fuel system maximum fuel
delivery. Correct value for this parameter is stamped on the engine information ratings plate. This parameter
must be programmed or a 268-02 Check Programmable Parameters diagnostic code will be generated.
Full torque setting (FTS)
Similar to the Full Load Setting. This parameter must be programmed or a 268-02 Check Programmable
Parameters diagnostic code will be generated.
Harness
The wiring loom that connects all components of the electronic system.
Hertz (Hz)
Measure of electrical frequency in cycles per second.

Diagnostic Manual, TSD 3457E, Issue 1 5

1 2300 Series
Histogram
A bar graph indicating the relative frequency of engine operation in specific operating ranges.
Injector codes
Four digit code etched on the tappet or stamped on individual injectors of the electronic unit injectors.
Intake manifold air temperature sensor
This sensor detects the intake manifold air temperature. The ECM monitors the inlet air temperature and
coolant temperature to adjust injection timing.
Integrated electronic controls
The engine is designed with the electronic controls as a necessary part of the system. The engine will not
operate without the electronic controls.
J1939 data link
An SAE (Society of Automotive Engineers) standard data link used to communicate between the electronic
engine, the transmission, and/or powertrain controls.
Logged diagnostic codes
Describes codes which are stored in memory. These codes are meant to be an indicator of possible causes
for intermittent problems. Refer to diagnostic fault code.
Oil pressure sensor
This sensor measures engine oil pressure and sends a signal to the ECM as part of Perkins Engine Monitoring.
Open circuit
Condition where an electrical wire or connection is broken or a switch is open, so that the signal or the supply
voltage can no longer reach its intended destination.
Original equipment manufacturer (OEM)
The manufacturer of equipment in which a Perkins engine is installed.
Parameter
A programmable value or limit which determines the characteristics or behaviour of the engine.
Parameter identifier (PID)
Two or three digit code which is assigned to each component in order to identify data via the data link to the
ECM.
Password
A group of numeric or alphanumeric characters that is designed to restrict access to parameters. The
electronic system requires correct passwords in order to change customer specified parameters (customer
passwords) or certain engine specifications (factory passwords). Passwords are also required to clear certain
diagnostic codes.

6 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 1
Pulse width modulation (PWM)
A signal consisting of variable width pulses at fixed intervals, whose ratio of "TIME ON" versus total "TIME
OFF" can be varied (also referred to as "duty cycle").

ON
10% Duty Cycle
OFF

ON
50% Duty Cycle
OFF

ON
90% Duty Cycle
OFF
TIME

Example of Pulse Width Modulation (PWM) Signals

Rated fuel limit

Indicates the maximum allowable fuel position (longest injection pulse). It will produce rated power for this
engine configuration.
Reference voltage
A regulated, unchanging voltage supplied by the ECM to a sensor. The reference voltage is used by the sensor
to generate a signal voltage.
Sensor
A device that is used to detect and convert a change in pressure, temperature, or mechanical movement into
an electrical signal.
Short circuit
A condition where an electrical circuit is unintentionally connected to an undesirable point. An example of a
short circuit is a wire which rubs against an engine frame until it eventually wears off its insulation and makes
electrical contact with the frame.
Subsystem
A part of the electronic system that relates to a particular function.
Supply voltage
A constant voltage supplied to a component to provide electrical power for its operation. It may be generated
by the ECM or may be battery voltage supplied by the equipment wiring.
System configuration parameters
Parameters that affect the power rating family or emissions.
"T" harness
A test harness that is designed to connect into the engine harness which allows normal circuit operation while
providing a breakout or "T" in order to measure signals.
Timing calibration
The adjustment of an electrical signal as a means of correcting the timing error between the crankshaft and
crankshaft position sensors.

Diagnostic Manual, TSD 3457E, Issue 1 7

1 2300 Series
TIPSS-EST
A service tool software program to run on a personal computer (PC).
Total tattletale
Total number of changes to all the customer specified parameters stored in the ECM.

8 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series

2
Electronic system overview 2

System operation
The 2300 and 2800 Series industrial diesel engines are designed for electronic control. The injection pump,
fuel lines and nozzles used in mechanical engines have been replaced with an electronic unit injector in each
cylinder. A solenoid on each injector controls the amount of fuel that is delivered by the injector. An Engine
Control Module (ECM) sends a signal to each injector solenoid in order to provide complete control of the
engine.

Electronic controls
The electronic system consists of the Engine Control Module (ECM), the engine sensors and the OEM
interface. The ECM is the computer which controls the engine and contains the software which controls how
the ECM behaves and stores the operating maps that define power, rev/min, etc.

Engine governor
The electronic controls on the engine serve as the engine governor, determining when and how much fuel to
deliver to the cylinders based on the actual and desired conditions at any given time.
The ECM uses one of three possible speed control inputs to determine the desired engine speed and
compares this to the actual engine speed determined through the crankshaft position sensor. If the desired
engine speed is greater than the actual engine speed, more fuel is injected in order to increase engine speed.

Timing considerations
Once the ECM has determined how much fuel is required, it must next determine when to inject the fuel.
Injection timing is determined by the ECM after considering input from the following components:
l Coolant temperature sensor
l Intake manifold air temperature sensor
l Atmospheric pressure sensor
l Intake manifold pressure sensor
The ECM determines where top centre on cylinder number one is located from the engine camshaft position
sensor signal. The ECM decides when injection should occur relative to top centre and provides the signal to
the injector at the desired time. The ECM adjusts timing for the best engine performance, fuel economy and
white smoke control.
Note: Actual or desired timing cannot be viewed with the TIPSS-EST service tool.

Diagnostic Manual, TSD 3457E, Issue 1 9

2 2300 Series
Fuel injection
The ECM controls the amount of fuel injected by varying the signals to the injectors. The injectors will pump
fuel only if the injector solenoid is energized. The ECM sends a high voltage signal to energize the solenoid.
By controlling the timing and duration of the high voltage signal the ECM can control injection timing and the
amount of fuel that is injected.
The software inside the ECM sets certain limits on the amount of fuel that can be injected. The fuel limit is a
limit based on boost pressure to control the air/fuel ratio for control of emissions. When the ECM senses a
higher boost pressure (more air into cylinder) it increases the fuel limit (allows more fuel into cylinder).
The Rated Fuel Limit is a limit that is based on the power rating of the engine and engine rev/min. It is similar
to the rack stops and torque spring on a mechanically governed engine. It provides power and torque curves
for a specific engine family and rating.
Note: All of these limits are determined at the factory in the ECM software and cannot be changed.

10 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 2
Engine monitoring
Perkins provides a factory installed engine monitoring system. The Perkins engine monitoring system monitors
the following parameters:
l Engine oil pressure
l Coolant temperature
l Intake manifold air temperature
l Engine speed
l Boost pressure
l Fuel temperature
The Perkins engine monitoring system has three levels of operation, WARNING, ACTION ALERT and
SHUTDOWN as described below.
Perkins engine monitoring WARNING operation
In the WARNING condition the ECM causes the Warning lamp to turn ON to indicate a problem has been
detected by the Engine Monitoring System. No further ECM or engine action occurs.
Perkins engine monitoring ACTION ALERT operation
In the ACTION ALERT condition the ECM begins by activating the Action Alert lamp ON to indicate a problem
has been detected by the Engine Monitoring System. This is also normally wired to cause a shutdown via the
OEM control panel.
Perkins engine monitoring SHUTDOWN operation
If the fault reaches the SHUTDOWN condition the ECM activates the shutdown lamp and unless the engine is
in CRITICAL OVERRIDE condition, the engine will shutdown.

Fuel temperature monitoring

The fuel temperature sensor monitors the fuel temperature, adjusting the ECM calculated fuel rate to
compensate for fuel temperature changes and to adjust the fuel rate for constant power. The sensor is also
used to warn the operator of excessive fuel temperature with a diagnostic event code because excessive fuel
temperatures can adversely affect engine performance.

Self diagnostics
The electronic system has the ability to diagnose problems. When a problem is detected, a diagnostic code is
generated and stored in permanent memory (logged) in the ECM. The diagnostic lamp is also activated.
When diagnostic codes occur, the diagnostic codes are referred to as Active diagnostic codes. They indicate
that a problem of some kind currently exists.
Diagnostic codes that are stored in memory are called Logged diagnostic codes. Since the problem may have
been temporary, or may have been repaired since the problem was logged, logged codes do not necessarily
mean that something needs to be repaired. They are instead meant to be an indication of probable causes for
intermittent problems.
Diagnostic codes that identify operating conditions outside the normal operating range are called Events.
Event codes are not typically an indication of an electronic system problem.
Note: Some of the diagnostic codes require passwords to clear.

Diagnostic Manual, TSD 3457E, Issue 1 11

2 2300 Series
Effect of diagnostic codes on engine performance
The discussion on engine monitoring mentions that the diagnostic lamp activates when a specific condition
exists. When the ECM detects an engine problem, it generates an active diagnostic code and also logs the
diagnostic code in order to indicate when, and if appropriate, how many times the problem occurred. There are
two types of diagnostic codes, Fault codes and Event codes.
Diagnostic fault codes
These are provided in order to indicate that an electrical or electronic problem has been detected by the ECM.
In some cases the engine performance can be affected when the condition causing the code exists. More
frequently, however, no difference in the engine performance can be detected.
Diagnostic event codes
Diagnostic event codes are used to indicate that some operational problem has been detected in the engine
by the ECM. This usually does not indicate an electronic malfunction.
The ECM also provides an ECM clock with date/time to date and time stamp the following critical event codes:
l 360-3 Low oil pressure Shutdown
l 361-3 High coolant temperature Shutdown
For a listing all of the diagnostic fault codes, along with the page number where details regarding the cause,
performance effect, and diagnosis of the code can be located, refer to "Diagnostic code quick reference" on
page 80.

Current totals stored in the ECM

The ECM maintains engine total data for the following parameters:
Total time
The total time is the engine’s operating hours. This does not include operating time when the ECM is powered
ON but the engine is not running.

Programmable parameters
Certain parameters affecting engine operation may be changed with the TIPSS-EST service tool. The
parameters are stored in the ECM, and are protected from unauthorized changes by passwords. These
parameters are either system configuration parameters or customer parameters.
System configuration parameters
These are set at the factory and affect emissions or power ratings within an engine family. Factory passwords
must be obtained and used to change the system configuration parameters.
Customer parameters
These are variable and can be used to tailor the engine to customer requirements within the limits set by the
factory and Perkins engine monitoring operation. Customer passwords may be required to change customer
parameters.
Caution: Some of the parameters may affect engine operation. Without adequate training, these parameters
may lead to power or performance complaints even when the engine is performing to specification.
Refer to "Programming parameters" on page 29 for further information.

12 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 2
Passwords
System configuration parameters are protected by factory passwords. Factory passwords are calculated on a
computer system that is available only to Perkins dealers.
Customer parameters can be protected by customer passwords. The customer passwords are programmed
by the customer. Factory passwords can be used to change customer passwords if they are lost.
Refer to "System configuration parameters" on page 30 for further information when passwords are needed
and how to obtain them.

Diagnostic Manual, TSD 3457E, Issue 1 13

2 2300 Series
Engine component diagram

Internal Injector Harness

12PIN Connector Service

Tool
Connector

Interface
Connector

OEM Interface Connectors

Main Engine Harness

Crank Speed/Timing
36-1 TOOTH
CRANK
GEAR
Inlet Manifold Temperature
Sensor

Cam Speed/Timing
Fuel Temperature Sensor

36+1 TOOTH
CAM GEAR

Cooolat Temperature Sensor

Boost
Atmospheric Pressure Sensor
Pres Sensor

Calibration
Probe
Lub Oil Pressure
Sensor

A HA0002

14 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 2
OEM connection diagram

To ECM J1 Connector

Customer connecter (If fitted) E-Stop

16A Breaker

+
Service Tool
Keyswitch Injector Disable
Connector
Optional

24V

-
Digital Speed Control
Optional

Optional
Speed
Raise/Lower

Critical Override
Optional

Optional
Lamp Box Throttle Adjust Pot
1: Diagnostics
2: Caution
3: Warning Speed Control
4: Shutdown 1 2 3
5: Overspeed Shutdown
Reset droop
6: High Coolant Temp Optional -B S D +B adjust
7: Low Pressure

Switched
Battery +ve
Optional
Droop/Isoch
Optional

Potentiometer

0.5-4.5V

Speed
Selection
Optional

Screen tied to
ECM -VE

A HA0003

Diagnostic Manual, TSD 3457E, Issue 1 15

2 2300 Series
Sensor and connector location diagram
1 Electronic Control Module (ECM)
2 J1/P1 Machine connector
3 J2/P2 Engine connector
4 Atmospheric pressure sensor
5 Oil pressure sensor
6 Crankshaft position sensor
7 Fuel temperature sensor
8 Camshaft position sensor
9 Coolant temperature sensor
10 Intake manifold pressure sensor
11 Intake manifold air temperature sensor
12 Electronic unit injector connector
13 Timing calibration pickup connector

16 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 2
Engine wiring diagram

ECM

B 5 B
J2/44 Injector Common Cylinders 1 & 2
B
7 B
J2/45 Injector Common Cylinders 3 & 4
B
6 B
J2/46 Injector Common Cylinders 5 & 6
A
10 A J2/55 Injector Cylinder 6
P 3 P J2/54 Injector Cylinder 5
G 11 G J2/39 Injector Cylinder 4
W
2 W J2/38 Injector Cylinder 3
12 K J2/37 Injector Cylinder 2
K
R
1 R J2/36 Injector Cylinder 1
Injector Injector Injector Injector Injector Injector J300 P300
Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6

Atmospheric Pressure Sensor

+5V A J2/2 +5VDC Supply

O
Signal C U J2/14 Atmospheric Pressure
Return B N J2/3 Analogue Return

P203 J203

Intake Manifold Pressure Sensor

+5V A
Signal C J2/40 Intake Manifold Pressure
U
Return B

P200 J200

Oil Pressure Sensor

+5V A
Signal C A
J2/24 Oil Pressure
Return B

P201 J201

Coolant Temperature Sensor

Signal C J2/32 Coolant Temperature

U
Return B

J100 P100

Fuel Temperature Sensor

Signal C U
J2/33 Fuel Temperature
Return B

J105 P105

Inlet Air Temperature Sensor

Signal C U
J2/35 Inlet Air Temperature
Return B J2/18 Return
N

J103 P103
Crankshaft Position Sensor

Signal 2 Y
J2/48 Crank Speed Timing +
Return 1 J2/49 Crank Speed Timing -
U

J401 P401
Camshaft Position Sensor

Signal 2 J2/58 Cam Speed timing +

Y
Return 1 U
J2/59 Cam speed timing -

J402 P402
Calibration Probe

Signal 1 Y J2/22 Calibration Probe +

Return 2 U J2/23 Calibration Probe -
J400 P400

P2 J2
A HA0005

Diagnostic Manual, TSD 3457E, Issue 1 17

2 2300 Series
Machine wiring diagram (all options)

This Wiring Supplied By OEM Customer

Outputs may be used to Interface
drive lamps or relays J3 P3 Connector ECM
Engine Running
11 J1/13 Engine Running Output
W
Shutdown
16 J1/10 Shutdown lamp Output
G
Action Alert
5 J1/19 Action Alert Lamp Output
U
Warning
4 J1/20 Warning Lamp Output
P
Diagnostics
3 J1/31 System Fault Lamp Output
I
Oil Pressure
8 J1/28 Oil Pressure Lamp Output
O
Coolant Temp
17 J1/29 Coolant Temperature Lamp Output
N
Overspeed
9 J1/30 Overspeed Lamp Output
A

2 J1/49 Digital Speed Control Enable

Digital Speed G
Control Enable
34 J1/62 Injection Disable
Injection U
Disable
29 J1/59 Lower Speed
Lower P
Speed
35 J1/64 Shutdown Emergency Override
Critical Override K
28 J1/7 Raise Speed
Raise O
Speed
25 J1/56 1500/1800 rpm Select
1500/1800 N
rpm Select
26 J1/46 Droop/Isochronous
Droop/ A
Isochronous
18 J1/41 Fault Reset
Fault Reset Y
12 J1/18 Digital Ground
B
27 J1/67 - Battery
B
To PWM
Ground 22 J1/5 Ground
B
Speed Control PWM 36 J1/66 PWM Input
(If Required) W
+8V 21 J1/4 +8V
R
23
680R B
5K Analogue 20 J1/3 Analogue Ground
Speed Setting B
Potentiometer or 24 J1/17 Analogue Speed Input
Input from Load W
Sharer/Synchroniser 19 J1/2 +5V
680R R
38 J1/61 - Battery
B
Charging - Battery
Alternator 39 J1/63
B
40 J1/65 - Battery
GRD POS
Emergency B
Stop Button 15 J1/48 Unswitched + Battery
R
33 J1/52 Unswitched + Battery
R
1 J1/53 Unswitched + Battery
R
10 J1/70 Switched + Battery
Key Y
Switch 31 J1/50 J1939 Data Link +
G
Circuit J1939
Breaker
32 J1/34 J1939 Data Link -
Data A
Link 11 J1/42 J1939 Screen
Starter Perkins 7 J1/8 Perkins Data Link +
Data G
Motor
Link 6 J1/9 Perkins Data Link -
Start N
Button J1/55 Unswitched + Battery
R
J1/69 - Battery
B
- + P1 J1
Battery
9 Pin Perkins Data
24V DC J H C G F D E A B Link Connector
A HA0006

18 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 2
Electrical connectors and functions

Connector Function
J1/P1 ECM connector (70-Pin OEM harness)
J2/P2 ECM connector (70-Pin Engine harness)
J3/P3 Machine wiring connector (40-Pin connector) - optional
J100/P100 Engine coolant temperature sensor (2-pin connector)
J103/P103 Engine intake manifold temperature sensor (2-pin connector)
J105/P105 Engine fuel temperature sensor (2-pin connector)
J200/P200 Engine intake manifold pressure sensor (3-pin connector)
J201/P201 Engine oil pressure sensor (3-pin connector)
J203/P203 Engine atmospheric pressure sensor connector (3-pin connector)
J300/P300 Injector solenoid harness (12-pin connector)
J400/P400 Engine timing calibration probe (2-pin connector)
J401/P401 Crankshaft position sensor (2-pin connector)
J402/P402 Camshaft position sensor (2-pin connector)

Colour codes

Key letter Colour

N Brown
U Blue
R Red
P Purple
G Green
W White
Y Yellow
B Black
O Orange
K Pink
A Grey

Diagnostic Manual, TSD 3457E, Issue 1 19

2 2300 Series
Service tools and diagnostics
The Perkins TIPSS-EST service tool is designed to help the service technician analyse and locate faults or
problems within the system. They are required to perform calibrations and to read or change engine
parameters.
Perkins TIPSS-EST is a software program that runs on a personal computer and requires a communication
adapter to translate information from the Perkins Data Link to the computer RS232 port.
Perkins TIPSS-EST can be used to display the following information:
l Programmable parameter settings
l Active and logged diagnostic codes
l Logged events
l Engine rating history
l Histograms
l Custom data
l ECM date/time clock
Perkins TIPSS-EST can also be used to perform the following functions:
l Diagnostic tests
l Sensor calibrations
l Flash programming
l Parameter programming
l Copy configuration (ECM replacement)
l Data logging
l Real time graphing
There are several adapter cables, breakout T cables, etc that are used in order to access measurements of
signals. A heavy duty multimeter is suitable in order to make the necessary measurements. A multimeter that
has the ability to measure duty cycle may also be required. Other special tools include those needed to
measure pressure and temperature. For further details refer to Chapter 5, Special tools.
A diagnostic code reader is also available. This is a hand held unit which allows reading certain parameters
and diagnostic codes.

20 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series

3
Programming parameters 3

Connecting the TIPSS-EST

The communications adapter is powered by 24 Volts DC from the engine battery. This permits operation
beside the engine to allow use during engine operation.
Use the following procedures to connect the service tool to the engine.
1 Stop the engine by turning the key switch to the OFF position.
2 Connect the service tool harness cable on the engine to the communication adapter. Refer "Connecting
TIPSS-EST using a TIPSS communication adapter" on page 22.
3 Connect the communication adapter to the PC using the appropriate cable.
4 Turn the key switch to the ON position in order to begin testing. The service tool will operate while the engine
is running or with the engine OFF and the key switch ON. If the tool does not communicate with the ECM
disconnect and reconnect the diagnostics connector cable. Check the communication. If the problem is still
present refer to Test 45: Perkins Data Link circuit test on page 118.

Notes:
l The service tool may restart during engine cranking due to a voltage dip on the battery line.
l The TIPSS-EST must be configured to communicate with the specific type of communication adapter used.
Go to the "Preferences" menu that is located under "Utilities" in order to select the appropriate
communication adapter.

Diagnostic Manual, TSD 3457E, Issue 1 21

3 2300 Series
Connecting TIPSS-EST using a TIPSS communication adapter
1 PC with TIPSS-EST installed
2 PC to communication adapter cable (27610169)
3 Communication adapter (27610165)
4 Service tool harness cable (27610168)

A HA0007

22 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 3
Passwords
Factory passwords
Factory passwords are required to perform each of the following functions:
1 Program a new ECM
When an ECM is replaced the system configuration parameters must be programmed into the new ECM. A
new ECM will allow these parameters to be programmed once without factory passwords. After the initial
programming these parameters are protected by factory passwords.
2 Rerate to another engine family
This requires changing the ECM software code, which is protected by factory passwords.
3 Read customer passwords
If the owner loses his customer passwords, he will not be able to program customer parameters. By using
factory passwords, one can read customer passwords, then use those customer passwords to program
customer parameters.
4 Clear certain diagnostic codes
Diagnostic code 253-02 Incorrect ECM software requires a factory password to clear the code. This diagnostic
code should be cleared only if you are certain that the ECM software is for the specific engine.
Caution: Operating the engine with ECM software not designed for that engine will result in engine damage.
Be sure the ECM software is correct for your engine.
5 Certain other codes require customer passwords. The majority of logged codes do not require passwords
to be cleared. To obtain factory passwords, proceed as if you already have the password. At some point, if the
factory passwords are actually needed, TIPSS-EST will request the factory passwords and display the
information required to obtain the passwords.
Customer passwords
If customer passwords have been entered, they are then required to change ANY customer parameter.
TIPSS-EST can be used to change customer parameters. To obtain customer passwords, contact the supplier
of the equipment. If the owner has lost the passwords, customer passwords may be read by using TIPSS-EST
(factory passwords are required in order to read customer passwords) by using the following procedure.
1 In TIPSS-EST access "Passwords" under the "Information" menu.
2 When the "Factory Password" screen appears, record the information listed.
3 Obtain the factory passwords. The information recorded above must be provided, and generates a
permanent record at Perkins of the access.
4 From the "Factory Password" screen, enter the factory passwords.
5 When the "View Customer Passwords" screen appears, record the customer passwords. The customer
passwords may then be used to change customer parameters.

Diagnostic Manual, TSD 3457E, Issue 1 23

3 2300 Series
Programming a new ECM
The Engine Control Module or ECM is the brain of the system. When a problem occurs, it is easy to assume
that the ECM is responsible. This is usually the wrong conclusion.
Most failures occur at the wiring and connectors or at a sensor input/output. Follow the diagnostic test
procedures and do not replace an ECM on speculation.
However, when your diagnosis indicates that a failure has in fact occurred in the ECM, the following procedure
outlines the steps required to replace a faulty ECM.
Note: If an ECM replacement is required, the ECM parameters and injector trim codes can be transferred from
the suspect ECM to the replacement ECM. This feature requires TIPSS-EST and is only possible if the suspect
ECM can communicate with the TIPSS-EST.
Replacing the ECM using TIPSS-EST ECM replacement feature
Note: The Test ECM referred to below is another identical ECM to that fitted to the engine. There is no special
Test ECM available.
1 Ensure that the ECM is the problem by first temporarily connecting a test ECM. Hang the test ECM on the
side of the engine. Flash program the identical software that was used in the suspect ECM into the test ECM.
Use the TIPSS-EST ECM replacement feature to copy the parameter configuration of the suspect ECM into
the test ECM. Ensure that the parameters in the test ECM are programmed the same as the parameters in the
suspect one.
2 If the test ECM repairs the problem, reconnect the suspect ECM. Check that the problem returns when the
suspect ECM is reconnected.
3 Select the ECM Replacement feature under the "Service/Copy Configuration" menu and load the
parameters from the failed ECM.
4 Temporarily connect the new ECM by connecting both ECM connectors. Do not mount the ECM on the
engine yet.
5 Flash program the ECM software into the new ECM if the software is not already installed.
Note: The new ECM may be shipped with no software installed or may have been pre-flashed at the factory.
Following reflashing the engine may be inoperable until a factory password has been obtained.
6 Use the TIPSS-EST ECM replacement feature to program the new ECM
7 Enter rating number parameter into the new ECM
8 Check for active codes. Program any required parameters that have not been programmed.
Note: On initial power-up of a new ECM, the Rating Number parameter must be programmed to avoid a
268-02 Check Programmable Parameters diagnostic code.
Install the new ECM on the engine and after checking for correct operation perform a timing calibration.

24 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 3
Replacing the ECM (if ECM replacement feature cannot be used)
1 Ensure that the ECM is the problem by first temporarily connecting a test ECM. Hang the test ECM on the
side of the engine. Flash program the identical software that was used in the suspect ECM into the test ECM.
Program any parameters that are necessary to use the ECM for the test. Program the parameters exactly the
same as they are in the suspect ECM.
2 If the test ECM repairs the problem, reconnect the suspect ECM. Check that the problem returns when the
suspect ECM is reconnected.
3 Obtain customer parameters from the failed ECM
Obtain and record the customer passwords. If the customer has lost or forgotten their passwords, obtain
factory passwords to get them.
Use TIPSS-EST to access customer specified parameters from the ECM that is being replaced. If the ECM
does not communicate with the electronic service tool, obtain the required parameter list from the OEM.
Record the customer parameters.
4 Record ECM current totals
5 Temporarily connect the new ECM by connecting both ECM connectors. Do not mount the ECM to the
engine until the timing calibration has been performed.
6 Flash program the software into the new ECM if the software is not already installed.
Note: The new ECM may be shipped with no software installed, or may have been pre-flashed at the factory.
7 Obtain factory passwords if required. The following parameters can be programmed once on a new ECM
without factory passwords:
l Full Load Setting (FLS)
l Full Torque Setting (FTS)
l Engine serial number
System configuration parameters must be entered before the customer specified parameters are entered
If customer parameters are entered before the system configuration parameters, the total tattletale will change.
It will then be necessary to obtain another set of factory passwords in order to access system configuration
parameters.
8 Record the following information from the engine information plate:
l Engine serial number
Obtain the following information from the factory:
l Full Load Setting (FLS)
l Full Torque Setting (FTS)
l Injector Trim Codes
Use TIPSS-EST to access system configuration parameters. When the "Factory Specified Passwords" screen
appears record the following information:
l ECM serial number
l Engine serial number
l TIPSS-EST serial number
l Total tattletale
l Reason code
Leave TIPSS-EST on the "Factory Specified Passwords" screen and obtain the factory passwords.
Continued

Diagnostic Manual, TSD 3457E, Issue 1 25

3 2300 Series
9 Program the new ECM
l On initial powerup of a new ECM the following three parameters must be programmed to avoid a 268-02
Check Programmable Parameters diagnostic code:
l Full Load Setting (FLS)
l Full Torque Setting (FTS)
l Engine serial number
Use TIPSS-EST to access system configuration parameters. Enter the recorded values for the following
parameters:
l Full Load Setting (FLS)
l Full Torque Setting (FTS)
l Engine serial number
l Injector trim codes
Use TIPSS-EST to access customer specified parameters. Enter the customer specified parameters and the
original customer passwords.
Use TIPSS-EST to access current totals from the "Read/Change Current Totals" main menu. Using the
recorded factory passwords enter the totals from the original ECM.
Use the "Service\Calibrations\Timing Calibration" menu to calibrate the timing. Refer to Test 46: Engine
speed/timing circuit test on page 126.
10 Install the new ECM on the engine.

26 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 3
Programming an ECM using flash programming
1 Connect the PC to the appropriate communication adapter and connect the communication adapter to the
ECM. Refer to "Connecting TIPSS-EST using a TIPSS communication adapter" on page 22.
2 Start the WinFlash PC Program.
3 Ensure that the key switch is ON and the engine is OFF.
4 Select the part number of the engine software that needs to be programmed into the ECM and proceed with
programming. A new ECM is shipped with no software loaded.
Note: The WinFlash PC program provides the ECM, application and software part number of the selected file.
Ensure that this file matches the engine before you begin to Flash the file into the ECM
PC program software messages and their meaning
A new ECM comes unprogrammed. An unprogrammed ECM will prompt you for all three of the following
messages. The information that is contained in the ECM Status will be scrambled and meaningless if the
module has not been programmed previously (this is normal).
Message: The engine ID in the flash file does not match the engine ID in the ECM
Meaning: The ECM has software for a different engine.
Solution: Stop the transfer and access information about the ECM Status under the "Electronic Control
Module" menu. Ensure that the file you are about to transfer matches the engine application.
Message: The application ID in the flash file does not match the application ID in the ECM
Meaning: The ECM has software for a different application.
Solution: Stop the transfer and access information about the ECM Status under the "Electronic Control
Module" menu. Ensure that the file you are about to transfer is for the correct engine type.
Message: The ID of the ECM in the flash file does not match the ID of the ECM in the ECM
Meaning: The ECM is not for use with this application.
Solution: Stop the transfer and access information about the ECM status under the "Electronic Control
Module" menu. Ensure that the ECM on the engine is for the correct application.
Note: If you access the ECM status under the "Engine Control Module" menu, but do not program the ECM,
complete the following procedure.
Turn the key switch to the OFF position, and then to the ON position before using TIPSS-EST. If the key switch
is not cycled after reading the ECM Status, the ECM will not communicate with your service tool or will not start.
Cycling the key switch is not necessary after the software has been successfully programmed using the
WinFlash program.
5 Start the engine and check for correct operation.
Program any parameters not previously in the old software if a 268-02 Check Programmable Parameters
diagnostic code is active. Read the diagnostic code from service tool "Active Diagnostic Code" screen in order
to determine the parameter(s) requiring programming.
On initial powerup of a new ECM three parameters must be programmed to avoid a 268-02 Check
Programmable Parameters diagnostic code:
l Full Load Setting (FLS)
l Full Torque Setting (FTS)
l Engine serial number
Refer to "Programming a new ECM" on page 24.

Diagnostic Manual, TSD 3457E, Issue 1 27

3 2300 Series
ECM date/time clock
ECM date/time stamped information
The ECM date and time can be programmed with the TIPSS-EST service tool (factory passwords are required
to change these parameters). This will display the programmed date in month/day/year format and the
programmed time in hour:minute:second format. The tool has the option to program any date/time or
automatically select the date/time stored in the PC real time clock.
The date and time will remain programmed in the ECM even if the unswitched battery connections are
removed.
The ECM Date/time clock is used to stamp the following critical event codes:
l 360-3 Low oil pressure Shutdown
l 361-3 High coolant temperature Shutdown
Before adjusting the ECM date/time clock
Before adjusting the ECM date/time clock, ask the owner/operator if the time stamped information should be
recorded. After the time stamped information is recorded, clear this information before adjusting the ECM date/
time clock. This is a very important step if the adjustment of the clock is a big adjustment. This will prevent
unnecessary confusion if someone else views the information at a later date.
Determining time stamped information occurrence
When viewing time stamped information remember that someone may have incorrectly or never set the clock.
Use the time currently set in the ECM to compare any ECM recorded information to the time the ECM indicates
to determine how long ago the time stamped event occurred.
Caution: Do not replace an ECM because of an incorrect time.
The following example indicates the correct use of the clock.
Example use of ECM date/time stamped information
The TIPSS-EST service tool indicates a Low Oil Pressure occurred on NOV 19 1998 10:30:46 and that the
current time of day in the ECM is NOV 24 1998 11:20:58.
This indicates that the problem occurred approximately 5 days and 50 minutes ago.
Caution: Do not compare it to the current time at your location.
If the ECM time is significantly different than your current time, for example the wrong month is programmed,
ensure you have recorded the time stamped information if it is important. After recording the information, clear
the code and then adjust the clock.

28 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 3
ECM diagnostic clock
The diagnostic clock should not be confused with the ECM date/time clock. The diagnostic clock records the
actual hours the ECM has been powered (key switch ON and engine running). This information is maintained
even if the unswitched battery connections are removed. The clock information is used to log diagnostic code
and event code occurrences. Logged diagnostic codes and event codes display the diagnostic clock hour of
the first and last occurrence and the total number of occurrences.
Note: Actual engine running hours (total time) can be obtained from the "Current Totals" menu of TIPSS-EST.

Injector codes
Injector codes are etched on each injector. The injector codes can be viewed/changed using TIPSS-EST by
selecting the "Calibrations" screen under the "Service" menu. The injector codes calibration is located under
the "Calibration" menu. The injector code must match the code on the corresponding injector. When an injector
is replaced, reprogram the new code for the new injector.

TIPSS-EST cylinder cut-out test

The 2300 and 2800 Series engines use electronic fuel injectors. These injectors are mechanically actuated
and electronically energized. The cylinder cut-out tests are used to confirm that the cylinders are functioning
correctly.
The cylinder cut-out test allows a specific cylinder to be cut out while the fuel position is monitored for the
remaining cylinders.
To perform a cylinder cut-out test, connect TIPSS-EST to the diagnostic connector as described in
"Connecting the TIPSS-EST" on page 21, and select the Cylinder cut-out test located under the "Diagnostics"
menu.
The Cylinder cut-out test opens with the manual test. At the bottom of the TIPSS-EST screen there is a row of
buttons that function as follows:
l Change toggles the highlighted cylinder between powered and not powered
l Power All returns all cylinders to the normal operating state
l Start initiates the automated Cylinder cut-out test.
l Stop terminates the automated test.
l Results displays the test results.
l Print allows the contents of the screen to be previewed or to be sent to a file or printer.

Programming parameters
Many programmable parameters affect engine operation. These parameters may be changed by using the
TIPSS-EST service tool. The parameters are stored in the ECM. Whilst any parameter can be read, passwords
can be used to protect parameters from unauthorized changes.
Two categories contain these various parameters:
System configuration parameters
System configuration parameters can only be altered with factory passwords by using TIPSS-EST.
Customer specified parameters
Customer specified parameters can be changed by using the TIPSS-EST service tool (this may require
customer passwords if customer passwords have been programmed). Refer to "Passwords" on page 13 for
more details on how to receive and use factory and customer passwords.

Diagnostic Manual, TSD 3457E, Issue 1 29

3 2300 Series
System configuration parameters
System configuration parameters affect critical settings for the engine. They are programmed at the factory
and would normally never need to be changed through the life of the engine. A complete list of these
parameters is given in the table on the following page.
Note: System Configuration Parameters must be reprogrammed if an ECM is replaced. Failure to programme
these parameters will result in a 268-02 Check Programmable Parameters diagnostic code.
Proper values for these parameters are stamped on the engine information ratings plate located on the valve
cover or air inlet manifold. Factory passwords are required to change these parameters. The following
information is a description of the system configuration parameters.
Full Load Setting (FLS)
Number representing fuel system adjustment made at the factory to “fine tune” the fuel system. The correct
value for this parameter is stamped on the engine information ratings plate. A new ECM requires this
parameter to be programmed to avoid generating a 268-02 Check Programmable Parameters diagnostic code.
Full Torque Setting (FTS)
Similar to Full Load Setting. This parameter must be programmed to avoid generating a 268-02 Check
Programmable Parameters diagnostic code.
Software part number
This is the part number of the software flashed into the ECM.
Engine serial number
This should be programmed to match the engine serial number that is stamped on the engine information plate.
A new ECM is delivered without the engine serial number programmed.
ECM serial number
This is a read-only parameter which displays the serial number of the ECM.
Software release date
This parameter is defined by the ECM software and is not programmable. It is used to provide the version of
the software. Customer parameters software changes can be tracked by this date. The date is provided in the
month and year (NOV99), where NOV is the month (November) and 99 is the year (1999).
Critical override switch installed
The critical override switch, if fitted and enabled, allows the engine to continue running even if engine oil
pressure or coolant temperature have reached the limits where the engine would normally be shutdown. If the
engine is run in this condition, the engine warranty is void and any events occurring are stored in the ECM with
time and date stamping. Implementation of this facility requires a factory password.
Total tattletale
Displays the total number of times the configuration parameters have been changed.

30 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 3
Configuration parameters
Configuration Parameter Description R/W Security
Selected Engine Rating
Rating Number Customer
Rated Frequency Read Only
Rated Genset Speed Read Only
Rated Real Genset Power Read Only
Rated Apparent Genset Power Read Only
Engine Rating Application Type Read Only
External Speed Selection Switch Installed Customer
ECM Identification Parameters
Equipment ID Customer
Engine Serial Number Factory
ECM Serial Number Read Only
ECM Software Part Number Read Only
ECM Software Release Date Read Only
ECM Software Description Read Only
Security Access Parameters
Total Tattletale Read Only
Engine/Gear Parameters
Engine Acceleration. Rate Customer
Droop/Isochronous Switch Installed Customer
Droop/Isochronous Selection Customer
Engine Speed Droop Customer
Critical Override Switch Installed Factory
Digital Speed Control Installed Customer
Speed Control Min Speed Customer
Speed Control Max Speed Customer
Digital Speed Control Ramp Rate Customer
Crank Terminate Speed Customer
I/O Configuration Parameters
Desired speed Arrangement Customer
System Parameters
FLS Factory
FTS Factory
Governor ProportionalGain None
Governor Minimum Stability Factor None
Governor Maximum Stability Factor None
Passwords
Customer Password 1 Customer
Customer Password 2 Customer

Diagnostic Manual, TSD 3457E, Issue 1 31

3 2300 Series
Customer specified parameters
Customer specified parameters allow the OEM to modify engine parameters to suit the application.
Customer parameters may be changed repeatedly as a customer changes his requirements. Customer
passwords are required to change these parameters.
The following information is a brief description of the customer specified parameters.
Rating duty selection
This enables selection of the engine rating from a series of maps within the ECM. Changing the rating requires
a customer password. The available ratings within the ECM will vary with engine type and specification.
Rated frequency
This displays the rated frequency of the set, i.e. 50 Hz or 60 Hz, determined by the rating selection and the
status of the external speed selection switch. This parameter is read only.
Rated speed
This displays the rated speed of the engine, i.e. 1500 rev/min or 1800 rev/min, determined by the rating
selection and the status of the external speed selection switch. This parameter is read only.
Rated real genset power
This displays the maximum power in kW of the currently selected rating. This parameter is read only.
Rated apparent genset power
This displays the maximum power in kVA of the currently selected rating. This parameter is read only.
Rating configuration
This displays the configuration of the currently selected rating. The possible configurations are:
l Standby power
l Limited time prime power
l Prime power
l Continuous or baseload power
For definitions of these ratings, refer to ISO8528. This parameter is read only.
Note: Not all of the above rating configurations will be available in a given ECM software file.
External speed selection switch enable
For dual speed (1500 rev/min or 1800 rev/min) applications, where an external speed selection switch is
required, this parameter enables the functionality of the speed selection switch within the software. Changing
this parameter requires a customer password.
Engine startup acceleration rate
Enables the acceleration rate of the engine in rev/min/s, from idle speed to rated speed, to be programmed.
Control of this parameter enables any overshoot in speed on start up to be limited. Changing this parameter
requires a customer password.
Droop/isochronous switch enable
Determines whether the external droop/isochronous switch is enabled or disabled. Changing this parameter
requires a customer password.
Droop/isochronous selection
The engine will normally be run in isochronous mode i.e. the engine speed is the same at all loads. For certain
applications where parallel operation with another generating set or with the grid is required, it is necessary for
stability reasons to run in droop condition where engine speed drops with load. This parameter enables droop/
isochronous running selection. Changing this parameter requires a customer password.
Note: If an external droop/isochronous switch is enabled, the position of this switch will over-ride the Droop/
Isochronous selection.

32 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 3
Engine speed droop
If droop operation is selected, this parameter allows the setting of percentage droop i.e. the percentage that
the engine speed will drop with load. This parameter has no effect when the engine is running in isochronous
mode. Changing this parameter requires a customer password.
Digital speed control installed
This parameter determines whether raise/lower switch input control of engine speed is installed. If digital speed
control is not installed, speed control reverts to the analogue or PWM inputs depending on which input is
selected via the desired speed input configuration detailed on the following page. Changing this parameter
requires a customer password.
Digital speed control min speed
This setting determines the minimum speed range of both the raise/lower button control and the analogue
control, for example: if this is set to 100 rev/min and the nominal engine speed is selected for 1500 rev/min,
the minimum speed setting is 1400 rev/min. It does not affect the PWM speed control range which has fixed
min/max limits. Changing this parameter requires a customer password.
Digital speed control max speed
This setting determines the maximum speed range of both the raise/lower button control and the analogue
control, i.e. if this is set to 100 rev/min and the nominal engine speed is selected for 1500 rev/min, the
maximum speed setting is 1600 rev/min. It does not affect the PWM speed control range which has fixed min/
max limits. Changing this parameter requires a customer password.
Digital speed control ramp rate
This setting determines the rate of change of engine speed in rev/min/s when the raise/lower switch inputs are
closed. Changing this parameter requires a customer password.
Crank terminate speed
This parameter is used to set the engine speed at which the crank terminate relay output will be switched.
Changing this parameter requires a customer password.
Desired speed input arrangement
This parameter allows selection of the analogue or PWM external speed control if the digital speed control is
not installed. The Analogue or PWM speed control inputs are normally used with generating set load sharing
and synchronising controllers. Changing this parameter requires a customer password.
Note: If PWM or Analogue speed control is selected but there are no inputs to the selected speed control
terminals, the engine will default to running at 1100 rev/min.
If it is not intended to use PWM or analogue speed control then the Digital speed control should be selected.
Governor gain parameters
The adjustable Governor Gain parameters are:
l Governor Gain Factor
l Governor Minimum Stability Factor
l Governor Maximum Stability

Notes:
l No engineering units associated with these numbers.
l The programmable range is wide for flexibility. The values are valid from 1- 40000. This wide programmable
range may not be fully used on any system. Do not expect to use the whole range.

Diagnostic Manual, TSD 3457E, Issue 1 33

3 2300 Series
Gain explanations
Governor gain factor
The governor gain factor is multiplied to the difference between desired speed and actual speed.
l If the governor gain factor value is too large, the engine speed can overshoot the desired speed. The
overshoot is caused by an overcorrection or a steady state instability.
l If the governor gain factor is too small, the response necessary to accelerate the engine to the desired
speed must be obtained by ramping the stability terms to a higher value. This process is time consuming
so, as a result, the engine speed is slow to respond.
Governor minimum/maximum stability factor
The stability factor terms work to eliminate a steady state speed error. There are two gain terms used for
stability. If the error is greater than 20 rev/min and the error is increasing, then the maximum stability gain is
functioning. If the error is less than 20 rev/min, then the minimum stability gain is used. This function allows
the use of a high gain that would otherwise cause the engine to be unstable when the engine is operating near
the desired speed.
l If either the minimum stability gain or the maximum stability gain is set too high, the governor will provide
more fuel than is necessary to bring the error to zero. The additional fuel will cause the engine speed to
overshoot and ring.
l If either the minimum stability gain or the maximum stability gain is set too low, the engine will take too long
to arrive at a steady state speed.
Tuning procedure
1 Turn the key switch to the OFF/RESET position. Connect the TIPSS-EST service tool and check that engine
overspeed protection is enabled before beginning the tuning process. Engine overspeed is configured on the
"Service\Monitoring System" screen on TIPSS-EST.
Warning! Performing engine governor tuning without engine overspeed protection could result in serious
engine damage. Ensure that this parameter is ON while performing this procedure.
2 Start the engine. Observe, on the engine mounted genset control panel, that the engine has reached rated
speed. This panel will serve as the speed reference point during this procedure.
3 Enter the "Configuration Parameters" screen on TIPSS-EST.
4 Determine the desired scenario to tune the engine. For example, is the engine having poor response during
specific load assignments or specific load dumps ?
5 Perform the desired load change from step 4. Observe the response of the engine by viewing the engine
speed on the genset mounted control panel, by looking at the system bus frequency response to the load
change, or by listening to the response of the engine.
6 Use the suggestions listed above to determine which gains should be adjusted.
Note: Usually, the governor gain factor should be somewhat lower that the governor minimum stability factor
for optimum performance. The maximum stability factor is typically a smaller value than the minimum stability
gain and governor gain factor.
7 Repeat steps 5,6, and 7 until a desired engine response can be met. Use large adjustments (10% of original
gain) at first to generally tune the engine in the proper manner. As the response is closer to desired, increase
the gains in smaller increments (1% of total gain).
Customer password 1, customer password 2
These are the customer password programmable parameters that can be used to protect certain configuration
parameters from unauthorised changes.

34 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series

4
Fault diagnosis 4

Introduction
This chapter has information that will assist with the diagnosis of mechanical and electronic faults on the
engine, and its management system.

The diagnostic process

Some engine symptoms are caused by conditions or components other than the electronic control system,
such as poor fuel quality or incorrectly adjusted valves.
The basic philosophy of diagnosing this engine is to follow the three steps listed below FIRST to diagnose a
malfunctioning engine:
1 Gather operator information. Check that the fault is not due to normal engine operation.
2 Perform a visual inspection of the engine. Check fuel and oil level, supply and/or condition. Check for visible
wiring and connector problems or damaged components.
3 Check and repair all ACTIVE/LOGGED diagnostic codes using the diagnostic procedures given in
"Diagnostic procedures with a diagnostic fault code" on page 76.
If ALL three of these inspections reveal no problems, identify probable causes using the procedure or
procedures in this chapter that best describes the symptoms. Narrow the probable causes given in the
procedure by considering operator information, operating conditions, and repair history of the engine.
Operator information
l What happened, and when ?
l Under what conditions ?
l Was the engine rev/min (speed) high or low ?
l Was the engine under load ?
l Are there any customer or dealer installed systems that could cause this symptom ?
l What else occurred ?
l When did the symptoms begin (and what else happened at that time) ?
Logged diagnostic codes
l Do they correlate to probable causes ?
l Did they occur at the same time as the symptoms ?
l Are some codes logged repeatedly ?
Other symptoms
l Are they related to this symptom ?
l Do they have common probable causes ?
Finally, test each probable cause using the tests suggested by the procedure
Be sure to check connectors, especially on intermittent problems. Refer to Test 39: Inspecting electrical
connectors on page 82 for details.

Diagnostic Manual, TSD 3457E, Issue 1 35

4 2300 Series
Diagnostic procedures without a diagnostic fault code

General information
This section is to be used for diagnosing problems that have symptoms but do not have ACTIVE diagnostic
codes.
Before using this section, be sure that you have gathered information about the fault to adequately describe
the symptoms, verified that the fault is not due to normal engine operation and repaired all ACTIVE diagnostic
codes. Refer to "Diagnostic procedures with a diagnostic fault code" on page 76.

36 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Diagnostic symptoms

Engine will not crank Test 1

Note: This is NOT an electronic system problem, the engine starter motor wiring is not supplied by Perkins.
Refer to the Workshop Manual and OEM Manual for additional information on the following tests.
Probable root causes
l Battery cables/batteries
l Emergency stop switch
l Starter motor solenoid or circuit problem (in system wiring)
l Starter motor/flywheel ring gear
l Engine accessory
l Hydraulic cylinder lock
l Internal engine problem
Perform the following tests
1 Check battery post and battery cables for loose connections and corrosion. If corroded, remove and clean
cables and connections. Check the optional battery disconnect switch.
2 Check that the optional emergency stop switch is not engaged. Load test batteries. If necessary, charge the
batteries.
3 Test starter motor solenoid operation. Check the system wiring to starter motor solenoid.
4 Test starter motor operation. Inspect starter motor pinion and ring gear for damage.
5 Check that the timing pin was not left in the flywheel housing after setting valve clearances. Use the engine
turning tool and attempt to manually turn the engine. If unable to turn the engine, remove and inspect engine
accessories that can lock up the engine. Repair or renew as necessary.
6 Remove injectors and check for fluid in the cylinders.
7 Disassemble engine to inspect for internal components that may be seized, broken, bent, out of alignment,
etc. Refer to the Workshop Manual.

Diagnostic Manual, TSD 3457E, Issue 1 37

4 2300 Series

Engine cranks but will not start Test 2

Probable root causes

l Starting aids/fuel waxing (cold temperature operation)
l Electrical connectors and wiring
l ECM software or ECM
l Engine speed/timing signal
l Electrical connections to the unit injector solenoids
l Fuel supply
l Restriction of the air supply or exhaust
l Combustion problem
Perform the following tests
1 If cold ambient conditions exist, check operation of starting aids. Check the coolant immersion heater for
malfunction and replace if required. Check for presence of congealed fuel (wax). Repair as required.
2 Check that the keyswitch and Injection Disable switches are closed.
3 Check for correct installation of the ECM connectors J1/P1 and J2/P2, engine speed/timing sensor
connectors J401/P401 and J402/P402, and unit injector connectors J300/P300. Check that the ECM is
receiving the correct voltage.
Note: Aftermarket engine protection devices may interrupt power to the ECM and prevent communications
with the TIPSS-EST service tool. Check for correct installation and operation of aftermarket engine protection
devices. Aftermarket devices may need to be bypassed to continue.
4 If the engine has an unprogrammed ECM it will crank but will not start. Access ECM Status in the WinFlash
PC program and follow the request to program the software. Refer to "Programming an ECM using flash
programming" on page 27. Failure to program the software will cause the engine to not start or communicate.
Cycling the key switch will allow access to the WinFlash PC program.
5 Check that none of the diagnostic lamps are illuminated. If any are, turn the key switch OFF and ON to try
and clear the fault. If the diagnostic lamps cannot be cleared refer to "Diagnostic procedures with a diagnostic
fault code" on page 76. Check that the speed/timing sensors are correctly installed and that no diagnostic
codes are active.
6 Check that there is not an active 268-02 Check Programmable Parameters diagnostic code. If the diagnostic
code is present, refer to "Programming an ECM using flash programming" on page 27.
7 Observe the engine speed on the TIPSS-EST "Status" screen while cranking the engine. If the electronic
service tool displays 0 rev/min while cranking the engine, there is a problem in the engine speed/timing sensor
circuit. Refer to Test 46: Engine speed/timing circuit test on page 126.
If the engine speed is greater than 50 rev/min the engine speed/timing circuitry appears to be operating
correctly. Check that the timing reference gear is installed correctly and keyed to the camshaft by means of
the locating dowel. If the gear was installed backwards or flipped over during assembly, the engine will not
start.
8 Check the calibration of the timing sensor and recalibrate if required. Refer to Test 47: Engine speed/timing
calibration on page 134. Check for correct orientation between crankshaft and camshaft drive gears, repair as
required.
9 Ensure the unit injector connectors are correctly installed. Refer to Test 48: Injector solenoids circuit test on
page 138 and perform the Injector Solenoid test as a quick check to confirm that the ECM can energize the
unit injector solenoids. Ensure that the injection disable switch (if fitted) is ON.
10 Check for a fuel supply problem and check fuel pressure. Refer to Test 29: Engine has a fuel supply
problem on page 65.
11 Check for combustion problems.

38 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Engine misfires, runs rough or is unstable Test 3

Note: If the problem is intermittent and cannot be recreated, refer to Test 6: Intermittent low power or power
cut-outs on page 42. If the problem is consistent and can be recreated, continue with this procedure.
Probable root causes
l Cold mode operation (normal operation, if the problem occurs only after start-up)
l Battery cables, battery
l Electrical connections to the ECM
l Loss of backup engine speed/timing sensor
l Throttle position signal
l Faulty electronic unit injector circuit (individual cylinder malfunction)
l Fuel supply
l Air inlet or exhaust restrictions or air system leaks
l Internal engine problem
Note: If the problem only occurs under certain conditions (high engine speed, full load or engine operating
temperature, etc), then perform the test under those operating conditions.
Perform the following tests
1 Check indicator lamps; refer to Test 39: Inspecting electrical connectors on page 82.
2 Check for a fuel supply problem and check fuel pressure.
3 Check air inlet and exhaust systems for restrictions and leaks. Look for a diagnostic lamp indication, or
tripped restriction indicators (if fitted) associated with plugged air filters. Replace plugged air filters, or clean
filters, as described in the User’s Handbook, and repair any leaks found. Also refer to Test 41: Analogue
sensor open or short circuit test on page 91. Refer to the Workshop Manual if an internal engine problem is
suspected.
4 Monitor the TIPSS-EST "Status" screen to check that the engine has exited cold mode and observe the
coolant temperature reading on the electronic service tool. The engine should exit cold mode operation
whenever the coolant temperature is above 17 °C (64 °F) and the engine has been running for five minutes.
5 Check battery post and battery cables for loose connections and corrosion. If corroded, remove and clean
cables and connections.
6 Check the ECM connectors J1/P1 and J2/P2, customer connector, engine speed/timing sensor connectors,
unit injector connectors and associated wiring for damage, abrasion or incorrect attachment. Refer to Test 39:
Inspecting electrical connectors on page 82.
7 Check the battery connection at the customer connector and ECM connector. Perform a pull test on the
customer connector. Perform a pull test on P1 pins 48, 52, 53, 61, 63, 65 and 70. The wires should remain in
the connectors during pull test. Refer to Test 39: Inspecting electrical connectors on page 82.
8 Check that a 190-11 Loss of Engine Speed Signal diagnostic code is not active. If the 190-11 code is active
check to see if a 342-11 Loss of Backup Engine Speed Sensor diagnostic code has been recently logged. If
the electronic service tool indicates that a 342-11 code has been recently logged perform a pull test on the
wires to the backup engine speed/timing sensor. Refer to Test 39: Inspecting electrical connectors on page
82. If a 342-11 code has not been recently logged and the 190-11 code is active refer to Test 46: Engine
speed/timing circuit test on page 126.
9 Connect an electronic service tool to the service tool connector. Turn the key switch to the ON position,
engine OFF. If a PWM speed control is fitted, check that a 91-08 Invalid PWM Speed Control Signal diagnostic
code has not been recently logged. Monitor the throttle position from low idle to full throttle.
10 Check for active or recently logged injector solenoid diagnostic codes. Use an electronic service tool and
cut out each cylinder at low idle to isolate the misfiring cylinder(s). Refer to Test 48: Injector solenoids circuit
test on page 138.

Diagnostic Manual, TSD 3457E, Issue 1 39

4 2300 Series

Low power/poor or no response to throttle Test 4

Probable root causes

l Customer specified parameters
l Cold mode operation (normal operation if the problem occurs only after start-up in cold weather)
l Engine is in a derated mode
l Electrical connections to the ECM
l External speed control
l Faulty electronic unit injector (individual cylinder malfunction)
l Fuel supply
l Intake manifold sensor signal
l Air inlet or exhaust system restrictions or leaks
l Incorrect adjustment of full load setting or full torque setting
Note: If the problem only occurs under certain conditions (high engine speed, full load or engine operating
temperature, etc), then perform the test under those operating conditions.
Perform the following tests
1 Check for a fuel supply problem and check fuel pressure. Refer to Test 29: Engine has a fuel supply problem
on page 65.
2 Check air inlet and exhaust systems for restrictions and leaks. Look for a diagnostic lamp indication, or
tripped restriction indicators (if fitted) associated with plugged air filters. Replace plugged air filters, or clean
filters, as described in the User’s Handbook, and repair any leaks found.
3 Check that the fault is not normal (programmed parameter) operation. Connect an electronic service tool
and check the system/customer parameters. If a 268-02 Check Customer Or System Parameters diagnostic
code is active, ensure ALL the system and customer parameters are programmed. Check that the injector
codes are programmed. Check that the correct rating is programmed.
4 Monitor the electronic service tool "Status" screen to check that the engine has exited cold mode. Observe
the coolant temperature reading on the electronic service tool. The engine should exit cold mode operation
whenever the coolant temperature is above 17 °C (64 °F) and the engine has been running for five minutes.
5 The engine may be derated due to altitude or other factors. Connect an electronic service tool and check for
active engine derates or diagnostic codes.
6 Check the ECM connectors J1/P1 and J2/P2, customer connector and the relevant speed setting inputs and
associated wiring for damage, abrasion or incorrect attachment. Refer to Test 39: Inspecting electrical
connectors on page 82.
7 If a PWM speed control is fitted, connect an electronic service tool to the service tool connector. Turn the
key switch to the ON position, engine OFF. Check that a 91-08 Invalid PWM Speed Control Signal diagnostic
code has not been recently logged. Monitor the PWM input. The duty cycle should be between 5 and 10
percent at low load and increase at full load. If the throttle position change is erratic or out of range the problem
is with the external speed control.
8 Check that a 262-03 +5 V Supply Above Normal or a 262-04 +5 V Supply Below Normal diagnostic code is
not present. If either of the codes are active refer to Test 41: Analogue sensor open or short circuit test on
page 91.

40 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Intermittent engine shutdowns Test 5

Note: Use this procedure only if the engine has shut down completely and has had to be restarted.
Probable root causes
l Customer specified parameters
l Electrical connections to the ECM
l Faulty electronic unit injector connector
l Engine fault
The ECM detects an engine fault, e.g. low oil pressure, etc. These fault codes may be viewed on the display
modules or an electronic service tool. They are logged in memory except as noted.
Note: If the problem only occurs under certain conditions (high engine speed, full load or engine operating
temperature, etc), then perform the test under those operating conditions.
Perform the following tests
1 The engine may be shut down due to low pressure levels, or other factors. Connect an electronic service
tool and check for active engine derates or diagnostic codes.
2 Check the ECM connectors J1/P1 and J2/P2, customer connector, engine speed/timing sensor connectors
and the unit injector connectors and associated wiring for damage, abrasion, corrosion or incorrect attachment.
Refer to Test 39: Inspecting electrical connectors on page 82 for additional information.
3 Check the electronic service tool for a logged 168-02 Intermittent Battery Power to the ECM diagnostic code.
Check the battery connection at the customer connector and the ECM connector. Refer to the electrical
schematic. Perform a pull test on the customer connector. Perform a pull test on P1 pins 48, 52, 53, 61, 63, 65
and 70. The wires should remain in the connectors during the pull test. Refer to Test 39: Inspecting electrical
connectors on page 82.
4 If the problem occurs only after the engine is warmed up and disappears after the engine has been allowed
to cool, the circuit breakers may be exceeding the trip point because of overheating. Check the circuit breakers
on the engine, reset if required.
Note: Aftermarket engine protection devices may interrupt power to the ECM. Check for correct installation
and operation of aftermarket engine protection devices. Aftermarket devices may need to be bypassed to
continue testing.
5 Check switch status on an electronic service tool. If the switch status is incorrect, refer to "Machine wiring
diagram (all options)" on page 18.
6 Check for a fuel supply problem and check fuel pressure. Refer to Test 29: Engine has a fuel supply problem
on page 65.

Diagnostic Manual, TSD 3457E, Issue 1 41

4 2300 Series

Intermittent low power or power cut-outs Test 6

Note: Use this procedure only if the engine DOES NOT shut down completely (the engine did not have to be
restarted).
Probable root causes
l Speed setting input signal
l Faulty electrical connections
l Fuel supply
Note: If the problem only occurs under certain conditions (high engine speed, full load or engine operating
temperature, etc) then perform the test under those operating conditions.
Perform the following tests
1 Check the ECM connectors J1/P1 and J2/P2, customer connector, engine speed/timing sensor connectors
and the unit injector connectors and associated wiring for damage, abrasion, corrosion or incorrect attachment.
Refer to Test 39: Inspecting electrical connectors on page 82 for additional information.
2 Check the electronic service tool for a logged 168-02 Intermittent Battery Power to the ECM diagnostic code.
Check the battery connection at the customer connector and the ECM connector. Refer to the electrical
schematic. Perform a pull test on the customer connector. Perform a pull test on pins 48, 52, 53, 61, 63, 65
and 70. The wires should remain in the connectors during the pull test. Refer to Test 39: Inspecting electrical
connectors on page 82.
3 If the problem occurs only after the engine is warmed up and disappears after the engine has been allowed
to cool, the circuit breakers may be exceeding the trip point because of overheating. Check the circuit breakers
on the engine, reset if required.
Note: Aftermarket engine protection devices may interrupt power to the ECM. Check for correct installation
and operation of aftermarket engine protection devices. Aftermarket devices may need to be bypassed to
continue testing.
4 If a PWM speed control is fitted, connect an electronic service tool to the service tool connector. Turn the
key switch to the ON position, engine OFF. Check that a 91-08 Invalid Throttle Signal diagnostic code has not
been recently logged. Monitor the PWM input. The duty cycle should be between 5 and 10 percent at low load
and increase with load. If the throttle position change is erratic or out of range the problem is with the external
speed control.
5 Connect an electronic service tool and check that a 190-02 Loss of Engine Speed Signal diagnostic code is
not active. The code should not be active. If the 190-02 code is active check to see if a 342-02 Loss of Backup
Engine Speed Sensor diagnostic code has been recently logged. If the electronic service tool indicates that a
342-02 code has been recently logged perform a pull test on the wires to the backup engine speed/timing
sensor. Refer to Test 39: Inspecting electrical connectors on page 82. If a 342-02 code has not been recently
logged and the 190-02 code is active refer to Test 46: Engine speed/timing circuit test on page 126.
6 Check for a fuel supply problem and check fuel pressure. Refer to Test 29: Engine has a fuel supply problem
on page 65.

42 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Electronic service tool will not communicate with the ECM Test 7

Probable root causes

l ECM software or ECM
l Electronic service tool or communication adapter cable problem
l Perkins Data Link
l Electrical power supply to the ECM connector or wiring problem in electronic system wiring harness
Perform the following tests
Note: If the engine starts but will not communicate proceed with this test. If the engine will not start, refer to
Test 2: Engine cranks but will not start on page 38. If the engine will not crank, refer to Test 1: Engine will not
crank on page 37. Aftermarket engine protection devices may interrupt power to the ECM and prevent
communications with the electronic service tool. Check for correct installation and operation of aftermarket
protection devices, they may need to be bypassed to continue.
1 In the event that the ECM on the engine is new, the engine will not start or communicate until the ECM is
programmed. Refer to "Programming an ECM using flash programming" on page 27.
2 Check the ECM connectors J1/P1 and J2/P2, customer connector, service tool connectors and associated
wiring for damage, abrasion, corrosion or incorrect attachment. Refer to Test 39: Inspecting electrical
connectors on page 82 for additional information.
3 Check that the key switch is in the ON position and any override switches are not creating the problem. Start
the engine and then connect the electronic service tool. If communication occurs when the engine is started,
but not when the key switch is in the ON position, some type of system override is interrupting power to the
ECM. Repair as required.
4 Check that battery voltage is present at pin-A and Pin-B of the service tool connector (the communication
adapter power LED will be off if it is not receiving power).
5 Check the electronic service tool connections and wiring. Connect another electronic service tool and cable
to the system to check that the fault is with the electronic service tool.
6 Disconnect the ECM P1 connector. Install a bypass harness, connect the bypass harness directly to the
electronic service tool cable and retest. Refer to Test 45: Perkins Data Link circuit test on page 118. If the ECM
communicates with the bypass installed, either the machine wiring or another device is causing the data link
communication problem. Repair as required.

Diagnostic Manual, TSD 3457E, Issue 1 43

4 2300 Series

ECM will not accept factory passwords Test 8

Probable root causes

l Error entering password
l Incorrect serial number (engine, ECM, or electronic service tool), total tattletale, or reason code used to
obtain password
Perform the following tests
1 Check that the correct passwords were entered. Check each character in the password for accuracy (for
instance letter I vs. number 1, Z vs. 2, O vs. 0, etc). Turn the key switch to the OFF position for 30 seconds
and then retry.
2 Check that the electronic service tool is on the "Factory Passwords" screen. Check the engine serial number
used to calculate the password is correct. Check the total tattletale, reason code, electronic service tool serial
number and ECM serial number is correct. Refer to "Factory passwords" on page 23 for more details.

44 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Excessive black smoke Test 9

Probable root causes

l Air inlet restriction or air system leaks
l Engine speed/timing signal: injection timing or calibration, incorrect engine speed/timing wheel orientation
assembly, engine speed/timing sensor calibration error after replacement
l Faulty inlet air manifold pressure sensor, atmospheric pressure sensor, or sensor calibration
l ECM/software problem
l Fuel supply: low supply pressure, air in low pressure fuel system, poor fuel quality
l Incorrect valve adjustment
Perform the following tests
1 Connect an electronic service tool and compare atmospheric and inlet pressure readings. Check for filter
restriction derates and alarms. Check air inlet and exhaust systems for restrictions and leaks. Check for a failed
turbocharger. Refer to the relevant procedure in the Workshop Manual. Replace plugged air filters, or clean
filters, as described in the User’s Handbook, and repair any leaks found. Check for correct operation of the
inlet air manifold pressure and atmospheric pressure sensors. Refer to Test 41: Analogue sensor open or
short circuit test on page 91.
2 Check calibration of the engine speed/timing sensor, recalibrate if required. Refer to Test 47: Engine speed/
timing calibration on page 134. Check for correct orientation between crankshaft and camshaft drive gears,
repair as required. Refer to the relevant procedure in the Workshop Manual.
3 Monitor atmospheric pressure with an electronic service tool. Observe inlet air manifold pressure, fuel
position, rated fuel position and smoke fuel limit while the engine is operating under full load.
Fuel position = rated fuel position
and
smoke fuel limit > rated fuel limit
Note: A problem with the smoke fuel limit will only create black smoke problems on acceleration, not steady
state operation. Check for a restriction in the atmosphere path, remove dirt and debris if required. Atmospheric
pressure should range from 50 to 100 kPa (7.5 to 15 lb/in2) depending on your area of operation. Refer to Test
41: Analogue sensor open or short circuit test on page 91.
4 Check for a fuel supply problem and check the fuel pressure. Refer to Test 29: Engine has a fuel supply
problem on page 65.
5 Check valve adjustment.

Diagnostic Manual, TSD 3457E, Issue 1 45

4 2300 Series

Excessive white smoke Test 10

Note: Some white smoke may be present during cold start-up conditions when the engine is operating
normally.
Probable root cause
l Faulty coolant temperature sensor
l Engine speed/timing signal: injection timing or calibration, incorrect engine speed/timing wheel orientation
assembly, engine speed/timing sensor calibration error after replacement
l ECM software
l Fuel supply
l Combustion system problem
Perform the following tests
1 Check for a fuel supply problem and check the fuel pressure. Refer to Test 29: Engine has a fuel supply
problem on page 65.
2 Ensure that the correct type of fuel is used and check that there is no water or other contaminants in the fuel.
3 Check that cold mode is active when the engine is cold. Monitor coolant temperature status on an electronic
service tool. Observe coolant temperature and ensure the reading is reasonable. If temperature reading is
incorrect, refer to Test 41: Analogue sensor open or short circuit test on page 91.
4 Check timing calibration of the engine speed/timing sensor, recalibrate if required. Refer to Test 47: Engine
speed/timing calibration on page 134. Check for correct orientation between crankshaft and camshaft drive
gears, repair as required.
5 Connect an electronic service tool and check that the correct software is installed for the engine
configuration and application. Refer to Chapter 3, Programming parameters.
6 Excessive valve, piston, ring and/or liner wear, or low cranking speed can result in reduced compression
pressure, resulting in white smoke. Coolant leakage into the cylinder or exhaust system can also produce
symptoms similar to white smoke emissions from unburned fuel. Refer to the Workshop Manual.

46 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Excessive blue smoke Test 11

Note: Blue smoke is produced by the engine when there is excessive oil in the cylinder bores.
Probable root cause
l Too much engine oil in the sump
l Air inlet or exhaust restriction
l Loose, worn or damaged turbocharger
l Combustion system problem
Perform the following tests
1 Check that the engine oil level is correct. If necessary, drain the engine oil until the correct level is obtained.
2 Check the crankcase breather for blockages or restrictions.
3 Check the air filter restriction indicator. Ensure that the filter element of the air cleaner is clean and
serviceable.
4 Check the air inlet and exhaust systems for blockages, restrictions or damage to pipes and hoses.
5 Check that the turbocharger mountings are not loose.
6 Check the turbine housing of the turbocharger for excessive dirt or carbon.
7 Check for worn turbocharger bearings.
8 Check the turbine blades for damage and ensure that the turbine rotates freely.
9 Check the compressor housing for indications of oil.
10 Check that the valve clearances are correct and adjust if necessary.
11 Refer to the Workshop Manual; low compression can be caused by:
l Broken, worn or sticking piston rings
l Worn cylinder bores
l Worn valves, valve stem seals or valve guides
l Valves not fully closed
l Cylinder head gasket faulty
l Cracked cylinder head

Diagnostic Manual, TSD 3457E, Issue 1 47

4 2300 Series

Engine cannot reach correct rev/min Test 12

Note: If this problem occurs only under load, refer to Test 4: Low power/poor or no response to throttle on
page 40.
Probable root causes
l Engine is in cold mode or derated
l ECM software
l External speed control input
l Faulty intake manifold pressure sensor, atmosphere signal or calibration
l Fuel supply
l Air inlet or exhaust restriction or air system leaks
l Air supply/low boost
Perform the following tests
1 Connect an electronic service tool and check that the engine has exited cold mode. Check for active engine
derates. Check that the programming parameters are correct. Refer to Chapter 3, Programming parameters.
Note: The engine may be derated due to altitude or other factors.
2 Monitor the external speed control (if fitted) on an electronic service tool. Observe the position and check
that it can reach 100 percent.
Note: If PWM or analogue speed controls are selected, i.e. digital speed control not installed, but the selected
PWM or analogue control is not connected, the engine will run at 1100 rpm.
3 Check for a fuel supply problem and check the fuel pressure. Refer to Test 29: Engine has a fuel supply
problem on page 65.
4 Check air inlet and exhaust systems for restrictions and leaks. Look for a diagnostic lamp indication, or
tripped restriction indicators (if fitted) associated with plugged air filters. Replace plugged air filters, or clean
filters, as described in the User’s Handbook, and repair any leaks found. Also refer to Test 41: Analogue
sensor open or short circuit test on page 91.

48 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Poor acceleration or response Test 13

Probable root causes

l The engine is in cold mode or a derate mode.
l ECM software
l External speed control input
l Incorrect intake manifold pressure sensor or atmosphere signal
l Air inlet or exhaust restriction or leaks
l Fuel supply
Perform the following tests
1 Connect an electronic service tool. Check that the engine has exited cold mode operation. The engine will
not respond as fast until it has warmed to operating temperature.
2 Check that the correct ECM software is installed. Refer to Chapter 3, Programming parameters.
3 Monitor the external speed control input on an electronic service tool. Observe position and check that the
reading is stable and can reach 100 percent.
4 Inspect ECM connectors J1/P1 and J2/P2, engine interface connectors, and the unit injector connectors for
correct connection. Repair or replace as required. Refer to Test 39: Inspecting electrical connectors on page
82. Perform the cylinder cut-out test to check for any non-operable unit injectors, and replace only those
diagnosed as faulty by the cylinder cut-out check. Connect an electronic service tool and cut-out each cylinder
to isolate the misfiring cylinder(s). If results are inconclusive, perform the test under load or shut off half of the
engine’s cylinders and repeat cut-out on the remaining active cylinders to locate those misfiring. If it can be
isolated to a specific cylinder(s), refer to Test 48: Injector solenoids circuit test on page 138.
5 Monitor atmospheric pressure with an electronic service tool. Observe intake manifold pressure while the
engine is operating under full load. Atmospheric pressure should range from 50 to 100 kPa (7.5 to 15 lb/in2).
6 Check air inlet and exhaust systems for restrictions and leaks. Look for a warning lamp or diagnostic lamp
indication, or tripped restriction indicators (if fitted) associated with plugged air filters. Replace plugged air
filters, or clean filters, as described in the User’s Handbook, and repair any leaks found.
7 Check for a fuel supply problem and check the fuel pressure. Refer to Test 29: Engine has a fuel supply
problem on page 65.

Diagnostic Manual, TSD 3457E, Issue 1 49

4 2300 Series

Poor fuel consumption Test 14

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Incorrect engine operation
l Engine speed/timing signal: injection timing or calibration, incorrect engine speed/timing wheel orientation,
engine speed/timing sensor calibration error after replacement
l Faulty electronic unit injector(s) (individual cylinder malfunction)
l Fuel supply
l Air inlet or exhaust restrictions or air system leaks
Perform the following tests
1 Check timing calibration of engine speed/timing sensor and recalibrate if required. Refer to Test 47: Engine
speed/timing calibration on page 134. Check for correct orientation between crankshaft and camshaft drive
gears, repair as required. Refer to the Workshop Manual.
2 Inspect ECM connector J2/P2 and the unit injector connector for correct connection. Refer to Test 39:
Inspecting electrical connectors on page 82. Connect an electronic service tool and cut out each cylinder to
isolate the misfiring cylinder(s). If results are inconclusive, shut off half of the engine’s cylinders and repeat cut-
out on remaining active cylinders to locate those that are misfiring. Refer to Test 48: Injector solenoids circuit
test on page 138.
3 Check for a fuel supply problem and check the fuel pressure. Refer to Test 29: Engine has a fuel supply
problem on page 65.
4 Check air inlet and exhaust systems for restrictions and leaks. Look for a warning lamp or diagnostic lamp
indication, or tripped restriction indicators (fitted) associated with plugged air filters. Replace plugged air filters,
or clean filters, as described in the User’s Handbook, and repair any leaks found.

50 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Too much vibration Test 15

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Possible root causes
l Loose or faulty vibration damper
l Engine supports are loose, wrong or are incorrectly torqued
l Equipment may not be in alignment or is out of balance
l Engine misfiring or running rough
Perform the following tests
1 Check vibration damper for damage. Tighten bolts. If vibration damper bolt holes have damage or wear,
replace with new parts. Install a new vibration damper if necessary.
2 Run the engine through its speed range while looking for loose or broken mounts or brackets. Tighten all
mounting bolts. Install new components if necessary.
3 Check alignment and balance, correct if required.
4 Refer to Test 3: Engine misfires, runs rough or is unstable on page 39.

Diagnostic Manual, TSD 3457E, Issue 1 51

4 2300 Series

Noise coming from cylinder Test 16

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Low quality fuel
l Incorrect fuel injection timing calibration
l Faulty electronic unit injector(s)
l Incorrect valve train operation or valve train noise (clicking)
l Damage to valve spring(s) or locks
l Not enough lubrication
l Loud tapping sound from rocker cover
l Damage to valve(s)
l Unit injector plunger
l Damaged camshaft lobe
l Little or no valve clearance, worn valve seat or face of valve
Perform the following tests
1 Check for a fuel supply problem and check the fuel pressure. Refer to Test 29: Engine has a fuel supply
problem on page 65.
2 Check and calibrate electronic injection timing with an electronic service tool. Refer to Test 47: Engine
speed/timing calibration on page 134.
3 Connect an electronic service tool and cut-out each cylinder to isolate the misfiring cylinder(s). If results are
inconclusive, perform test under load or shut off half of the engine’s cylinders and repeat cut-out on remaining
active cylinders to locate those misfiring. Refer to Test 48: Injector solenoids circuit test on page 138.
4 Damage to valve spring(s). Replace damaged parts. Damage to camshaft. Replace damaged parts. Clean
engine valve train thoroughly. Replace damaged valve lifters. Inspect camshaft lobes for damage. Look for
valves that do not move freely. Adjust using the procedure in the Workshop Manual. Refer to Test 18: Valve
rotocoil or spring lock is free on page 54.
5 Install new parts where necessary.
Caution: Broken locks can cause the valve to fall into the cylinder.This will cause severe damage.
6 Check lubrication in valve compartment. There must be a strong flow of oil at high engine idle rev/min, but
only a small flow of oil at low rev/min. Oil passages must be clean, especially those that send oil to the cylinder
head.
7 Refer to Test 17: Excessive valve clearance on page 53. Adjust using the procedure in the Workshop
Manual.
8 Replace the valve(s) and adjust using the procedure in the Workshop Manual.
9 Plunger may be stuck, repair as required with reference to the Workshop Manual.
10 Refer to the Workshop Manual.
11 Reconditioning of cylinder head is required.

52 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Excessive valve clearance Test 17

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Not enough lubrication
l Rocker arm worn at face that contacts bridge
l Bridges for valves worn/incorrect adjustment
l End of valve stem worn
l Worn cams on camshaft
l Loose or broken rocker shaft retaining bolt
Perform the following tests
1 Check lubrication in valve compartment. There must be a strong flow of oil at high engine idle rev/min, but
only a small flow at low rev/min. Oil passages must be clean.
2 If there is too much wear, install new parts or rocker arms. Adjust valve clearance using the procedure in
the Workshop Manual.
3 Adjust or replace bridges as necessary. If there is too much wear, install new parts. Adjust valve clearance
using the procedure in the Workshop Manual.
4 If there is too much wear, adjust valve clearance using the procedure in the Workshop Manual.
5 Clean engine valve train thoroughly. Check camshaft for wear. Check for free movement of valves or bent
valve stem. Adjust using the procedure in the Workshop Manual.
6 Check valve clearance. Check for free movement of valves or bent valve stems. Install a new camshaft.
Adjust using the procedure in the Workshop Manual.
7 Repair or replace rocker shaft retaining bolt as required.

Diagnostic Manual, TSD 3457E, Issue 1 53

4 2300 Series

Valve rotocoil or spring lock is free Test 18

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Cracked inlet valve Rotocoil
l Broken spring locks
l Broken valve spring(s)
l Broken valve
Perform the following tests
1 Determine cause of engine overspeed that would crack the Rotocoil.
2 Install new parts where necessary.
Caution: Broken locks can cause the valve to fall into the cylinder, and will cause severe damage.
3 Install new valve spring(s).
4 Replace valve and other damaged parts.

54 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Mechanical noise (knock) in engine Test 19

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Faulty accessory or driven equipment
l Damaged camshaft lobe
l Damaged gears
l Failure of bearing for connecting rod or damaged crankshaft
Perform the following tests
1 Attempt to isolate the source of the noise. If suspected, remove and inspect engine accessories. Repair or
renew as necessary. Refer to the Workshop Manual.
2 If noise may be coming out of the cylinder head, check for damage to camshaft or valve train components.
Replace damaged parts. Clean the engine valve train thoroughly. Check for valves that do not move freely.
Adjust using the procedure in the Workshop Manual. Refer to Test 16: Noise coming from cylinder on page 52.
3 Install new parts where necessary.
4 Inspect the connecting rod bearings and the bearing surfaces (journals) on the crankshaft. Install new parts
where necessary.

Diagnostic Manual, TSD 3457E, Issue 1 55

4 2300 Series

Oil in cooling system Test 20

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Faulty engine oil cooler core or driven equipment oil cooler (if fitted)
l Failure of cylinder head gasket or coolant seals
Perform the following tests
1 Inspect each cooler and replace or repair faulty oil cooler.
2 Check cylinder liner projection. Install a new cylinder head gasket and new coolant seals in the spacer plate.
Tighten the cylinder head bolts according to the procedure in the Workshop Manual.

56 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Fuel in cooling system Test 21

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Internal cylinder head problem
Perform the following tests
1 Remove the valve cover. Remove the fuel supply and fuel return line from cylinder head. Cap the fuel return
connector and apply 700 kPa (100 lb/in2) maximum air pressure to the fuel supply connector. Check for fuel
leakage around the unit injector. If leakage is present, it will be necessary to remove the unit injector and install
a new O-Ring seal.

Diagnostic Manual, TSD 3457E, Issue 1 57

4 2300 Series

Coolant in lubricating oil Test 22

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Failure of any of the oil cooler cores
l Failure of cylinder head gasket or coolant seals
l Crack in cylinder head
l Cracked or broken cylinder liner
l Crack in cylinder block
Perform the following tests
1 Install a new oil cooler core. Drain crankcase and refill with clean lubricant. Install new oil filters.
2 Check cylinder liner projection. Install a new cylinder head gasket and new liner coolant seals in the spacer
plate. Tighten the cylinder head bolts according to the procedure in the Workshop Manual.
3 Check for cracks in cylinder head. Repair or replace as required.
4 Check for cracked liners. Replace cracked cylinder liners.
5 Repair or replace cylinder block.

58 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Fuel dilution of lubricating oil Test 23

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Leaking fuel seals on unit injector case or barrel
l Leaking fuel seals on cylinder head adapters
l Unit injector nozzle tip leakage or breakage
l Cracked fuel supply manifold
l Fuel transfer pump seal leaking with plugged weep hole
Perform the following tests
1 Inspect for signs of damage to unit injector fuel seals, replace if required.
2 Inspect for signs of damage to cylinder head fuel seals, replace if required.
3 Inspect for signs of unit injector damage, replace as required.
4 Inspect for signs of fuel supply manifold damage, replace if required.
5 Repair or replace fuel lift pump.

Diagnostic Manual, TSD 3457E, Issue 1 59

4 2300 Series

Engine has early wear Test 24

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Dirt in lubricating oil
l Air inlet leaks
l Fuel leakage into lubricating oil
l Low oil pressure
Perform the following tests
1 Remove dirty lubricating oil. Install new filters. Put clean oil in the engine. Check oil filter bypass valve for a
weak or broken spring.
2 Inspect all gaskets and connections. Repair if leaks are found.
3 Fuel leakage into lubricating oil will cause high fuel consumption and low engine oil pressure. This condition
may also increase the oil level in the crankcase. Refer to Test 23: Fuel dilution of lubricating oil on page 59.
4 Refer to Test 25: Engine has low oil pressure on page 61.

60 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Engine has low oil pressure Test 25

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Caution: Do not operate engine with low oil pressure, engine damage will result. If measured oil pressure is
low, discontinue engine operation until the problem is corrected.
Probable root causes
l Low Engine Oil Pressure Warning (event code) 360-01
Oil pressure data is below normal operating range for two seconds. The fault and event will be active, and
logged only if the engine has been running for at least 15 seconds. The warning lamp is also illuminated.
l Low Engine Oil Pressure Action Alert (event code) 360-02
Oil pressure data is below normal operating range for two seconds. The fault and event will be logged.
l Low Engine Oil Pressure Shutdown (event code) 360-03
Engine oil pressure has reached a level where the engine is shutdown unless critical override is active.
l Oil level may be too low
l Dirty oil filters or restriction in oil cooler(s)
l Diesel fuel in lubricating oil
l Oil pressure relief valve does not close
l Oil pump suction pipe problem, faulty oil pump or scavenge oil pump
l Too much clearance between rocker arm shaft and rocker arms
l Too much clearance between camshaft and camshaft bearings
l Too much clearance between crankshaft and crankshaft bearings
Perform the following tests
1 Add oil if required.
2 Check the operation of the bypass valve for the filter. Install new oil filters if required. Clean or install new
oil cooler core(s). Remove dirty oil from the engine. Put clean oil in the engine.
3 Check for presence of fuel in lubricating oil. Refer to Test 23: Fuel dilution of lubricating oil on page 59.
4 Clean the bypass valve and housing. Install new parts as necessary.
5 Check the oil pump inlet screen for obstructions. Check for air leakage into the supply to the oil pump.
Examine oil pump for excessive wear. Repair or replace as needed.
6 Install new camshaft and camshaft bearings if necessary.
7 Inspect the main bearings and replace as necessary.

Diagnostic Manual, TSD 3457E, Issue 1 61

4 2300 Series

Engine uses too much lubricating oil Test 26

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Oil leaks
l Too much lubricating oil in engine
l Oil temperature is too high
l Too much oil in the valve compartment
l Turbocharger seal ring failure
l Worn valve guides
l Worn piston rings
Perform the following tests
1 Find all oil leaks. Repair as required. Check for dirty crankcase breather(s).
2 Remove extra oil. Find where extra fluid comes from. Repair as required. Put correct amount of oil in engine.
3 Check for restrictions in the oil cooler or an oil cooler bypass valve stuck in the open position.
4 Check for high coolant temperature. Refer to Test 27: Engine coolant is too hot on page 63.
5 Check that the dowel is installed in the left bolt hole of the rocker shaft. This dowel is located between the
rocker shaft and valve cover base. Check shaft and valve cover base. Check for dirty breather element.
6 Check inlet manifold for oil and repair the turbocharger if necessary.
7 Reconditioning of the cylinder head is required.
8 Inspect and install new parts as required.

62 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Engine coolant is too hot Test 27

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l High Coolant Temperature Warning (event code) 361-01
The engine is running, the coolant temperature sensor reading is greater than or equal to the preset
temperature for two seconds. Diagnostic codes 262-03 +5V Supply Above Normal or 262-04 +5V Supply
Below Normal are not active.
l High Coolant Temperature Action Alert (event code) 361-02
The coolant temperature sensor reading is greater than or equal to the preset temperature for two seconds.
Diagnostic code 262-03 +5V Supply Above Normal is not active. The fault and event will be logged.
l High Coolant Temperature Shutdown (event code) 360-03
Engine coolant temperature has reached a level where the engine is shutdown unless Critical Override is
active.
l Radiator damage or obstruction
l Low coolant level in system
l Combustion gases in coolant
l Incorrect fuel injection timing calibration
l Faulty coolant thermostats
l Faulty coolant pump
l Too much load on the system
Perform the following tests
1 Clean obstructions from the radiator; check that there are no restrictions to the air flow.
2 Check that the fan belts are not slipping.
3 Add coolant to cooling system. Check for leaks.
4 Inspect coolant for presence of bubbles.
5 Check coolant thermostats for correct operation. Inspect coolant pump impeller vanes for damage or
erosion. Repair as necessary.
6 Reduce the load.

Diagnostic Manual, TSD 3457E, Issue 1 63

4 2300 Series

Oil at the exhaust Test 28

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Turbocharger seal ring failure
l Too much oil in the valve compartment
l Worn valve guides
l Worn piston rings
Perform the following tests
1 Check inlet manifold for oil and repair the turbocharger if necessary.
2 Check that the dowel is installed in the left bolt hole of the rocker shaft.
3 Reconditioning of the cylinder head is required.
4 Inspect and install new parts as required.

64 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Engine has a fuel supply problem Test 29

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l Low fuel level
l Poor fuel quality
l Unit injector priming problem
l Low supply pressure
l Fuel supply circuit
l Incorrect fuel type
l Water in fuel
Perform the following tests
1 Visually check fuel level (do not rely on fuel gauge only). Check the fuel pressure.
2 In temperatures below 0 °C (32 °F) check for congealed fuel (wax). Check fuel tank for foreign objects which
may block the fuel supply.
3 Check for fuel line restrictions and repair or replace as required. Refer to the Workshop Manual.
4 Monitor exhaust for smoke while cranking. If smoke is not present there may be a fuel supply problem.
5 Check for air in the low pressure fuel supply system. Purge air from the low pressure fuel supply circuit with
the hand priming pump and cranking the engine in 30 second cycles, pausing at least 2 minutes between
cranking cycles to allow the starter motor to cool. Loosen low pressure fuel line fitting on inlet to pressure
regulating valve and hand prime again if air in fuel continues. Also, use of a sight glass in the low pressure
supply line can be helpful in diagnosing air in the fuel.
6 Check fuel pressure after the filter in the supply circuit during cranking. Refer to the Workshop Manual for
correct pressure values. If pressure is low, check for plugged fuel filters. If pressure is still low, repair or replace
fuel lift pump, fuel lift pump coupling, and fuel pressure regulating valve as needed.
7 Check for air in the low pressure fuel supply system after replacing filters, working on the low pressure fuel
supply circuit or replacing unit injectors. Check fuel pressure after the filter in the supply circuit during cranking.
Refer to the Workshop Manual for correct pressure values. If pressure is low, check for plugged fuel filters. If
pressure is still low, repair or replace fuel lift pump, fuel lift pump coupling, and fuel pressure regulating valve
as needed.

Diagnostic Manual, TSD 3457E, Issue 1 65

4 2300 Series

Indicator lamp not functioning correctly Test 30

Probable root causes

Notes:
l For details regarding wiring harness refer to the engine electrical schematic. This wiring is the responsibility
of the OEM.
l Faulty bulb
l Engine wiring
l Battery voltage
Perform the following tests
1 Turn key switch OFF and check ECM connector J1/P1 and associated wiring for damage, abrasion,
corrosion or incorrect attachment. Refer to Test 39: Inspecting electrical connectors on page 82.
2 Measure the voltage between (+Battery) and (-Battery) at ECM connector J1/P1. The voltage should be
between 22.0 and 27.0 Volts DC for a 24 Volt system. If the voltage is out of range refer to Test 40: Electrical
power supply to the ECM on page 88.
3 Connect a jumper wire between the suspect lamp driver of ECM connector J1/P1 and (-Battery) for J1/28 to
J1/31 or (+Battery) for J1/10, J1/19 and J1/20. If the lamp illuminates the circuit is functioning normally but the
ECM is not completing the lamp circuit. Refer to Test 40: Electrical power supply to the ECM on page 88.
Indicator lamp schematic
Outputs may be used to drive lamps or relays. Refer to the wiring diagrams for full connection details.
Note: If very low current lamps or LED’s are connected to these outputs, a diagnostic code may be generated
even if the lamps or LED’s are functioning correctly.

ECM
Crank
Terminate Crank Terminate Output
J1/13

Shutdown
J1/10 Shutdown Lamp Output

Action Alert
J1/19 Action Alert Lamp Output

Warning
J1/20 Warning Lamp Output

System Fault
J1/31 Diagnostic Lamp Output
B-
Oil Pressure
J1/28 Oil Pressure Lamp Output

Coolant Temp
J1/29 Coolant Temperature Lamp Output

Overspeed
J1/30 Overspeed Lamp Output

P1 J1

B+

A HA0008

66 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Inlet air manifold temperature is too high Test 31

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l High Inlet Air Temperature Warning (event code) 368-01
The engine is running, the inlet air manifold temperature sensor reading is greater than the preset level for two
seconds. Diagnostic codes 262-03 +5 V Supply Above Normal or 262-04 +5 V Supply Below Normal are not
active. The event code and diagnostic code will be logged.
l High Inlet Air Temperature Action Alert (event code) 368-02
The engine is running, the inlet air manifold temperature sensor reading is greater than or equal to the preset
level for at least two seconds. Diagnostic codes 262-03 +5 V Supply Above Normal or 262-04 +5 V Supply
Below Normal are not active. The event code and diagnostic code will be logged.
l Incorrect fuel injection timing calibration
l Low air inlet system pressure
l Air inlet system has a restriction
Perform the following tests
1 Connect an electronic service tool and check for engine speed/timing error. Test 47: Engine speed/timing
calibration on page 134.
2 Check pressure in the air inlet manifold. Check for air inlet leaks. Look for restrictions at the air cleaner.
Check for leaks between inlet manifold and turbocharger. Repair or renew as necessary.
3 Check for air inlet restrictions. Refer to the Workshop Manual. Repair as necessary.

Diagnostic Manual, TSD 3457E, Issue 1 67

4 2300 Series

Engine has a high fuel temperature Test 32

Note: This is NOT an electronic system problem. Refer to the Workshop Manual for additional information on
the following tests.
Probable root causes
l High Fuel Temp Warning (event code) 363-01
The engine speed is greater than 1000 rev/min, the fuel temperature sensor reading is greater than 60 °C
(140 °F) for 30 seconds. Diagnostic codes 262-03 +5V Supply Above Normal or 262-04 +5V Supply Below
Normal are not active. The event code and diagnostic code will be logged and the warning lamp is illuminated.
l Incorrect sensor installation
l Low fuel level
l Poor fuel quality
l Low supply pressure
l Insufficient size of fuel tank
l A fuel cooler may be required
Perform the following tests
1 Check that the fuel temperature sensor has been correctly installed. Refer to the Workshop Manual.
2 Refer to Test 29: Engine has a fuel supply problem on page 65.

68 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Diagnostic procedures with an event code

General information
This section is to be used for diagnosing problems that have event codes but do not have ACTIVE diagnostic
codes.

Event codes
Event codes indicate an actual engine fault, e.g. low oil pressure, rather than an electronic component failure.
There are three possible levels of severity of the fault.
Level 1 - Operator Warning
To warn the operator or machine control system of a possible condition that requires operator attention.
Level 2 - Action (Derate or Alert)
To inform the operator or machine control system to take action to enable the correct control of the system. In
most cases the OEM will use this level for a controlled shutdown of the engine in order to protect it from
damage.
Note: There are no derates set on the 2806/2306 engines. The TIPSS/EST Service Tool incorrectly shows
Action Alerts as Derates on certain screens.
Level 3 - Shutdown
At this level the ECM will immediately stop the engine unless critical override is enabled and signal that a
critical fault level has been reached.
Caution: If critical override is enabled the product is now operating in a condition outside its scope of supply
and may cause injury or be damaged in such a way as to invalidate the warranty.

Diagnostic Manual, TSD 3457E, Issue 1 69

4 2300 Series
Diagnostic tests

High intake manifold pressure Test 33

Event Code
High intake manifold pressure Warning E162-1
High intake manifold pressure Action Alert E162-2

Probable root causes

l Engine overload
Perform the following tests
1 Intake manifold pressure sensor circuit
Check the intake manifold pressure reading with TIPSS-EST and ensure it is reasonable. The pressure should
decrease as load decreases. If the reading is not correct, diagnose the sensor circuit.

70 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Low oil pressure Test 34

Event Code
Low oil pressure Warning E360-1
Low oil pressure Action Alert E360-2
Low oil pressure Shutdown E360-3

Probable root causes

l Low oil level
l High oil temperature/low viscosity
l Blocked oil filter
l Oil pressure sensor circuit
l Blocked oil cooler
l Faulty oil pump/oil pump bypass valve
Perform the following tests
1 Low oil level
Check oil level and add oil as necessary.
2 High oil temperature/low viscosity
If present, diagnose the oil cooler circuit. High oil temperature causes oil viscosity to be low which can cause
low oil pressure.
3 Blocked oil filter
Replace oil filters if there is any doubt as to their condition
4 Oil pressure sensor circuit
Diagnose the sensor circuit.
5 Blocked oil cooler
An oil cooler restriction can cause low oil pressure and high oil temperature.

Diagnostic Manual, TSD 3457E, Issue 1 71

4 2300 Series

High coolant temperature Test 35

Event Code
High coolant temperature Warning E361-1
High coolant temperature Action Alert E361-2
High coolant temperature Shutdown E361-3

Probable root causes

l High ambient temperature
l Low coolant level/cooling system leaks
l Insufficient air or coolant flow through heat exchanger or radiator
l Faulty coolant thermostats
l Coolant temperature sensor circuit
l Insufficient coolant flow
l High inlet air temperature
l Exhaust restriction
l Combustion gasses in coolant
Perform the following tests
1 High ambient temperature
Determine if ambient air temperature is within design specifications for the cooling system.
2 Low coolant level/cooling system leaks
Check coolant level. Low coolant level can be the effect of overheating rather than the cause. Run the engine
to operating temperature and determine if leaks occur before the engine overheats.
3 Insufficient air or coolant flow through heat exchanger or radiator
Check radiator cooling fins for obstructions. Check radiator cooling fan (if fitted) operation. Check for sufficient
flow and temperature of coolant through the heat exchanger (if fitted).
4 Faulty coolant temperature control
Check thermostats.
5 Coolant temperature sensor circuit
Check the coolant temperature reading on TIPSS-EST and ensure it is reasonable. The coolant temperature
reading should rise steadily as the engine is warmed. If the reading is not correct, diagnose the sensor circuit.
6 Insufficient coolant flow
Check the coolant pumps for correct operation. Check the coolant thermostats for correct operation.
7 High inlet air temperature
Check air temperature into the engine.
8 Exhaust restriction
Check exhaust system back pressure.

72 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Engine overspeed Test 36

Event Code
Engine overspeed Warning E362-1
Engine overspeed Action Alert E362-2
Engine overspeed Shutdown E362-3

Probable root causes

l Engine overspeed set point
l Incorrect speed setting
l Driven equipment motoring
l Slow governor response
Perform the following tests
1 Engine overspeed set point
Check that the engine overspeed set point is correctly programmed. Only the Warning level can be changed
using the electronic service tool, The Action Alert and Shutdown levels are factory set and cannot be changed.
2 Check analogue, PWM or remote manual throttle settings.
3 Driven equipment motoring
Determine if the driven equipment has additional energy inputs that could drive the engine beyond it’s rated
rev/min.
4 Slow governor response
Watch the engine response to worst case step loading and step unloading on the TIPSS-EST graphing screen.
Refer to "Governor gain parameters" on page 33 if the engine speed undershoot or engine speed overshoot
is excessive.

Diagnostic Manual, TSD 3457E, Issue 1 73

4 2300 Series

High fuel temperature Test 37

Event Code
High fuel temperature Warning E363-1
High fuel temperature Action Alert E363-2

Probable root causes

l Fuel temperature sensor circuit
l Inadequate size of fuel tank or low fuel level in tank
Perform the following tests
1 Fuel temperature sensor circuit
Check the temperature reading on TIPSS-EST and ensure it is reasonable. If the reading is not correct,
diagnose the sensor circuit.
2 Fuel is used to cool the injectors and surplus fuel is passed back to the fuel tank
If the fuel tank capacity is inadequate this return fuel will heat up the tank until the fuel temperature is
unacceptable. If necessary fit a fuel cooler.

74 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
High intake manifold air temperature Test 38

Event Code
High inlet air temperature Warning E368-1
High inlet air temperature Action Alert E368-2

Probable root causes

l Air temperature sensor circuit
l Insufficient coolant flow through charge cooler
l High ambient temperature
Perform the following tests
1 Air temperature sensor circuit
Check the air temperature reading on TIPSS-EST and ensure it is reasonable and rises steadily as the engine
is warmed. If the reading is not correct, diagnose the sensor circuit.
2 Insufficient coolant flow through charge cooler
Check the coolant inlet temperature and compare to regulated temperature. If OK, check air cooler coolant
outlet temperature. A high temperature difference between outlet and inlet temperature indicates insufficient
flow rate.
3 If ambient temperature exceeds 50 °C (122 °F) engine power must be derated.

Diagnostic Manual, TSD 3457E, Issue 1 75

4 2300 Series
Diagnostic procedures with a diagnostic fault code

General information
Some of the wiring detailed in this section may be supplied by the OEM and may differ from the diagrams in
this manual.
Refer to the OEM supplied wiring diagrams where appropriate.

Diagnostic codes
Diagnostic codes alert the operator that a problem exists and indicate the nature of the problem to the service
technician. Diagnostic codes may be viewed using an electronic service tool (TIPSS-EST).
Diagnostic codes consist of three parts, MID, CID and FMI
l The MID or Module IDentifier indicates which electronic module generated the diagnostic code. The ECM
is MID=24.
l The CID, or Component IDentifier, indicates which component in the system the diagnostic code is for.
l The FMI, or Failure Mode Identifier indicates what the failure mode is. Refer to "Diagnostic terminology" on
page 78 for additional details.
Note: Do not confuse diagnostic codes with diagnostic events. Events can be logged in the ECM to track
information about the engine. An example would be a low oil pressure event. An event is generated when the
engine oil pressure is low but not out of range for the sensor. This does not indicate a problem with the sensor,
rather it indicates a problem with the engine oil pressure. Refer to "Diagnostic procedures with an event code"
on page 69 for more information.
Active diagnostic codes
An active diagnostic code represents a problem with the electronic control system that should be investigated
and corrected as soon as possible.
When an active diagnostic code is generated, the diagnostic warning indicator is activated to alert the operator.
If the condition generating the diagnostic occurs only for a brief moment, the message will disappear and the
diagnostic code will be Logged in the ECM memory.
Logged diagnostic codes
When the ECM generates a diagnostic code, it usually logs the code in permanent memory within the ECM.
The ECM has an internal diagnostic clock and will record the hour of the first occurrence, the hour of the last
occurrence and the number of occurrences of the code.
Knowing when and how often the code was generated can be a valuable indicator when diagnosing
intermittent problems.
An electronic service tool can retrieve and delete Logged codes. Any Logged diagnostic codes will
automatically be deleted if no additional occurrences are recorded in 100 hours.
When investigating logged diagnostic codes, keep in mind the following information.
l Some diagnostic codes may be easily triggered and do not result in operator complaints. If the time the
code was logged does not relate to a complaint, there may be nothing to fix.
l The most likely cause of an intermittent problem is a faulty connection or damaged wiring. Next likely is a
component failure (sensor or switch). Least likely is failure of the ECM itself.
l Diagnostic codes that are logged repeatedly may indicate a problem that needs special investigation.
Continued

76 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
To diagnose a logged diagnostic code, refer to "Diagnostic code quick reference" on page 80. The code
number will direct you to the correct diagnostic test.
If the symptoms continue, use the appropriate procedure for diagnosing the symptoms that have been
experienced by the operator. Refer to "Diagnostic procedures without a diagnostic fault code" on page 36.
Note: Always clear logged diagnostic codes after investigating and correcting the problem which generated
the code.
Example: Output voltage from coolant temperature sensor. This diagram is for reference only and should not
be used to diagnose the coolant temperature sensor.

Sensor Diagnostic Generated

(Electronic Problem)
4.8 V

Logged Event, warning,

Engine is too hot,
derate, and shutdown occur
but there is not an
if applicable.
electronic problem
107 °C
4.2 V
(225 °F)

Warm Mode Temperature

Range 20 to 106 °C
(68 to 223 °F)

NORMAL
ENGINE
TEMPERATURE
RANGE.
63 °C
2.8 V
(145 °F)
Cold Mode Temperature
Range -40 to 20 °C
(-40 to 68 °F)

0.2 V
Sensor Diagnostic Generated
(Electronic Problem)
A HA0009

Logged events
The ECM can log events. Events refer to engine operating conditions such as low oil pressure or high coolant
temperature. Logged events do not indicate an electronic system problem, but may indicate an engine system
problem. The example diagram shown indicates the output voltage from a coolant temperature sensor and
how the ECM responds to that voltage.

Diagnostic Manual, TSD 3457E, Issue 1 77

4 2300 Series
Diagnostic terminology
Module Identifier (MID) - Two or three digit code which is assigned to each module or control system.
Module ID Description
024 Engine Control Module (ECM)

Component Identifier (CID) - Two or three digit code which is assigned to each component or system.
Failure Mode Identifier (FMI) - Type of failure the component experienced (adopted from SAE standard
practice J1587 diagnostics).
Failure Mode Identifier Description
00 Data valid, but above normal operational range
01 Data valid, but below normal operational range
02 Data erratic, intermittent, or incorrect
03 Voltage above normal or shorted high
04 Voltage below normal or open circuit
05 Current below normal or open circuit
06 Current above normal or grounded circuit
07 Mechanical system not responding correctly
08 Abnormal frequency, pulse width, or period
09 Abnormal update
10 Abnormal rate of change
11 Failure mode not identifiable
12 Faulty device or component
13 Uncalibrated device or component
14 - 31 Reserved for future assignment

Active Code - The MID, CID and FMI can be viewed on TIPSS-EST.
Logged Code - The diagnostic will be entered into the permanent memory (Diagnostic Log) when it becomes
Active. The number of occurrences will be saved in the good to bad counter in the permanent memory
(Diagnostic Log). First and last occurrence time (engine hours) will also be saved in the permanent memory
(Diagnostic Log). This information is then available for display on TIPSS-EST.

78 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Connectors
Deutsch connectors - These connectors have a plastic housing. The pins and sockets are crimped onto the
electrical wires. The connector has a locking mechanism to hold the pins and sockets. These connectors are
repairable without cutting the wires.
1 Deutsch DT connector receptacles
2 Deutsch DT connector plugs
3 Deutsch and AMP pin
4 Deutsch and AMP socket
5 Deutsch and AMP sealing plug

Diagnostic Manual, TSD 3457E, Issue 1 79

4 2300 Series
Diagnostic code quick reference

CID-FMI Diagnostic Code Description Fault finding

1-11 Injector Cylinder #1 Fault See Test 48 on page 138
2-11 Injector Cylinder #2 Fault See Test 48 on page 138
3-11 Injector Cylinder #3 Fault See Test 48 on page 138
4-11 Injector Cylinder #4 Fault See Test 48 on page 138
5-11 Injector Cylinder #5 Fault See Test 48 on page 138
6-11 Injector Cylinder #6 Fault See Test 48 on page 138
41-03 8 Volt Sensor Power Supply Open/Short to B+ See Test 44 on page 112
41-04 8 Volt Sensor Power Supply Short to ground See Test 44 on page 112
91-08 PWM Speed Control Abnormal See Test 44 on page 112
100-03 Engine Oil Pressure Sensor Open/Short to B+ See Test 41 on page 91
100-04 Engine Oil Pressure Sensor Short to ground See Test 41 on page 91
110-03 Engine Coolant Temp Sensor Open/Short to B+ See Test 41 on page 91
110-04 Engine Coolant Temp Sensor Short to ground See Test 41 on page 91
168-02 Intermittent Battery Power to the ECM See Test 40 on page 88
172-03 Intake Manifold Temperature Sensor Open/Short to B+ See Test 41 on page 91
172-04 Intake Manifold Temperature Sensor Short to ground See Test 41 on page 91
174-03 Fuel Temperature Sensor Open/Short to B+ See Test 41 on page 91
174-04 Fuel Temperature Sensor Short to ground See Test 41 on page 91
190-02 Engine Speed Sensor Data Intermittent See Test 47 on page 134
190-09 Engine Speed Sensor Abnormal Update See Test 47 on page 134
190-11, 12 Engine Speed Sensor Mechanical Fault See Test 47 on page 134
248-09 Perkins Data Link Communications Abnormal See Test 45 on page 118
See "System configuration
253-02 Check Customer or System Parameters
parameters" on page 12
See "Programming a new ECM"
254-12 ECM Fault
on page 24
261-13 Engine Timing Calibration Required See Test 47 on page 134
262-03 5 Volt Sensor Power Supply Open/Short to B+ See Test 43 on page 107
262-04 5 Volt Sensor Power Supply Short to ground See Test 43 on page 107
See "Programmable
268-02 Check Programmable Parameters
parameters" on page 12
273-03 Turbo Outlet Pressure Sensor Open/Short to B+ See Test 41 on page 91
273-04 Turbo Outlet Pressure Sensor Short to ground See Test 41 on page 91
274-03 Atmospheric Pressure Sensor Open/Short to B+ See Test 41 on page 91
274-04 Atmospheric Pressure Sensor Short to ground See Test 41 on page 91
281-05 Action Alert Lamp Open Circuit See Test 42 on page 101
281-06 Action Alert lamp Short to ground See Test 42 on page 101
282-03 Engine Overspeed lamp Open/Short to B+ See Test 42 on page 101
282-04 Engine Overspeed lamp Short to ground See Test 42 on page 101
285-03 Engine Coolant temperature lamp Open/Short to B+ See Test 42 on page 101
285-04 Engine Coolant temperature lamp Short to ground See Test 42 on page 101
286-03 Engine Lubricating oil pressure lamp Open/Short to B+ See Test 42 on page 101
286-04 Engine Lubricating oil pressure lamp Short to ground See Test 42 on page 101
323-05 Engine Shutdown Lamp Open Circuit See Test 42 on page 101
323-06 Engine Shutdown lamp Short to ground See Test 42 on page 101
324-05 Engine Warning Lamp Open Circuit See Test 42 on page 101
324-06 Engine Warning lamp Short to ground See Test 42 on page 101
342-02 Engine Speed Sensor No. 2 Data Intermittent See Test 46 on page 126
342-11, 12 Engine Speed Sensor No. 2 Mechanical Fault See Test 46 on page 126
80 Diagnostic Manual, TSD 3457E, Issue 1
2300 Series 4
CID-FMI Diagnostic Code Description Fault finding
443-05 Crank Terminate Relay Open Circuit See Test 42 on page 101
443-06 Crank Terminate Relay Short to ground See Test 42 on page 101
799-12 Service Tool Fault Contact Help Desk
1266-03 Diagnostic lamp Open/Short to B+ See Test 42 on page 101
1266-04 Diagnostic lamp Short to ground See Test 42 on page 101
1690-8 Analogue Throttle Signal Abnormal See Test 49 on page 146

Diagnostic Manual, TSD 3457E, Issue 1 81

4 2300 Series
Diagnostic tests

Inspecting electrical connectors Test 39

Functional test

System operation
Many of the diagnostic tests in this manual will direct you to check a specific electrical connector.
Use this test to thoroughly inspect the connectors and determine if they are the cause of a fault. If a problem
is found in an electrical connector, repair the connector and check that the fault has been corrected.
Intermittent electrical faults are often caused by poor connections. Always check for an active diagnostic code
before breaking any connections and check again immediately after reconnecting the connector to see if the
fault has been corrected. Simply disconnecting and then reconnecting connectors can sometimes correct a
fault. If this occurs, likely causes are loose terminals, bent terminals, incorrectly crimped terminals or corrosion.
ECM terminal connections (general layout)

ECM AMP Connectors

17 2 3 4 5 6 8 9 10 11 12 13
13 12 11 10 9 8 7 6 5 4 3 2 1
14 15 16 17 18 >PEI< 19 20 21 22 23
23 22 21 20 19 18 17 16 15 14
31 30 29 28 27 26 25 24 24 25 26 27 28 29 30 31

39 38 37 36 35 34 33 32 32 33 34 35 36 37 38 39

47 46 45 44 43 42 41 40 40 41 42 43 44 45 46 47
48 49 50 51 52 53 54 55 56 57
57 56 55 54 53 52 51 50 49 48
70 69 68 67 66 65 64 63 62 61 60 59 58 58 59 60 61 62 63 64 65 66 67 68 69 70

ECM Side Harness Connector P1 Harness Side

13 12 11 10 9 8 7 6 5 4 3 2 1 17 2 3 4 5 6 8 9 10 11 12 13

23 22 21 20 19 18 17 16 15 14 14 15 16 17 18 >PEI< 19 20 21 22 23

31 30 29 28 27 26 25 24 24 25 26 27 28 29 30 31

39 38 37 36 35 34 33 32 32 33 34 35 36 37 38 39

47 46 45 44 43 42 41 40 40 41 42 43 44 45 46 47

57 56 55 54 53 52 51 50 49 48 48 49 50 51 52 53 54 55 56 57

70 69 68 67 66 65 64 63 62 61 60 59 58 58 59 60 61 62 63 64 65 66 67 68 69 70

ECM Side Harness Side

Harness Connector P2
A HA0011

82 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Functional test
Test 39 - Inspecting electrical connectors
Test step Result Action
Step 1: Check the connector mating
l Ensure that the plug and receptacle are correctly locked á Go to step 2.
together and cannot be pulled apart.
l Check that the connector locking tab is correctly locked and à Repair or renew as
necessary.
returns to the fully locked position.
STOP.
l Check that the connector and the locking mechanism is not
damaged.
l Check that the connector interface is free from dirt and dust.
The connector will securely lock. The connector and locking
mechanism is without cracks or breaks.
Step 2: Check the ECM connector Allen screw
l Ensure the Allen screw is correctly tightened to not more than á Go to step 3.
3,0 Nm (2.2 lb ft) 0,31 kgf m when mating the 70-terminal
“AMP” connector to the ECM. à Repair or renew as
necessary.
The ECM connector is secure and the ECM connector bolt is
STOP.
correctly torqued.
Step 3: Perform a 45 N (10 lb) pull test on each terminal and wire
l Each terminal and connector should easily withstand 45 N á Go to step 4.
(10 lb) of pull and remain in the connector body. This test
checks if the wire is crimped correctly in the terminal and if the à Repair or renew as
necessary.
terminal was correctly inserted into the connector.
STOP.
Note: Terminals should always be crimped onto the wires using an
appropriate tool. Do not solder terminals.
Each terminal and connector easily withstands 45 N (10 lb) of
pull, and remains in the connector body.
Step 4: Observe the effect of the pull test on the electronic service tool
Warning! There is a strong electrical shock hazard while the á Go to step 5.
engine is turning. Do not touch wires associated with the injector
circuit while the engine is cranking or running. à Repair or renew as
necessary.
l If there is an active diagnostic code pertaining to the circuit: STOP.
l Monitor the TIPSS-EST "Active Code" screen while pulling
on all harnesses and connectors that connect to the
component with the active diagnostic code. If the active
diagnostic code disappears while pulling on the harness,
there is a problem in the wiring or connector.
l If there are no active diagnostic codes:
l Monitor the TIPSS-EST "Status" screen for the component
while pulling on the harnesses. If the reading changes
erratically while pulling, there is a problem in the wiring or
connector.
l If there are no active diagnostic codes and there is a sudden
intermittent engine speed changes or misfire:
l Run the engine and listen for engine speed changes or
misfire while pulling on the wiring or connectors. If the
engine speed changes or cuts out while pulling on the
harness, there is a problem in the wiring or connector.
The problem appears to be external to the harnesses and
connectors. Tugging on the harnesses and connectors has no
affect on the active diagnostic code, component status, or
engine performance.

Diagnostic Manual, TSD 3457E, Issue 1 83

4 2300 Series
Test 39 - Inspecting electrical connectors (Continued)
Test step Result Action
Step 5: Check wires for damage to the insulation
l Carefully inspect each wire for signs of abrasion or cuts. Likely á Go to step 6.
locations to check are anywhere the insulation is exposed,
points where the wire rubs against the engine or a sharp point. à Repair or renew as
necessary.
l Check all harness clamps to ensure the harness is correctly
STOP.
fitted and the clamp is not compressing the harness. Pull the
harness sleeves away to check for flattened wires where the
clamp holds the harness.
The wires are free of abrasion or cuts and the harness is
correctly clamped.
Step 6: Check connectors for moisture or corrosion
l Ensure the connector seals and the white sealing plugs are in á Go to step 7.
place. Refer to "Sealing plug insertion" on page 87. If any of the
seals or plugs are missing, renew the seal, plug, or if à Repair or renew wiring or
connectors as necessary.
necessary, the connector.
Ensure all seals are correctly
l Check all wiring harnesses to ensure that the harness does not
installed and that connectors
make a sharp bend out of a connector. Refer to "Harness
are completely mated.
routing" on page 86. This will deform the connector seal and
create a moisture entry path. Check that the repair
eliminates the fault by
l Thoroughly inspect the ECM connectors J1/P1 and J2/P2 for
running the engine for
evidence of moisture entry.
several minutes and check
Note: It is normal to see some minor seal abrasion on the ECM again for moisture.
connector seals. Minor seal abrasion will not allow moisture entry.
If moisture reappears, it is
l If moisture or corrosion is evident in the connector, the source wicking into the connector.
of the moisture entry must be found and repaired or the fault will Even if the moisture entry
occur again. Simply drying the connector will not correct the path is repaired, it may be
fault. Likely moisture entry paths are: necessary to renew the
l Missing or incorrectly fitted seals wires that have moisture
wicking through them as the
l Cuts in the insulation
wires may have moisture
l Unmated connectors. trapped inside the insulation.
l Moisture can also travel or “wick” from one connector through Check that the repair
the inside of a wire to the ECM connector. If moisture is found eliminates the fault.
in the ECM connector, thoroughly check all connectors and
STOP.
wires on the harness that connect to the ECM.
Note: The ECM is not the source of the moisture. Do not renew an
ECM if moisture is found in either ECM connector.
Caution: If corrosion is evident on pins, sockets or the connector
itself, use only denatured alcohol to clean/remove the corrosion
with a cotton swab or a soft brush. Do not use any cleaners that
contain 1,1,1 trichloro-ethylene because it may damage the
connector.
All connectors/seals are completely mated/inserted, and the
harness/wiring is free of corrosion, abrasion or pinch points.
Step 7: Inspect the connector terminals
l Check that the terminals are not damaged. Check for correct á Go to step 8.
alignment and location of terminals in the connector.
The terminals are correctly aligned and appear undamaged.
à Repair or renew as
necessary.
STOP.

84 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 39 - Inspecting electrical connectors (Continued)
Test step Result Action
Step 8: Check individual pin retention into the socket
Note: This is especially important for intermittent faults. á STOP.
l Insert a new pin into a socket of the female connector to check à Repair or renew as
for a good grip on the pin by the socket. Repeat this test with necessary.
the same pin in each socket of the connector. STOP.
l Repeat the test for each pin on the male side of the connector,
by use of a new socket on each pin. The terminal contact (pin
or socket) should stay in place when the connector is held
upside down.
The pins and sockets appear to be in good condition.

Diagnostic Manual, TSD 3457E, Issue 1 85

4 2300 Series
Harness routing

B HA0012

86 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Sealing plug insertion

C HA0013

Diagnostic Manual, TSD 3457E, Issue 1 87

4 2300 Series

Electrical power supply to the ECM Test 40

Diagnostic codes Functional test

System operation
This procedure tests if the correct voltage is supplied to the ECM by the equipment wiring. Use this procedure
if a 168-02 Intermittent Battery Power to the ECM diagnostic codes is logged, or if you suspect the ECM is not
receiving battery supply voltage.
The ECM input at connector P1 terminal-70 (SWITCHED +BATTERY) receives battery voltage from the
engine key switch supplied by the OEM. When the ECM detects battery voltage at this input, the ECM will
power up.
When battery voltage is removed from this input, the ECM will power down after the engine has safely shut
down.
The cause of an intermittent power supply to the ECM can occur on either the positive (UNSWITCHED
+BATTERY) or negative (-BATTERY) side. Both sides are routed from the ECM to the battery.
The three Unswitched +Battery connections should be routed through a dedicated protection circuit.
ECM electrical power supply schematic
Note: Refer to the wiring diagram for full connection details. This wiring is supplied by the OEM.

J1 ECM
61 - Battery
Emergency 63 - Battery
Stop Button 65 - Battery

48 Unswitched + Battery
52 Unswitched + Battery
53 Unswitched + Battery

70 Switched + Battery
Circuit Key
Breaker Switch

Start
Starter Button
Motor

- +
Battery
24V DC

A HA0014

88 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Diagnostic codes

Diagnostic
Conditions that could cause the code System response To find the fault
fault code
168-02 Intermittent Battery Power to the ECM Engine response Proceed with Test
Indicates the battery circuit to the ECM has The engine may experience 40: Electrical power
either an intermittent or low battery condition intermittent engine speed supply to the ECM.
while the engine is running. changes, intermittent and/or
If battery voltage disappears without complete engine shutdowns while
returning, the ECM will not log this diagnostic the conditions causing this
code and the engine will shut down. diagnostic code are present.

Functional test
Test 40 - Electrical power supply to the ECM
Test step Result Action
Step 1: Inspect electrical connectors and wiring
l Thoroughly inspect the ECM harness connector J1/P1, the á Go to step 2.
breaker and battery connections, and the connections to the
engine key switch. Refer to Test 39: Inspecting electrical à Repair or renew wiring or
connectors as necessary.
connectors on page 82 for details.
Check all seals are correctly
l Check the emergency stop switch.
installed and that connectors
l Perform a 45 N (10 lb) pull test on each of the wires in the ECM are completely mated.
connector associated with the Unswitched +Battery
Check that the repair
(terminal-52, 53 and 48), -Battery (terminal-63, 65 and 61), and
eliminates the fault.
Switched +Battery (terminal-70) connections. Refer to "ECM
Terminal connections" on page 90. STOP.
l Check that the ECM connector Allen screw is correctly
tightened to not more than 3,0 Nm (2.2 lb ft) 0,31 kgf m.
l Check the harness and wiring for abrasion and pinch points
from the battery to the ECM, and from the key switch to the
ECM.
All connectors/pins/sockets are completely mated/inserted,
and the harness/wiring is free of corrosion, abrasion or pinch
points.
Step 2: Check battery input voltage at the ECM
l Turn the key switch to the ON position. á The ECM is currently
l Measure the voltage at the battery post terminals. If the voltage receiving the correct
is not between 24.8 and 29 Volts DC, diagnose the charging voltage.
system. If the fault is intermittent
Note: If using a power supply instead of batteries, the minimum refer to Test 39: Inspecting
requirement is 22 Volts DC at 16 Amps. electrical connectors on
page 82.
l Measure the voltage between P1 terminal-52 (UNSWITCHED
STOP.
+BATTERY) and P1 terminal-63 (-BATTERY). Refer to "ECM
Terminal connections" on page 90. à The correct voltages do not
appear at P1.
The voltage measurements at P1 are constant and within
2 Volts DC of the voltage measured at the battery post Check for breakers and/or
terminals. an emergency stop switch.
Check through the wiring
with a voltmeter to find the
source of the voltage drop.
Refer to the "ECM electrical
power supply schematic" on
page 88.
Repair as required.
STOP.

Diagnostic Manual, TSD 3457E, Issue 1 89

4 2300 Series
ECM Terminal connections
Note: Using ECM connector P1.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 Unswitched + Battery 48
31 30 29 28 27 26 25 24
Unswitched + Battery 52
39 38 37 36 35 34 33 32
Unswitched + Battery 53
47 46 45 44 43 42 41 40
Switched + Battery 70
57 56 55 54 53 52 51 50 49 48
- Battery 61
70 69 68 67 66 65 64 63 62 61 60 59 58
- Battery 63
- Battery 65
Terminal side

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
B HA0015

90 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Analogue sensor open or short circuit test Test 41

Diagnostic codes Functional test

System operation
Use this procedure to diagnose open or short circuit diagnostic codes for the oil pressure sensor, atmospheric
pressure sensor, turbo outlet pressure sensor, fuel temperature sensor, engine coolant temperature sensor,
and intake manifold temperature sensor.
Note: The engine coolant temperature sensor, fuel temperature sensor and intake manifold temperature
sensor do not require +5 V supply voltage from the ECM.
The diagnostic procedures for each sensor open and short circuit diagnostic code are identical.
The ECM provides supply voltage from ECM connector J2/P2 terminal-2 (+5 V Supply) to the sensor connector
terminal-A. The sensor return (ground) connection is also shared, provided from ECM connector J2/P2
terminal-3 (analogue return) to each sensor connector terminal-B. The signal voltage from each sensor is
supplied from the sensor connector terminal-C to the appropriate sensor signal terminal at ECM connector J2/
P2. Refer to the "Analogue sensor schematic" on page 92 for further details.

Diagnostic Manual, TSD 3457E, Issue 1 91

4 2300 Series
Analogue sensor schematic
Note: Refer to the wiring diagram for full connection details.

Atmospheric Pressure Sensor

+5V A J2/2 +5VDC Supply

Signal C J2/14 Atmospheric Pressure
Return B J2/3 Analogue Return

ECM
Turbo Outlet Pressure Sensor

+5V A
Signal C J2/40 Turbo Outlet Pressure
Return B

Oil Pressure Sensor

+5V A
Signal C J2/24 Oil Pressure
Return B

Coolant Temperature Sensor

Signal C J2/32 Coolant Temperature

Return B

Fuel Temperature Sensor

Signal C J2/33 Fuel Temperature

Return B

Intake Manifold Temperature Sensor

Signal C J2/35 Intake Manifold Temperature

Return B J2/18 Return

A HA0016

92 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Diagnostic codes

Diagnostic
Conditions that could cause the code System response To find the fault
fault code
100-03 Oil Pressure Sensor Open Or Shorted The ECM assumes a default Proceed with Test
High filtered oil pressure and engine 41: Analogue
The oil pressure sensor signal input to the protection monitoring for low or sensor open or
ECM is greater than 4.8 Volts DC, indicating excessive oil pressure is disabled. short circuit test.
an open circuit or short to a positive voltage This diagnostic code remains
source active until the engine control
AND switch is turned to the OFF
position.
A +5 V Sensor Supply diagnostic code
(262-03 or 262-04) is NOT active. Note: Since engine protection is
no longer available, the engine is
shut down.
100-04 Oil Pressure Sensor Short To Ground The ECM assumes a default Proceed with Test
The oil pressure sensor signal input to the filtered oil pressure and engine 41: Analogue
ECM is less than 0.2 Volts DC, indicating a protection monitoring for low or sensor open or
short to ground excessive oil pressure is disabled. short circuit test.
AND This diagnostic code remains
active until the engine control
A +5 V Sensor Supply diagnostic code
switch is turned to the OFF
(262-03 or 262-04) is NOT active.
position.
Note: Since engine protection is
no longer available, the engine is
shut down.
110-03 Coolant Temperature Sensor Open The ECM assumes a default Proceed with Test
The coolant temperature sensor signal input coolant temperature and engine 41: Analogue
to the ECM is above acceptable range, protection monitoring for low or sensor open or
indicating an open circuit or short to a positive excessive coolant temperature is short circuit test.
voltage source. disabled.
This diagnostic code remains
active until the engine control
switch is turned to the OFF
position.
Note: Since engine protection is
no longer available, the engine is
shut down.
110-04 Coolant Temperature Sensor Short to The ECM assumes a default Proceed with Test
Ground coolant temperature. Engine 41: Analogue
The coolant temperature sensor signal input protection monitoring for low or sensor open or
to the ECM is below acceptable range, excessive coolant temperature is short circuit test.
indicating a short to ground. disabled.
This diagnostic code remains
active until the engine control
switch is turned to the OFF
position.
Note: Since engine protection is
no longer available, the engine is
shut down.

Diagnostic Manual, TSD 3457E, Issue 1 93

4 2300 Series
Diagnostic
Conditions that could cause the code System response To find the fault
fault code
172-03 Intake Manifold Temperature Sensor Open The ECM assumes a default Proceed with Test
The intake manifold temperature sensor intake manifold temperature. 41: Analogue
signal input to the ECM is greater than 4.8 Engine protection monitoring for sensor open or
Volts DC, indicating an open circuit or short to excessive inlet manifold short circuit test.
a positive voltage source. temperature is disabled and the
air-fuel ratio control no longer
compensates for manifold
temperature.
Engine performance may be
affected.
172-04 Intake Manifold Temperature Sensor Short The ECM assumes a default Proceed with Test
To Ground intake manifold temperature. 41: Analogue
The intake manifold temperature sensor Engine protection monitoring for sensor open or
signal input to the ECM is less than 0.2 Volts excessive inlet manifold short circuit test.
DC, indicating a short to ground. temperature is disabled and the
air-fuel ratio control no longer
compensates for manifold
temperature.
Engine performance may be
affected.
174-03 Fuel Temperature Sensor Open The ECM assumes a default fuel Proceed with Test
The fuel temperature sensor signal input to temperature. Engine protection 41: Analogue
the ECM is greater than 4.8 Volts DC, monitoring for high fuel sensor open or
indicating an open circuit or short to a positive temperature is disabled. short circuit test on
voltage source. This diagnostic code remains page 91
active until the engine control
switch is turned to the OFF
position.
174-04 Fuel Temperature Sensor Short To The ECM assumes a default fuel Proceed with Test
Ground temperature. Engine protection 41: Analogue
The fuel temperature sensor signal input to monitoring for high fuel sensor open or
the ECM is less than 0.2 Volts DC, indicating temperature is disabled. short circuit test on
a short to ground. This diagnostic code remains page 91
active until the engine control
switch is turned to the OFF
position.
273-03 Intake Manifold Pressure Sensor Open The ECM assumes a default Proceed with Test
The turbo outlet pressure sensor signal input pressure and engine protection 41: Analogue
to the ECM is greater than 4.8 Volts DC, monitoring for boost pressure is sensor open or
indicating an open circuit or short to a positive disabled. short circuit test.
voltage source Engine performance may be
AND affected.
A +5 V Sensor Supply diagnostic code
(262-03 or 262-04) is NOT active.
273-04 Intake Manifold Pressure Sensor Short To The ECM assumes a default Proceed with Test
Ground pressure and engine protection 41: Analogue
The intake manifold pressure sensor signal monitoring for boost pressure is sensor open or
input to the ECM is less than 0.2 Volts DC, disabled. short circuit test.
indicating a short to ground Engine performance may be
AND affected.
A +5 V Sensor Supply diagnostic code
(262-03 or 262-04) is NOT active.

94 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Diagnostic
Conditions that could cause the code System response To find the fault
fault code
274-03 Atmospheric Pressure Sensor Open The ECM assumes a default Proceed with Test
The atmospheric pressure sensor signal input pressure. Engine power may be 41: Analogue
to the ECM is greater than 4.8 Volts DC, de-rated. sensor open or
indicating an open circuit or short to a positive Note: Since engine protection is short circuit test.
voltage source no longer available, the engine is
AND shut down.
A +5 V Sensor Supply diagnostic code If the Atmospheric Pressure
(262-03 or 262-04) is NOT active. Sensor is faulty, the Oil Pressure
and Intake Manifold pressure
sensors will display ’Abnormal/
Incorrect Data’ on TIPSS/EST.
274-04 Atmospheric Pressure Sensor Short To The ECM assumes a default Proceed with Test
Ground pressure. Engine power may be 41: Analogue
The atmospheric pressure sensor signal input de-rated. sensor open or
to the ECM is less than 0.2 Volts DC, Note: Since engine protection is short circuit test.
indicating a short to ground no longer available, the engine is
AND shut down.
A +5 V Sensor Supply diagnostic code If the Atmospheric Pressure
(262-03 or 262-04) is NOT active. Sensor is faulty, the Oil Pressure
and Intake Manifold pressure
sensors will display ’Abnormal/
Incorrect Data’ on TIPSS/EST.

Diagnostic Manual, TSD 3457E, Issue 1 95

4 2300 Series
Functional test
Test 41 - Analogue sensor open or short circuit test
Test step Result Action
Step 1: Check for active +5 V sensor supply codes
l Connect the TIPSS-EST service tool to the service tool á This procedure will not work
connector. if a sensor supply diagnostic
l Turn the key switch to the ON position. Wait at least 10 code is active.
seconds for codes to become active. Refer to Test 43: +5 V
l Check if any of the following diagnostic codes are active: Sensor voltage supply circuit
test on page 107.
l 262-03 +5 V Supply Above Normal
STOP.
l 262-04 +5 V Supply Below Normal
Are any diagnostic codes listed above active ? à Go to step 2.

Step 2: Check for active analogue sensor diagnostic codes

l Check if any of the following diagnostic codes are active: ACTIVE SHORT A SHORT circuit diagnostic
100-03, 100-04, 110-03, 110-04, 172-03, 172-04, 174-03, (FMI=04) code is active at this time.
174-04, 273-03, 273-04, 274-03, 274-04. Go to step 3.
l If any of the codes listed above are active, determine if it is an ACTIVE OPEN An OPEN circuit diagnostic
Open Circuit (-03) or Short To Ground (-04) fault. (FMI=03) code is active at this time.
Note: Diagnostic code 262-03 + 5 V Supply Above Normal or Go to step 4.
262-04 +5 V Supply Below Normal should not be active.
Are any diagnostic codes listed above active ?
à If the codes listed are logged
only and the engine is
currently not running
correctly, refer to
"Diagnostic procedures
without a diagnostic fault
code" on page 36.
If the engine is running
correctly at this time, there
may be an intermittent
problem in the harness
causing the logged codes.
Refer to Test 39: Inspecting
electrical connectors on
page 82.
STOP.

96 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 41 - Analogue sensor open or short circuit test (Continued)
Test step Result Action
Step 3: Disconnect sensor to create an open circuit
l Turn the key switch to the OFF position. á A SHORT circuit diagnostic
l Disconnect the sensor with the SHORT circuit diagnostic code. code was active before
disconnecting the sensor.
l Turn the key switch to the ON position.
An OPEN circuit diagnostic
l Access the "Active Diagnostic Code" screen of the electronic
code became active after
service tool. Wait 10 seconds after turning the key switch ON.
disconnecting the sensor.
Check for an active OPEN circuit diagnostic code.
Temporarily reconnect the
l Measure the voltage between pin-A (+5 V) and pin-B (Return) suspect sensor.
on the engine harness sensor connector (ignore this step if
diagnosing the temperature sensors). If the sensor short circuit
diagnostic code reappears,
An OPEN circuit diagnostic code for the disconnected sensor
renew the sensor.
is now active.
Check the diagnostic code is
no longer active with the
new sensor installed.
Clear all logged diagnostic
codes.
STOP.

à There is a short circuit

between the sensor harness
connector and the ECM.
Leave the sensor
disconnected.
Refer to Test 39: Inspecting
electrical connectors on
page 82.
If the problem still exists, Go
to step 6.
+5 V SUPPLY NOT There is an open circuit in
OK the sensor supply.
Refer to Test 39: Inspecting
electrical connectors on
page 82.
STOP.
Step 4: Check supply voltage is present at the sensor
l Disconnect the suspect sensor. á Supply voltage is present at
l Proceed to the next step if diagnosing the temperature sensors the sensor.
(+5 V supply not used). Go to step 5.
l Measure the voltage between pin-A (+5 V) and pin-B (Return) à The +5 V sensor supply
on the engine harness sensor connector. Refer to "DT voltage is not reaching the
connectors" on page 100. sensor.
The voltage should measure between 4.5 and 5.5 Volts DC. Most likely there is an OPEN
circuit in either the sensor
common or sensor supply
wire in the engine harness
between the ECM and the
sensor.
Refer to Test 39: Inspecting
electrical connectors on
page 82.
STOP.

Diagnostic Manual, TSD 3457E, Issue 1 97

4 2300 Series
Test 41 - Analogue sensor open or short circuit test (Continued)
Test step Result Action
Step 5: Create short circuit between signal and return terminals at the sensor connector
l Turn the key switch to the OFF position. á The engine harness and
l Fabricate a jumper wire (100 to 150 mm, 4 to 6 inches long) ECM have checked OK.
with Deutsch terminals on both ends. Refer to "DT connectors" Thoroughly inspect the
on page 100. sensor connector.
l Install the jumper wire (short circuit) between the signal and Refer to Test 39: Inspecting
return inputs of the suspect sensor connector (engine harness electrical connectors on
side). page 82.
l Turn the key switch to the STOP position. Wait at least 10 Reconnect the sensor.
seconds for the SHORT circuit diagnostic code to become If the OPEN circuit
active. diagnostic code reappears,
A sensor SHORT circuit diagnostic code is active with the temporarily replace the
jumper installed. sensor (connect a new
sensor to the harness, but
do not install it into the
engine).
Ensure the diagnostic code
is no longer active.
If the diagnostic code
disappears when the new
sensor is connected, renew
the sensor.
Clear all logged diagnostic
codes.
STOP.

à Most likely there is an OPEN

circuit in either the sensor
common or sensor signal
wire in the engine harness
between the ECM and the
sensor.
Remove the jumper.
Refer to Test 39: Inspecting
electrical connectors on
page 82.
If the problem still exists, Go
to step 6.

98 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 41 - Analogue sensor open or short circuit test (Continued)
Test step Result Action
Step 6: Check ECM operation by creating open and short circuits at the ECM connector
l Remove power from the engine control system. Turn the key á The ECM is operating
switch to the OFF position. correctly.
l Disconnect ECM engine harness connector J2/P2. Thoroughly Repair or renew the
inspect both halves of the connector for signs of corrosion or defective wiring harness as
moisture. Repair as necessary. necessary.
l Reconnect J2/P2. Clear all diagnostic codes.
l Use a terminal removal tool to remove the signal wire for the Check that the repair
circuit creating the open or short circuit diagnostic code. eliminates the fault.
l Restore power to the engine control system and turn the key STOP.
switch to the ON position.
l Monitor the TIPSS-EST "Active Diagnostic Code" screen. Wait
à Either the OPEN circuit
diagnostic code is NOT
at least 10 seconds for diagnostic codes to appear. active with the harness
l An OPEN circuit diagnostic code should be active for the disconnected (open circuit),
suspect sensor. or the SHORT circuit
diagnostic code is NOT
l Turn the key switch to the OFF position.
active with the jumper wire
l Fabricate a jumper wire with Deutsch pins on both ends. Refer (short circuit) installed.
to "DT connectors" on page 100.
Renew the ECM.
l Insert the jumper wire between the suspect sensor input
STOP.
terminal and ECM ground. Refer to "ECM terminal
connections" on page 100.
l Turn the key switch to the ON position.
l A SHORT circuit diagnostic code should be active with the
jumper wire installed. Wait at least 10 seconds for
diagnostic codes to appear.
OPEN circuit and SHORT circuit diagnostic codes are active
as indicated by the test procedure.

Diagnostic Manual, TSD 3457E, Issue 1 99

4 2300 Series
ECM terminal connections
Note: Using ECM connector P2.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 +5 VDC Supply 2
31 30 29 28 27 26 25 24 Analogue Return 3
39 38 37 36 35 34 33 32
Intake Manifold Temperature 35
47 46 45 44 43 42 41 40
Coolant Temperature 32
57 56 55 54 53 52 51 50 49 48
Fuel Temperature 33
70 69 68 67 66 65 64 63 62 61 60 59 58
Turbo Outlet Pressure 40
Atmospheric Pressure 14
Terminal side Oil Pressure 24
Temperature Sensor Return 18

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
B HA0017

DT connectors
Note: Using Deutsch DT connectors - terminal side shown.

C Jack Plug HA0018

100 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
ECM Status indicator output circuit test Test 42

Diagnostic codes Functional test

System operation
The ECM has eight available outputs that indicate engine operating status:
l Overspeed - maximum current 0.3 amp
l Coolant temperature - maximum current 0.3 amp
l Oil pressure - maximum current 0.3 amp
l Diagnostics - maximum current 0.3 amp
l Warning - maximum current 1.0 amp
l Action alert - maximum current 1.0amp
l Shutdown - maximum current 1.5 amp
l Crank terminate - maximum current 1.5 amp
They can be used to drive indicator lamps or to interface with other controls. Each output provides a maximum
current connection as indicated above to either battery positive or battery negative when ON, and an open
circuit when OFF.
The DIAGNOSTICS output indicates that a fault exists on the electronic system rather than with the engine.
The TIPSS-EST service tool should be used to diagnose the fault.
The OVERSPEED output indicates that an overspeed fault exists. The severity of the fault is indicated by the
WARNING, ACTION ALERT or SHUTDOWN lamps.
The COOLANT TEMPERATURE lamp indicates a high coolant temperature fault. The severity of the fault is
indicated by the WARNING, ACTION ALERT or SHUTDOWN lamps.
The OIL PRESSURE lamp indicates an engine low oil pressure fault. The severity of the fault is indicated by
the WARNING, ACTION ALERT or SHUTDOWN lamps.
The ACTION ALERT output indicates the existence of an engine fault of sufficient severity that the engine
should be shutdown. This output would normally be used by the OEM to trip the generator circuit breaker and
stop the engine.
The CRANK TERMINATE output indicates that the engine has reached the crank terminate speed (adjustable
from 200 rev/min to 700 rev/min using TIPSS-EST).
ECM Status indicator output circuit schematic
Note: Outputs may be used to drive lamps or relays. Refer to the wiring diagrams for full connection details

ECM
Crank
Terminate Crank Terminate Output
J1/13

Shutdown
J1/10 Shutdown Lamp Output

Action Alert
J1/19 Action Alert Lamp Output

Warning
J1/20 Warning Lamp Output

System Fault
J1/31 Diagnostic Lamp Output
B-
Oil Pressure
J1/28 Oil Pressure Lamp Output

Coolant Temp
J1/29 Coolant Temperature Lamp Output

Overspeed
J1/30 Overspeed Lamp Output

P1 J1

A B+
HA0019

Diagnostic Manual, TSD 3457E, Issue 1 101

4 2300 Series
Diagnostic codes

Diagnostic
Conditions that could cause the code System response To find the fault
fault code
281-05 Action Alert Open Circuit The ECM will limit fault current to 1 Proceed with Test
The ECM detects output is open circuit. Amp and the status display will not 42: ECM Status
be correct. indicator output
Note: This code does not occur when the
circuit test.
output is ON.
281-06 Action Alert Output Shorted Low The ECM will limit fault current to 1 Proceed with Test
The ECM detects excessive output current, Amp and the status display will not 42: ECM Status
indicating a short to ground. be correct. indicator output
circuit test.
Note: This code does not occur when the
output is OFF.
282-03 Overspeed Output Shorted High The ECM will limit fault current to Proceed with Test
The ECM detects excessive output current, 0,3 Amps and the indicator status 42: ECM Status
indicating a short to +Battery. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is OFF.
282-04 Overspeed Output Shorted Low The ECM will limit fault current to Proceed with Test
The ECM detects output is open circuit/ 0,3 Amps and the indicator status 42: ECM Status
shorted to ground. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is ON.
285-03 Coolant Temperature Output Shorted High The ECM will limit fault current to Proceed with Test
The ECM detects excessive output current, 0,3 Amps and the status display 42: ECM Status
indicating a short to +Battery. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is OFF.
285-04 Coolant Temperature Output Shorted Low The ECM will limit fault current to Proceed with Test
The ECM detects output is open circuit/ 0,3 Amps and the status display 42: ECM Status
shorted to ground. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is ON.
286-03 Oil Pressure Output Shorted High The ECM will limit fault current to Proceed with Test
The ECM detects excessive output current, 0,3 Amps and the indicator status 42: ECM Status
indicating a short to +Battery. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is OFF.
286-04 Oil Pressure Output Shorted Low The ECM will limit fault current to Proceed with Test
The ECM detects output is open circuit/ 0,3 Amps and the indicator status 42: ECM Status
shorted to ground. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is ON.
323-05 Engine Shutdown Output Open Circuit The ECM will limit fault current to Proceed with Test
The ECM detects output is open circuit. 1,5 Amps and the status display 42: ECM Status
will not be correct. indicator output
Note: This code does not occur when the
circuit test.
output is ON.
323-06 Engine Shutdown Output Shorted Low The ECM will limit fault current to Proceed with Test
The ECM detects excessive output current, 1,5 Amps and the status display 42: ECM Status
indicating a short to ground. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is OFF.

102 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Diagnostic
Conditions that could cause the code System response To find the fault
fault code
324-05 Engine Warning Output Open Circuit The ECM will limit fault current to 1 Proceed with Test
The ECM detects output is open circuit. Amp and the status display will not 42: ECM Status
be correct. indicator output
Note: This code does not occur when the
circuit test.
output is ON.
324-06 Engine Warning Output Shorted Low The ECM will limit fault current to 1 Proceed with Test
The ECM detects excessive output current, Amp and the status display will not 42: ECM Status
indicating a short to ground. be correct. indicator output
circuit test.
Note: This code does not occur when the
output is OFF.
443-05 Crank Terminate Output Open circuit The ECM will limit fault current to Proceed with Test
The ECM detects output is open circuit. 1,5 Amps and the status display 42: ECM Status
will not be correct. indicator output
Note: This code does not occur when the
circuit test.
output is ON.
443-06 Crank Terminate Output Shorted Low The ECM will limit fault current to Proceed with Test
The ECM detects excessive output current, 1,5 Amps and the status display 42: ECM Status
indicating a short to ground. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is OFF.
1266-03 Diagnostics Output Shorted High The ECM will limit fault current to Proceed with Test
The ECM detects excessive output current, 0,3 Amps and the status display 42: ECM Status
indicating a short to +Battery. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is OFF.
1266-04 Diagnostics Output Shorted Low The ECM will limit fault current to Proceed with Test
The ECM detects output is open circuit/ 0,3 Amps and the status display 42: ECM Status
shorted to ground. will not be correct. indicator output
circuit test.
Note: This code does not occur when the
output is ON.

Diagnostic Manual, TSD 3457E, Issue 1 103

4 2300 Series
Functional test
Test 42 - ECM Status indicator output circuit test
Test step Result Action
Step 1: Inspect electrical connectors and wiring
l Check and renew any burned out engine status indicator lamps á Go to step 2.
(if fitted).
l Check equipment wiring to determine if engine status à Repair or renew the harness
as necessary.
indicators are present and directly controlled by the ECM status
STOP.
indicator circuit. Refer to "ECM Status indicator output circuit
schematic" on page 101. Some indicator panels may obtain
engine status over a data link.
Note: If status indicators are not directly controlled by the ECM,
stop this test.
l Thoroughly inspect ECM connector J1/P1 and the indicator
circuit wiring and connectors. Refer to Test 39: Inspecting
electrical connectors on page 82 for details.
l Perform 45 N (10 lb) pull test on each of the wires associated
with the status indicator circuit. Refer to "ECM terminal
connections" on page 106.
l Check that the ECM connector Allen screw is correctly
tightened to not more than 3,0 Nm (2.2 lb ft) 0,31 kgf m.
l Check the harness and wiring for abrasion and pinch points
from the status indicators back to the ECM.
All connectors/pins/sockets should be completely mated/
inserted, and the harness/wiring should be free of corrosion,
abrasion or pinch points.
Step 2: Check for active status indicator diagnostic codes
l Connect the electronic service tool at the service tool á Go to step 4.
connector.
l Attempt to start the engine while viewing the status indicators. à Go to step 3.

l Check for active diagnostic codes.

Diagnostic codes 281-04, 282-04, 285-03, 286-03, 323-04 or
1266-03 should not be active.
Step 3: Check indicator for shorts
l Disconnect the suspect indicator control wire at the electrical á The short is no longer
indicator (i.e., lamp or PLC input). present.
l Attempt to start the engine while viewing the status indicators. Repair or renew the ECM
l Check for active diagnostic codes. driven indicator as
necessary.
Diagnostic codes 281-04, 282-04, 285-03, 286-03, 323-04 or
1266-03 should not be active. STOP.

à Go to step 5.

104 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 42 - ECM Status indicator output circuit test (Continued)
Test step Result Action
Step 4: Check indicator circuit using a jumper wire
l Turn the key switch to the OFF position. á The harness and indicators
l Disconnect ECM connector J1/P1. check OK.
l Turn the key switch to the ON position. Reconnect all connectors
and recheck ECM indicator
l Observe the engine status indicators while using a jumper wire
operation.
with Deutsch pins crimped on each end to connect between:
If the problem still exists,
l P1 pin 13 and B+
renew the ECM.
l P1 pin 10 and B+
STOP.
l P1 pin 19 and B+
l P1 pin 20 and B+
à There is a problem in the
indicator circuit.
l P1 pin 31 and B- Recheck electrical
l P1 pin 28 and B- connections, wiring, etc., for
l P1 pin 29 and B- damage, corrosion, or
abrasion.
l P1 pin 30 and B-
Repair as required.
Each lamp should illuminate only when the appropriate
jumper is inserted at the ECM connector P1. STOP.

Step 5: Check for shorts in the harness

l Use a wire removal tool to disconnect the suspect indicator á The short is in the harness.
control wire from the ECM connector. Refer to "ECM terminal Repair or renew the harness
connections" on page 106. as necessary.
l Attempt to start the engine while viewing the status indicators. STOP.
l Check for active diagnostic codes.
Diagnostic codes 281-04, 282-04, 285-03, 286-03, 323-04 or
à The short circuit diagnostic
code is present when the
1266-03 should not be active. circuit is disconnected from
the ECM.
Disconnect J1/P1 and check
for damage or corrosion.
Refer to Test 39: Inspecting
electrical connectors on
page 82.
If the problem is not
resolved, renew the ECM.
STOP.

Diagnostic Manual, TSD 3457E, Issue 1 105

4 2300 Series
ECM terminal connections
Note: Using ECM connector P1.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 Shutdown Lamp 10
31 30 29 28 27 26 25 24 Action Alert Lamp 19
39 38 37 36 35 34 33 32
Warning Lamp 20
47 46 45 44 43 42 41 40
Diagnostics Lamp 31
57 56 55 54 53 52 51 50 49 48
Oil Pressure Lamp 28
70 69 68 67 66 65 64 63 62 61 60 59 58
Coolant Temp Lamp 29
Overspeed Lamp 30
Terminal side Crank Terminate Output 13

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
B HA0020

106 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
+5 V Sensor voltage supply circuit test Test 43

Diagnostic codes Functional test

System operation
Use this procedure to diagnose the system when there is an active, or easily repeated, 262-03 +5 V Supply
Above Normal or 262-04 +5 V Supply Below Normal or if directed here by another diagnostic procedure.
The Electronic Control Module (ECM) supplies +5 V to the oil pressure, atmospheric pressure and turbo outlet
pressure sensors. The +5 V sensor supply is routed from the ECM through the ECM engine harness connector
J2/P2 terminal-2 to terminal-A of each +5 V sensor connector. The supply voltage is 5.0 +/- 0.5 Volts DC.
The +5 V short circuit diagnostic code is most likely caused by a short or open circuit in the harness, next likely
is a sensor, and least likely is the ECM.
5 V supply to analogue sensor schematic
Note: Refer to the wiring diagrams for full connection details.

Atmospheric Pressure Sensor

+5V A J2/2 +5VDC Suppl y

Signal C J2/14 Atmospheric Pressure
Return B J2/3 Analogue Return

ECM
Turbo Outlet Pressure Sensor

+5V A
Signal C J2/40 Intake Manifold Pressure
Return B

Oil Pressure Sensor

+5V A
Signal C J2/24 Oil Pressure
Return B

A HA0021

Diagnostic Manual, TSD 3457E, Issue 1 107

4 2300 Series
Diagnostic codes

Diagnostic
Conditions that could cause the code System response To find the fault
fault code
262-03 +5 V Supply Above Normal Electronic system response Proceed with Test
The ECM supply voltage for the sensors is All ECM +5 V analogue sensor 43: +5 V Sensor
exceeding normal level, indicating a possible inputs assume default values and voltage supply
short to a positive voltage source. all diagnostic codes for ECM +5 V circuit test.
analogue sensors are disabled
while this diagnostic code is
active.
TIPSS may indicate DIAG next to
the default value Sensor Status to
indicate the sensor is operating at
the value shown due to an active
diagnostic code.
This diagnostic code remains
active until the engine control
switch is turned to the OFF
position.
Note: Since engine protection is
no longer available, the engine is
shut down.
262-04 +5 V Supply Below Normal Electronic system response Proceed with Test
The ECM supply voltage for the intake All ECM +5 V analogue sensor 42: ECM Status
manifold pressure, atmospheric pressure and inputs assume default values and indicator output
oil pressure sensors is below normal level, all diagnostic codes for ECM +5 V circuit test.
indicating a possible short to ground or short analogue sensors are disabled
between sensor supply and return. while this diagnostic code is
active.
TIPSS may indicate DIAG next to
the default value Sensor Status to
indicate the sensor is operating at
the value shown due to an active
diagnostic code.
This diagnostic code remains
active until the key switch is turned
to the OFF position.
Note: Since engine protection is
no longer available, the engine is
shut down.

108 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Functional test
Test 43 - +5 V Sensor voltage supply circuit test
Test step Result Action
Step 1: Connect an electronic service tool and note all active diagnostic codes
l Connect the TIPSS-EST service tool to the service tool ACTIVE A 262-03 or 262-04
connector. diagnostic code is active.
l Turn the key switch to the ON position. Go to step 2.
l Access the TIPSS "Active" and "Logged Diagnostic Code" LOGGED ONLY A 262-03 or 262-04
screen(s) (wait at least 15 seconds for diagnostic codes to diagnostic code is logged
become active). but NOT active.
l Check for active or logged 262-03 +5 V Supply Above Normal Refer to Test 39: Inspecting
or 262-04 +5 V Supply Below Normal diagnostic codes. electrical connectors on
Select the condition of code 262-03 or 262-04. page 82.
If OK, Go to step 4..
NOT ACTIVE OR The +5 V sensor supply is
LOGGED operating correctly at this
time.
STOP.
Step 2: Disconnect +5 V sensors and monitor active diagnostic codes
l Access the "Active Diagnostic Code" screen and check there is á The +5 V diagnostic code is
an active +5 V Sensor Supply diagnostic code (262-03 or still active.
262-04). Leave the sensors
l Disconnect the following sensors and turn the key switch to the disconnected.
OFF position, then to the ON position: oil pressure, Go to step 3.
atmospheric pressure and turbo outlet pressure sensors.
Check the TIPSS-EST screen after disconnecting each sensor à Disconnecting a specific
to determine if disconnection of a specific sensor deactivates sensor makes the +5 V
the +5 V diagnostic code. diagnostic code no longer
active.
Note: When the sensors are disconnected and the key switch is in
the ON position, open circuit diagnostic codes will be active/logged Reconnect the sensor
when the +5 V diagnostic codes are no longer active. This is suspected of causing the
normal. Clear these diagnostic codes after this test step is problem.
completed. If the problem reappears,
and then disappears
Is the original +5 V diagnostic code (262-03 or 262-04) still following disconnection,
active ? renew the sensor.
Clear all diagnostic codes.
Check that the repair
eliminates the fault.
STOP.

Diagnostic Manual, TSD 3457E, Issue 1 109

4 2300 Series
Test 43 - +5 V Sensor voltage supply circuit test (Continued)
Test step Result Action
Step 3: Isolate the sensor supply harness From The ECM
l Remove power from the engine control system. Turn the key á Isolating the engine harness
switch to the OFF position and disconnect the power from the from the ECM does not
engine. eliminate the active +5 V
l Disconnect J2/P2 and inspect for damage or corrosion. Repair Sensor Supply diagnostic
as necessary. code.
l Use a wire removal tool to remove the +5 V supply wire from Renew the ECM.
ECM connector P2 terminal-2. Reconnect J2/P2. STOP.
l Restore power to the engine control system and turn the key à The +5 V Sensor Supply
switch to the ON position. diagnostic code is no longer
l Access the "Active Diagnostic Code" screen and determine active when the harness is
there is an active +5 V Sensor Supply diagnostic code (262-03 isolated.
or 262-04). There is a short circuit in the
Does the +5 V diagnostic code remain active with the engine harness.
harness isolated ? Refer to Test 39: Inspecting
electrical connectors on
page 82.
If OK, Go to step 4..
Step 4: Check the engine harness
l Remove power from the engine control system. Turn the key á The +5 V line is not shorted
switch to the OFF position and disconnect the power from the in the engine harness.
engine. Reconnect all connectors.
l Disconnect P2 and check ALL of the +5 V engine sensors There does not appear to be
attached to the P2 engine harness are disconnected (oil a problem at this time.
pressure, atmospheric pressure and turbo outlet pressure
Clear all diagnostic codes.
sensors).
Continue to diagnose until
l Set a multimeter to measure resistance on the range closest to,
the original condition is
but not less than, 2k Ohms. Measure from P1 terminal-2 (+5 V
resolved.
Supply) to each of the sensor signal terminals (P1
terminals-14, 17, 24, 26, and 27) and to P1 terminal-3 STOP.
(analogue return). Wiggle the harness during measurement to
reveal any intermittent short condition. Refer to "ECM terminal
à Repair the engine harness.
Clear all logged diagnostic
connections" on page 111.
codes.
l Measure the resistance from P2 terminal-2 (+5 V Supply) to
Check that the repair
engine ground.
eliminates the fault.
Each resistance measurement is more than 2k Ohms.
STOP.

110 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
ECM terminal connections
Note: Using ECM connector P2.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 +5 VDC Supply 2
31 30 29 28 27 26 25 24 Analog Return 3
39 38 37 36 35 34 33 32
Intake Manifold Pressure 40
47 46 45 44 43 42 41 40
Atmospheric Pressure 14
57 56 55 54 53 52 51 50 49 48
Oil Pressure 24
70 69 68 67 66 65 64 63 62 61 60 59 58

Terminal side

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
B HA0022

Diagnostic Manual, TSD 3457E, Issue 1 111

4 2300 Series

PWM desired speed setting circuit test Test 44

Diagnostic codes Functional test

System operation
Note: This procedure is only applicable if the PWM speed control method is selected.
Use this procedure if a 91-08 Invalid PWM Speed Control Signal, 41-03 8 Volt Supply Above Normal or 41-04
8 Volt Supply Below Normal diagnostic code is indicated.
PWM speed control
The PWM speed control is used to provide a desired speed setting signal to the ECM. Output is a constant
frequency signal with a pulse width that varies with the speed control signal. This output signal is referred to
as either “Duty Cycle” or a “Pulse Width Modulated” (PWM) signal and is expressed as a percentage between
3 and 100 percent.
Note: The PWM speed control is an external device supplied by the OEM.
The speed control must produce a duty cycle of 2.6 to 9.9 percent for 1141 rev/min (1369 rev/min if 1800 rev/
min is selected) and 90.1 to 95 percent for full speed of 1621 rev/min (1945 rev/min is 1800 rev/min is
selected).
The PWM speed control may be powered by the ECM supplied from +8 V from connector P1 terminal-4.
If PWM speed control is selected but there is no PWM input, the engine will run at 1100 rev/min.
PWM Speed control circuit
Note: Refer to the wiring diagrams for full connection details.

To OEM J1/5 Ground

ECM
Supplied PWM J1/4 + 8V
Speed Control J1/66 PWM Input

P1 J1

A HA0023

112 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Diagnostic codes

Diagnostic
Conditions that could cause the code System response To find the fault
fault code
41-03 8 Volt Supply Above Normal Engine response Proceed with Test
The PWM speed control supply voltage is An active diagnostic code may not 44: PWM desired
higher than it should be. cause any noticable effect on speed setting circuit
engine response unless the test.
voltage is significantly above 8
volts. The engine may be limited to
low idle.
41-04 8 Volt Supply Below Normal Engine response Proceed with Test
The PWM speed control supply voltage is An active diagnostic code may not 44: PWM desired
lower than it should be. cause any noticable effect on speed setting circuit
engine response unless the test.
voltage is significantly below 8
volts. The engine may be limited to
low idle.
91-08 Invalid PWM Speed Control Signal Electronic system response The diagnostic code
The ECM is not receiving a correct speed The ECM returns the engine to is most likely
control signal from either the PWM or nominal speed as soon as the caused by an open
analogue speed control input, according to problem is detected. The circuit in the PWM
the control selected. diagnostic code is only logged if or analogue speed
the engine is running. control signal
circuit, or voltage
Engine response
supply circuit.
The engine will remain at nominal
Proceed with Test
speed while the diagnostic code is
44: PWM desired
active.
speed setting circuit
If there is no PWM input, the test.
engine will run at 1100 rev/min.

Diagnostic Manual, TSD 3457E, Issue 1 113

4 2300 Series
Functional test
Test 44 - PWM desired speed setting circuit test
Test step Result Action
Step 1: Inspect electrical connectors and wiring
l Thoroughly inspect ECM connector J1/P1, the OEM connector á Go to step 2.
and the external wiring. Refer to Test 39: Inspecting electrical
connectors on page 82. à Repair or renew wiring or
connectors as necessary.
l Perform a 45 N (10 lb) pull test on each of the wires in the ECM
Ensure that all seals are
connector P1 associated with the PWM speed control
correctly installed and that
(terminals 3, 4, 5, 66 and 68). Refer to "ECM terminal
connectors are completely
connections" on page 117.
mated.
l Check that the ECM connector Allen screw is correctly
Check that the repair
tightened to not more than 3,0 Nm (2.2 lb ft) 0,31 kgf m.
eliminates the fault.
l Check the harness and wiring for abrasion and pinch points
If the conditions are not
from the sensor back to the ECM.
resolved, Go to step 2.
All connectors, pins and sockets are completely mated/
inserted, and the harness/wiring is free of corrosion, abrasion
or pinch points.
Step 2: Check for active diagnostic codes
l Connect an electronic service tool to the data link connector. RESULT 1 Go to step 3.
l Turn the key switch ON, engine OFF. RESULT 2 Go to step 5.
l Monitor the electronic service tool "Active Diagnostic Code" RESULT 3 Go to step 3.
screen, check and record active diagnostic codes.
Note: When the ECM is first powered it automatically calibrates
new duty cycle values for the low and high speed positions. It
assumes 10 percent at low speed and 95 percent for the high
speed duty cycle. Following some cycling of the speed input
between the low and high positions, the ECM will adjust its
calibration automatically, provided that the high idle stop position is
within the 90 to 95 percent duty cycle range and the low speed is
in the 2.6 to 9.9 percent duty cycle range.
Result 1 - Diagnostic code 91-08 is active.
Result 2 - Diagnostic code 41-03 or 41-04 is active.
Result 3 - There are no active diagnostic codes that are related
to the speed control circuit at this time, but a problem is
suspected with its operation.
Step 3: Check PWM speed control duty cycle
l Connect an electronic service tool to the data link connector (if á The PWM speed control is
not already installed). currently operating correctly.
l Turn the key switch ON, engine OFF STOP.
l Monitor the speed control range on the electronic service tool. à The PWM speed control is not
Is the PWM speed control operating correctly ? operating correctly.
Go to step 4.
Step 4: Check PWM speed control supply voltage at the speed control
l Connect a voltmeter to the +8 V and ground terminals. á Go to step 7.
l Turn the key switch ON, engine OFF.
à The speed control is not
l Measure the voltage at the +8 V supply with reference to receiving the correct voltage.
ground. Go to step 5.
Is the measured voltage between 7.5 and 8.5 Volts DC ?

114 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 44 - PWM desired speed setting circuit test (Continued)
Test step Result Action
Step 5: Disconnect PWM speed control while monitoring active diagnostic codes
l Access the "Active Diagnostic Code" screen of the electronic á Ensure the speed control has
service tool. Ensure that either a 41-03 8 Volt Supply Above been reconnected before
Normal or 41-04 8 Volt Supply Below Normal diagnostic code continuing.
is active before proceeding. Go to step 6.
l Monitor the "Active Diagnostic Code" screen while
disconnecting and reconnecting the PWM speed control. à Temporarily install another
PWM speed control.
Is the 41-03 8 Volt Supply Above Normal or 41-04 8 Volt Supply Use an electronic service tool
Below Normal still active after the control is disconnected ? and check if the +8 V
diagnostic code is still active.
If the problem is corrected
with the new speed control
and returns when the old
speed control is connected,
renew the speed control.
STOP.
Step 6: Disconnect PWM speed control supply terminals at the ECM
l Turn the key switch OFF, engine OFF. á Check the battery voltage
l Remove terminal-4 (+8 V) and terminal-5 (SENSOR/ SWITCH from P1 terminal-61 and
SENSOR COMMON) from machine harness connector P1 terminal-63 (UNSWITCHED
(disconnect ECM harness connector J1/P1 if necessary). +BATTERY) to terminal-48
and terminal-52 (-BATTERY)
l Reconnect ECM connector J1/P1.
to ensure that it is 22.0 to 27.0
l Turn the key switch ON, engine OFF. Volts DC for a 24 Volt system.
l Use an electronic service tool and check if the diagnostic code If the battery voltage is
is still active. correct, temporarily connect a
Is the 41-03 8 Volt Supply Above Normal or 41-04 8 Volt Supply test ECM.
Below Normal still active after the power terminals are Use an electronic service tool
disconnected ? and check if the diagnostic
code is still active.
If the problem is corrected
with the test ECM, reconnect
the old ECM and check that
the problem returns.
If the test ECM works and the
old ECM does not, renew the
ECM.
STOP.

à There is a problem in the

wiring between the ECM and
the PWM speed control.
Connect the removed wires
one at a time while watching if
the diagnostic code
reappears. First connect
terminal 5 and then connect
terminal 4 to determine which
is causing the problem.
Repair or renew the damaged
wires as necessary.
Check that the repair
eliminates the fault.
STOP.

Diagnostic Manual, TSD 3457E, Issue 1 115

4 2300 Series
Test 44 - PWM desired speed setting circuit test (Continued)
Test step Result Action
Step 7: Check PWM speed control duty cycle at the speed control
Refer to OEM instructions for the correct procedure. á Go to step 8.

à Renew the speed control unit.

STOP.
Step 8: Check PWM speed control duty cycle at the ECM
l Turn the key switch OFF, engine OFF. á A good speed control signal is
l Use a multimeter capable of measuring PWM duty cycle. reaching the ECM.
l Remove the speed control wire (terminal-66) from the machine Check that the ECM is
harness side (P1) of ECM connector P1/J1. It may be receiving the correct battery
necessary to disconnect ECM connector P1 in order to remove voltage. If so temporarily
the speed control signal terminal. connect a test ECM.
l Connect multimeter probes between the removed wire and If the problem disappears with
terminal 5 (SENSOR/SWITCH SENSOR COMMON) of P1. the test ECM connected,
reconnect the suspect ECM
l Reconnect ECM connector P1 to the ECM.
to check that the problem
l Turn the key switch ON, engine OFF. returns. If the test ECM works
l Use the multimeter to display the duty cycle output of the PWM and the old one does not,
speed control while moving the sensor assembly from low idle renew the ECM.
to high idle. Record the results. STOP.
Does the duty cycle measure between 10 percent at the low
speed position and increase to 90 percent in the high speed
à There is a problem with speed
control signal wire in the
position ? machine wiring harness.
l Turn the key switch OFF, engine OFF. Go to step 9.
l Insert terminal-66 into the 70-terminal ECM connector P1/J1.
Step 9: Route supply bypass wires to the PWM speed control
l Turn the key switch OFF, engine OFF. á The wiring from the ECM to
l Remove the speed control wire (terminal-66) from the ECM the speed control appears
connector P1. faulty.
l Route new wiring from the ECM to the external speed control. Renew the wiring.
l Turn the key switch ON, engine OFF. Check that the repair
eliminates the fault.
l Check the speed control duty cycle with an electronic service
tool while changing the speed setting over the full range. STOP.
Does the duty cycle measure between 10 percent at the low à Double check the wiring, the
speed position and increase to 90 percent in the high speed ECM machine harness
position ? connector J1/P1 and the
connectors.
If a problem still exists, restart
the test procedure.
STOP.

116 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
ECM terminal connections
Note: Using ECM connector P1.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 Ground 5
31 30 29 28 27 26 25 24 + 8V 4
39 38 37 36 35 34 33 32
PWM input 66
47 46 45 44 43 42 41 40

57 56 55 54 53 52 51 50 49 48
70 69 68 67 66 65 64 63 62 61 60 59 58

Terminal side

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
B HA0024

Diagnostic Manual, TSD 3457E, Issue 1 117

4 2300 Series

Perkins Data Link circuit test Test 45

Functional test

System operation
Use this procedure if the electronic service tool will not power up or communicate with the ECM through the
data link.
Background
The Perkins Data Link is the standard data link used by the ECM to communicate with electronic service tools
such as TIPSS-EST.
The ECM provides two data link connection terminals from the ECM machine harness connector J1, terminal-
9 (DATA LINK NEGATIVE) and terminal-8 (DATA LINK POSITIVE).
The OEM provides twisted pair wiring from the ECM to the data link connector.
Communication with the key switch OFF
With the key switch OFF, the ECM will not communicate with the electronic service tool. In order to avoid this
problem turn the key switch ON when working with the electronic service tool.
TIPSS-EST may indicate an error message that the ECM version is not recognized and the integrity of the
changed parameters and displayed data is not guaranteed. This will indicate that you have not installed the
latest release of the TIPSS-EST software or the ECM software is newer than the TIPSS-EST software.
Perkins Data Link schematic
Note: Refer to the wiring diagrams for full connection details.

ECM
9 Pin D J1/8 Perkins Data Link +
Perkins E J1/9 Perkins Data Link -
Data Link A Battery +
Connector B Battery - P1 J1

A HA0025

118 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Functional test
Test 45 - Perkins Data Link circuit test
Test step Result Action
Step 1: Check electrical connectors and wiring
l Thoroughly inspect the ECM machine harness connector J1/ á Go to step 2.
P1, data link connector, electronic service tool connectors and
cables, and the Perkins Data Link (terminals-8 and 9) in the à Renew or repair wiring or
connectors as necessary.
connectors.
Ensure all seals are correctly
l Refer to "ECM terminal connections" on page 123.
installed and that connectors
l Refer to Test 39: Inspecting electrical connectors on page are completely mated.
82.
Check that the repair
l Perform a 45 N (10 lb) pull test on each of the wires in the eliminates the fault.
connectors associated with the Perkins Data Link.
STOP.
l Check that the ECM connector Allen screw is correctly
tightened to not more than 3,0 Nm (2.2 lb ft) 0,31 kgf m.
l Check the harness and wiring for abrasion and pinch points
from the sensor back to the ECM.
All connectors, pins and sockets are completely mated/
inserted and the harness/wiring is free of corrosion, abrasion
or pinch points.
Step 2: Determine the type of data link problem
l Connect an electronic service tool to the data link connector. RESULT 1 There is not a problem with
l Start the engine. the data link at this time.
Result 1 - Engine starts and electronic service tool powers up If an intermittent condition
and communicates without error. exists, thoroughly inspect all
wiring and connectors.
Result 2 - Engine starts and electronic service tool powers up
Refer to Test 39: Inspecting
but displays an error.
electrical connectors on
Result 3 - Engine cranks but will not start regardless of the page 82
condition of the electronic service tool. STOP.
Result 4 - Engine will not crank regardless of the condition of RESULT 2 The electronic service tool
the electronic service tool. displays an error message.
Result 5 - Engine starts but the electronic service tool does The ECM is receiving battery
not power up. power.
Go to step 5.
Note: To determine if the electronic service tool has powered up,
check the display screen or check the communication adapter RESULT 3 Refer to Test 2: Engine
display. The electronic service tool will display information that cranks but will not start on
shows if the tool is getting power, and will be blank if it is not. If the page 38.
electronic service tool or the communication adapter powers up, STOP.
the data link connector is receiving power.
RESULT 4 Refer to Test 1: Engine will
not crank on page 37.
STOP.
RESULT 5 The electronic service tool or
communications adapter
does not power up.
Ensure that the ECM is
receiving the correct battery
power.
Go to step 3.

Diagnostic Manual, TSD 3457E, Issue 1 119

4 2300 Series
Test 45 - Perkins Data Link circuit test (Continued)
Test step Result Action
Step 3: Check the battery voltage supply to the data link connector
l Turn the key switch ON, engine OFF á The data link connector is
l Use a multimeter to measure the voltage from the data link currently receiving the
connector + BATTERY terminal to the - BATTERY terminal. correct voltage.
Refer to "Pin allocation for communications connector" on page Go to step 4.
123.
Is the voltage is between 22.0 and 27.0 Volts for a 24 Volt
à The data link connector is
not receiving the correct
system ? voltage.
Inspect the wiring and fuses
to the connector.
Repair or renew the wiring or
batteries as required.
Check that the repair
eliminates the fault.
STOP.
Step 4: Change electronic service tool components
l If another engine or ECM is available connect the electronic RESULT 1 Go to step 5.
service tool to the other engine using the same cables. RESULT 2 Send the faulty electronic
l Turn the key switch ON, engine OFF. Determine if the service tool for repair.
electronic service tool operates correctly on the other engine. If STOP.
another engine is not available, find a different set of electronic
service tool cables.
l Connect the electronic service tool to the data link connector
using the new cables.
l Turn the key switch ON, engine OFF.
l If changing cables allows the electronic service tool to operate
correctly, replace (one at a time) the pieces from the old cable
set into the one that does operate and repower the electronic
service tool each time to determine which piece is faulty.
l If changing cables does not allow the electronic service tool to
operate correctly, connect a different electronic service tool.
l Turn key switch to the ON, engine OFF.
Result 1 - The original electronic service tool works on
another engine.
Result 2 - A different electronic service tool works on the
original engine while the engine is being tested.

120 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 45 - Perkins Data Link circuit test (Continued)
Test step Result Action
Step 5: Check battery voltage at the ECM
l Ensure that the electronic service tool is connected to the data á The ECM is currently
link connector. receiving the correct voltage.
l Disconnect the ECM machine harness connector J1/P1 and Go to step 6.
insert a 70-terminal breakout T in series, or if signal reading
probes are available and ECM connector P1 is accessible à The ECM is not receiving the
correct voltage.
(without disconnecting), insert probes into terminal-52
(UNSWITCHED +BATTERY) and terminal-65 (-BATTERY). Ensure that there is not an
Refer to "Breakout connector" on page 124. aftermarket engine
protection switch overriding
l Turn the key switch ON, engine OFF. battery power to the ECM.
l Measure the voltage between ECM connector PP terminal-52 Refer to Test 40: Electrical
(UNSWITCHED +BATTERY) and terminal-65 (-BATTERY). power supply to the ECM on
l Measure the voltage between P1 terminal-70 (KEY SWITCH) page 88.
and terminal-65 (- BATTERY). STOP.
The voltage is between 22.0 and 27.0 Volts with the key switch
ON ?
Step 6: Connect the electronic service tool directly to the ECM

Warnings! á There is a problem in the

machine wiring.
l Batteries give off flammable fumes which can explode. Do not Re-insert the two data link
strike a match, cause a spark, or smoke in the vicinity of a lines into the ECM connector
battery during the test procedure. P1.
l Do not connect the electronic service tool bypass harness to Contact the OEM for repair.
the battery until the 20 Amp in-line fuse has been removed from
the +Battery line. If the fuse is not removed before connection Check that the repair
to the battery a spark may result. eliminates the fault.

l Turn the key switch OFF, engine OFF. STOP.

l Disconnect the ECM machine harness connector J1/P1 from à Check that the 20 Amp fuse
the ECM. in the bypass harness of the
electronic service tool is not
l Install an electronic service tool power bypass cable. Connect open (blown).
the bypass directly to the electronic service tool harness and
ECM. Refer to "Service tool bypass harness schematic" on Go to step 7.
page 125.
Note: This bypass connects the key switch circuit directly to the
ECM. The ECM will remain powered until the connection to the
+BATTERY line is disconnected. Remove the 20 Amp fuse from
the in-line fuse holder to power down the ECM. Do not connect or
remove the bypass connections to the battery posts without first
removing the 20 Amp in-line fuse.
Is the electronic service tool operating correctly ?

Diagnostic Manual, TSD 3457E, Issue 1 121

4 2300 Series
Test 45 - Perkins Data Link circuit test (Continued)
Test step Result Action
Step 7: Connect the electronic service tool and ECM to another battery

Warnings! á Refer to Test 40: Electrical

power supply to the ECM on
l Batteries give off flammable fumes which can explode. Do not page 88.
strike a match, cause a spark, or smoke in the vicinity of a STOP.
battery during the test procedure.
l Do not connect the electronic service tool bypass harness to à Temporarily connect a test
ECM. Repeat the test step.
the battery until the 20 Amp in-line fuse has been removed from
the +Battery line. If the fuse is not removed before connection If the problem is corrected
to the battery a spark may result. with the test ECM, and
returns when the old ECM is
l Connect the battery wires from the bypass harness of the connected, renew the ECM.
electronic service tool to a different battery not on the engine.
Refer to "Service tool bypass harness schematic" on page 125. Check that the repair
eliminates the fault.
Does the electronic service tool operate correctly ?
STOP.

122 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Pin allocation for communications connector

Pin No. Description

D Battery +
A
E B Battery -
C
C CAN Bus Screen
F A B D Perkins Data Link +
E Perkins Data Link -
J
G F J1939 CAN -
H G J1939 CAN +
H J1922 Bus +
J J1922 Bus -
Deutsch 9 Pin Perkins Data Link Connector
B HA0027

ECM terminal connections

Note: Using ECM connector P1.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 Perkins Data Link + 8
31 30 29 28 27 26 25 24 Perkins Data Link - 9
39 38 37 36 35 34 33 32
47 46 45 44 43 42 41 40

57 56 55 54 53 52 51 50 49 48
70 69 68 67 66 65 64 63 62 61 60 59 58

Terminal side

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
C HA0026

Diagnostic Manual, TSD 3457E, Issue 1 123

4 2300 Series
Breakout connector
Note: Using ECM connector P1.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 Unswitched Battery + 52
31 30 29 28 27 26 25 24 Unswitched Battery + 53
39 38 37 36 35 34 33 32
Key switch 70
47 46 45 44 43 42 41 40
Battery - 67
57 56 55 54 53 52 51 50 49 48
Battery - 65
70 69 68 67 66 65 64 63 62 61 60 59 58

Terminal side

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
D HA0028

124 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Service tool bypass harness schematic

20 Amp
Red In line Fuse

ECM
Black
J1/70 Key Switch
J1/52 Unswitched Battery +
J1/53 Unswitched Battery +
Unswitched Battery + A J1/65 Battery -
Battery - B J1/67 Battery -
Perkins Data Link + D J1/8 Perkins Data Link +
Perkins Data Link - E J1/9 Perkins Data Link -
J1922 Data Link - J J1/1 J1922 Data Link -
J1922 Data Link + H J1/14 J1922 Data Link +
J1939 Data Link + G J1/34 J1939 Data Link +
J1939 Data Link - F J1/50 J1939 Data Link -
J1939 Data Link Screen C J1/42 J1939 Data Link Screen

9 Pin J1
Perkins Data Link
Connector

E HA0029

Diagnostic Manual, TSD 3457E, Issue 1 125

4 2300 Series

Engine speed/timing circuit test Test 46

Diagnostic codes Functional test

System operation
Use this procedure to diagnose the system only when there is an active or easily repeated diagnostic code that
is associated with either the crankshaft or camshaft position sensor circuit or if you have been referred to this
test from a diagnostic procedure without a diagnostic fault code.
The engine uses two engine speed/timing sensors. One sensor picks up the camshaft gear and the other the
crankshaft gear. Both detect engine speed and timing reference from a unique pattern on the gear. The ECM
counts the time between pulses created by the sensor as the gear rotates in order to determine rev/min.
Under normal operation, the camshaft position sensor is used to determine timing (when the piston in cylinder
number 1 is at the top of the compression stroke) for starting purposes. When the timing has been established,
the crankshaft position sensor is then used to determine engine speed and the camshaft position sensor signal
is ignored.
After locating No. 1 cylinder, the ECM triggers each injector in the correct firing order and at the correct time.
The actual timing and duration of each injection is based on engine rev/min and load. If the engine is running
and the signal from the crankshaft position sensor is lost, a slight change in engine performance will be noticed
when the ECM switches to the camshaft position sensor.
Loss of the camshaft position sensor signal during engine operation will not result in any noticeable change in
engine performance. However, if the camshaft position sensor signal is not present during start-up the engine
may take slightly longer to start, or may run rough for a few seconds until the ECM determines the correct firing
order by using the crankshaft position sensor only.
The engine will start and run when only one sensor signal is present from either of the sensors. The loss of the
signal from both sensors will result in the ECM terminating injection and shutting down the engine, or
preventing it from starting.
Both sensors are magnetic with a connector on a "flying lead’.
Caution: The two sensors are not interchangeable, do not switch sensor positions.
If the sensors are replaced a timing calibration is NOT necessary for the engine.
Note: Timing calibration is only necessary after replacing an ECM that will not communicate.
If the ECM is replaced, it will be necessary to do a Timing Calibration.
The crankshaft position sensor is connected to the ECM through the engine harness connector J2/P2 terminal-
48 (CRANK SPEED/TIMING POSITIVE) and terminal-49 (CRANK SPEED/TIMING NEGATIVE).
The camshaft position sensor is connected to the ECM through engine harness connector J2/P2 terminal-58
(CAM SPEED/TIMING POSITIVE) and terminal-59 (CAM SPEED/TIMING NEGATIVE).

126 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
When installing the sensors
l Lubricate the O-ring with oil.
l Ensure that the sensor has a connector face seal inside the connector body. If a seal is damaged or
missing, replace the seal.
l Ensure that the sensor is fully seated into the engine before tightening the bracket bolt.
l Ensure that the connector is latched on both sides.
l Ensure that the harness is correctly secured and the tie-wraps are placed in the correct location.
Speed/timing sensors schematic
Note: Refer to the wiring diagrams for full connection details.

Crankshaft Position Sensor ECM

Signal 2 J2/48 Crank Speed Timing +

Return 1 J2/49 Crank Speed Timing -

J401 P401
Camshaft Position Sensor

Signal 2 J2/58 Cam Speed timing +

Return 1 J2/59 Cam speed timing -

J402 P402 P2 J2

A HA0030

Diagnostic Manual, TSD 3457E, Issue 1 127

4 2300 Series
Diagnostic codes

Diagnostic
Conditions that could cause the code System response To find the fault
fault code
261-13 Cam Sensor To Crank Sensor Calibration Electronic system response Proceed with Test
A timing calibration has been correctly Default timing is used. This code is 46: Engine speed/
performed. The calibration between the active only. This code will not be timing circuit test.
camshaft position sensor and the crankshaft logged. The diagnostic lamp will
position sensor is offset by more than 4°. be illuminated when this code is
There may be a problem with the camshaft active.
position sensor or engine assembly. Engine response
If the camshaft is incorrectly
installed, poor engine response
will occur.
342-12 Loss Of Engine Cam Sensor rev/min Electronic system response Proceed with Test
342-11 Signal The engine may misfire or run 46: Engine speed/
The signal for the camshaft position sensor is rough during starting. The timing circuit test.
342-02
intermittent or lost. diagnostic lamp will not be ON for
this code unless the code has
been active for 10 hours. The code
is logged.
Engine response
There should not be a noticeable
change in engine response unless
the crankshaft position sensor
signal is also lost, which will shut
the engine down.
190-12 Loss Of Engine Crank Sensor rev/min Electronic system response Proceed with Test
190-11 Signal The ECM will use the camshaft 46: Engine speed/
The signal for the crankshaft position sensor position sensor to determine timing circuit test.
190-02
is intermittent or lost. engine speed. The diagnostic
Engine Speed Sensor Mechanical Fault lamp will not be ON for this code
unless the code has been active
The wiring to the speed sensor is broken or
for 10 hours. The code is logged.
the sensor is missing.
Engine response
190-09 Engine Speed Sensor Abnormal Update
There may be a slight change in
The speed sensor is not seeing the correct engine response as the ECM is
pulse sequence. switches to the camshaft position
sensor.

128 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Functional test
Test 46 - Engine speed/timing circuit test
Test step Result Action
Step 1: Connect an electronic service tool and note all active and logged diagnostic codes
l Connect the electronic service tool to the data link connector. 342-12, 190-12 or There is an active or logged
l Turn the key switch ON, engine OFF. 261-13 diagnostic code.
l Check for one of the following logged or active diagnostic Go to step 3.
codes: NO CODE If none of the codes listed
l 261-13 Camshaft Sensor To Crank Sensor Calibration are active or logged and the
engine is not running
l 342-12 Loss Of Engine Cam Sensor rev/min Signal
correctly, refer to the
l 190-12 Loss Of Engine Crank Sensor rev/min Signal appropriate symptoms in
"Diagnostic procedures
Notes: without a diagnostic fault
l If the diagnostic code is logged but not active, run the engine code" on page 36.
until it is at normal operating temperature. The problem may STOP.
only occur when the engine is at the normal operating
temperature. If the engine will not start monitor the engine rev/ NO ENGINE REV/ Engine rev/min is not
min from the electronic service tool while cranking the engine. MIN indicated on an electronic
The electronic service tool may need to be powered from service tool.
another battery while cranking the engine to ensure that the Go to step 2.
electronic service tool does not reset.
l If there are occurrences of the 342-12 and 190-12 faults refer
to Test 39: Inspecting electrical connectors on page 82.
l If you have been referred here from a diagnostic procedure
without a diagnostic fault code because engine rev/min was
not indicated on an electronic service tool select NO ENGINE
REV/MIN.
Are any of the diagnostic codes listed above logged or
active ?
Step 2: Check Sensors and Bracket Installation
Note: To ensure correct operation the sensor flange should be á The sensors and the bracket
flush against the engine. are correctly installed.
l Inspect the bracket to ensure that the installation allows the Go to step 3.
sensor flange to be flush against the engine. Check that the
bracket is not bent. Refer to "Speed/timing sensors schematic"
à Loosen the bolt holding the
sensor bracket to the
on page 127. The bracket cannot be replaced separately. engine.
l Ensure that one O-ring has been installed on the sensor, and Seat the sensor and tighten
that it is free of damage. the bolt. If the sensor will not
l If a 261-13 Camshaft Sensor To Crank Sensor Calibration seat, repair or replace the
diagnostic code is active, there may be a problem with the sensor as necessary. The
assembly of the engine. sensor must not be removed
from the bracket.
Are the sensors and the bracket are correctly installed ?
Ensure that the sensor is
correctly oriented and the
harness is secured in the
correct location.
STOP.

Diagnostic Manual, TSD 3457E, Issue 1 129

4 2300 Series
Test 46 - Engine speed/timing circuit test (Continued)
Test step Result Action
Step 3: Measure the sensor resistance through the engine harness
l Turn the key switch OFF, engine OFF. á The engine harness and
l Thoroughly inspect ECM engine harness connector J2/P2. sensor do not indicate a
Refer to Test 39: Inspecting electrical connectors on page 82. short or open circuit.
l Perform a 45 N (10 lb) pull test on ECM engine harness Go to step 5.
connector P2 terminals-48, 49, 58 and 59. Refer to "ECM
terminal connections" on page 132.
à The sensor resistance is not
within the acceptable range
l Ensure that connector latching tab is correctly latched and is in when measured through the
the fully latched position. engine harness.
l Check that the ECM connector Allen screw is correctly Go to step 4.
tightened to not more than 3,0 Nm (2.2 lb ft) 0,31 kgf m.
l Repair the harness or connector if a problem is found.
l Ensure that the wiring harness is correctly routed and secured
at the correct locations.
Note: Ensure that the wiring harness is not pulled too tight causing
intermittent connections when vibration or movement occurs.
l Inspect the sensor harness wiring for cuts and abrasions.
l If the harness and the connector are OK, disconnect engine
harness ECM connector J2/P2.
l Use a multimeter to measure the sensor resistance (Ohms)
from engine harness connector P2 as indicated below. Move
the harness (pull/shake the wires, especially directly behind the
sensors) while taking a measurement to check for an
intermittent open or short circuit. Refer to "ECM terminal
connections" on page 132.
Crankshaft position sensor - The resistance from P2 terminal-48
(CRANK SPEED/TIMING POSITIVE) and terminal-49 (CRANK
SPEED/TIMING NEGATIVE) is between 75.0 and 230.0 Ohms.
Camshaft position sensor - The resistance from P2 terminal-58
(CAM SPEED/TIMING POSITIVE) and terminal-59 (CAM SPEED/
TIMING NEGATIVE) is between 600 and 1800 Ohms.
Do the readings agree with the values listed above ?

130 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 46 - Engine speed/timing circuit test (Continued)
Test step Result Action
Step 4: Measure sensor resistance at the sensor
l Turn the key switch OFF, engine OFF. á The sensor resistance is
l Check the harness and wiring for abrasion and pinch points correct.
from the sensor back to the ECM. Go to step 5.
l Disconnect the suspect sensor from the engine harness as à The sensor resistance is out
described below. of range, obtain a new
l Thoroughly inspect ECM engine harness sensor connector sensor.
J401/P401 or J402/P402. Refer to Test 39: Inspecting Before installing the new
electrical connectors on page 82 for details. sensor, measure the
l Use a multimeter to measure the sensor resistance (Ohms) at resistance of the new sensor
the sensor connector between terminal-A and terminal-B. as outlined in the test step
using the same test setup
Crankshaft position sensor - The resistance from J401 terminal-
(test harness, multimeter
2 (CRANK SPEED/TIMING POSITIVE) and J401 terminal-1
and meter settings). If the
(CRANK SPEED/TIMING NEGATIVE) is between 75.0 and 230.0
new sensor is in range,
Ohms.
install the new sensor in the
Camshaft position sensor - The resistance from J402 terminal-2 engine.
(CAM SPEED/TIMING POSITIVE) and J402 terminal-1 (CAM
Loosen the bolt holding the
SPEED/TIMING NEGATIVE) is between 600 and 1800 Ohms.
sensor bracket to the
Note: Timing calibration is not necessary following replacement of engine. Ensure the O-ring is
the Crankshaft Position or camshaft position sensor. Refer to installed and free of
"When installing the sensors" on page 127. damage. Seat the sensor
Do the readings agree with the values that are listed above ? and tighten the bolt.
If the sensor will not seat,
repair or replace the sensor,
as necessary.
The sensor must not be
removed from the bracket.
Ensure that the sensor is
correctly oriented and the
harness is secured in the
correct location.
STOP.
Step 5: Install engine speed/timing bypass harness
l Ensure the key switch is OFF, engine OFF. á Permanently install a new
l Disconnect engine harness ECM connector J2/P2 (if not harness section.
already disconnected). STOP.
l For the crankshaft position sensor - install 16 AWG à Double check to ensure that
wires from J2/P2 terminal-48 to P401 terminal-2 and from the correct terminals have
J2/P2 terminal-49 to P401 terminal-1. been installed in the correct
l For the camshaft position sensor - install 16 AWG wires location of the ECM engine
from J2/P2 terminal-58 to P402 terminal-2 and from J2/P2 harness connector P2.
terminal-59 to P402 terminal-1. If the temporary harness
l Reconnect the engine harness connector J2/P2. was installed correctly,
install the original wiring.
l Start the engine to determine if the bypass harness repairs the
problem. Go to step 6.
Is the problem corrected with the bypass installed ?

Diagnostic Manual, TSD 3457E, Issue 1 131

4 2300 Series
Test 46 - Engine speed/timing circuit test (Continued)
Test step Result Action
Step 6: Check the ECM
l Turn the key switch OFF, engine OFF. á If the test ECM works and
l Temporarily connect a test ECM. the suspect ECM does not,
replace the ECM.
l Start the engine and run it to repeat the conditions when the
problem occurs. Determine if the problem is corrected with the STOP.
test ECM. à Replace the sensor and
l If the problem does not return with the test ECM, reinstall the ensure that the problem is
suspect ECM and ensure that the problem returns. corrected.
Does the problem remain with the suspect ECM ? STOP.

ECM terminal connections

Note: Using ECM connector P2.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 Crank Speed/Timing Signal + 48
31 30 29 28 27 26 25 24 Crank Speed/Timing Signal - 49
39 38 37 36 35 34 33 32
Cam Speed/Timing Signal + 58
47 46 45 44 43 42 41 40
Cam Speed/Timing Signal - 59
57 56 55 54 53 52 51 50 49 48
70 69 68 67 66 65 64 63 62 61 60 59 58

Terminal side

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
B HA0031

132 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Speed and timing sensors
1 Crankshaft speed and timing sensor
2 Mounting bracket
3 Cable connection
Note: This is not a connector. Do not try to disassemble.
4 Connector
5 Camshaft speed and timing sensor

2
3
5

C HA0032

Diagnostic Manual, TSD 3457E, Issue 1 133

4 2300 Series

Engine speed/timing calibration Test 47

Diagnostic codes Functional test

Special tools
Part Number Description
GE50038 Timing calibration probe
GE50040 Harness adapter for deutsch “DT” timing probe connection
GE50039 Timing calibration probe adapter sleeve
CH11148 Engine turning tool

System operation
Use this procedure if diagnostic code 261-13 Check Timing Sensor Calibration is present, if the ECM has been
replaced or if work has been done to the engine front drive train.
The crankshaft position sensor provides an engine speed signal (rev/min) to the ECM. The signal is created
as the crankshaft gear rotates past the pickup of the crankshaft position sensor. The camshaft position sensor
provides the timing signal to the ECM. The signal is created as the camshaft gear rotates past the pickup of
the camshaft position sensor. A unique pattern on the gear allows the ECM to determine the crankshaft
position and when the cylinder number one piston is at the top of the compression stroke. In the event that the
signal is lost from one of the sensors, a diagnostic code is generated. The ECM then uses special logic to allow
the engine to start and run on only one sensor.
If the ECM requires replacement or if work has been performed on the front drive train, a timing calibration
must be performed.
Timing calibration is accomplished by installing a special magnetic pickup into the side of the engine block.
The magnetic pickup senses a special slot on the crankshaft counterweight. The magnetic pickup is then
connected to the ECM through the engine harness speed/timing calibration connector P400, while the engine
is running.
In order to carry out a timing calibration, the engine must be running at 1100 rev/min. Since this speed is not
within the range of the normal speed setting controls, proceed as follows:
1 Set the "Digital Speed Control Installed" to "Not Installed" from the TIPSS-EST configuration screen.
2 If an analogue speed control is fitted, select PWM speed control in the "Desired Speed Input Arrangement"
option on the configuration screen. If a PWM speed control is fitted, select Analogue speed control in the
"Desired Speed Input Arrangement" on the configuration screen.
Note: If both analogue and PWM speed inputs are connected, one must be disconnected and the associated
speed control selected.
3 If the engine is now run, it should run up to 1100 rev/min and timing calibration can be carried out.
4 After completion of the timing calibration, ensure that all parameters are returned to their original values.
Note: Timing calibration will not increase or decrease the available engine power. Do not calibrate the engine
timing expecting an increase in engine power.

134 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Timing calibration
1 GE50038 TC probe
2 Slot
3 Counterweight

Diagnostic codes

Diagnostic
Conditions that could cause the code System response To find the fault
fault code
261-13 Check Timing Sensor Calibration Electronic system response Proceed with Test
Timing has not been calibrated since the The ECM uses default timing. 47: Engine speed/
ECM was installed or the calibration is out of Timing can be out of specification timing calibration.
specification more than the ECM will allow. by as much as 4°.
Engine response
The engine may run rough, emit
white smoke in the exhaust or
there may not be any noticeable
performance effect.

Diagnostic Manual, TSD 3457E, Issue 1 135

4 2300 Series
Functional test
Test 47 - Engine speed/timing calibration
Test step Result Action
Step 1: Install the timing adapter group
l Turn the key switch OFF, engine OFF á Go to step 2.
l Use the turning tool to put either the No. 1 or No. 6 piston at top
centre. After locating top centre, rotate the engine back (rotate
the engine in opposite direction of correct engine rotation) 60°.
l Remove the timing calibration plug from the left side of the
engine and install the timing probe adapter sleeve into the hole
for the plug.
Step 2: Install GE50038 TC probe on the engine
Caution: If the crankshaft is not in the correct position when the á Go to step 3.
timing probe is installed, the timing probe will be damaged when
the engine is started.
l Put a 2D-6392 O-ring on the end of the magnetic pickup sensor
(a small amount of clean engine oil will allow the seal to slide
onto the sensor more easily).
l Push the sensor through the adapter until it comes in contact
with the outermost portion of the crankshaft counterweight.
Move the O-ring downward against the adapter.
l Withdraw the magnetic transducer 1,0 mm (0.04 in) and hand
tighten the nut on the adapter sleeve in order to secure the
magnetic pickup in place.
l Connect the GE50038 timing probe to the GE50040 Deutsch
DT timing harness adapter.
Step 3: Start engine and allow coolant to reach operating temperature
l Start the engine and run until the engine has warmed up á Go to step 4.
enough to exit cold mode operation. The electronic service tool
"Status" screen will display “COLD MODE” in the upper corner
when cold mode operation exists.
l Check for ACTIVE diagnostic codes. Use the procedures in this
manual to diagnose and repair any ACTIVE diagnostic codes
before attempting a calibration check. The engine must not
have any diagnostic fault conditions present during the timing
calibration, other than 261-13 Check Timing Sensor
Calibration.
l Stop the engine.
Step 4: Connect an electronic service tool
l Connect an electronic service tool to the data link connector. á Go to step 5.
l Follow the procedure in "System operation" on page 134 so
that the engine will run at 1100 rev/min.
l Access the "Timing Calibration" screen located under the
"Service\Calibrations" menu on TIPSS-EST.
Note: To perform a timing calibration, the engine rev/min must be
held as steady as possible at approximately 1100 rev/min. Any
changes to engine rev/min (greater than 100 rev/min) will slow
down the procedure and reduce accuracy. The correct engine
speed is set using the procedure described "System operation" on
page 134.
l Connect the GE50040 Deutsch DT adapter harness for the
GE50038 timing probe to the speed/timing calibration
connector P400.
l Be certain that all connections (TC Probe, electronic service
tool, etc) are made correctly.
l Start the engine

136 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 47 - Engine speed/timing calibration (Continued)
Test step Result Action
Step 5: Calibrate the speed/timing sensor
l To calibrate the timing to the correct setting select Continue on á The timing calibration
the electronic service tool and wait until the electronic service procedure was completed
tool indicates that the timing is CALIBRATED. successfully.
Note: If the electronic service tool display reads CALIBRATION Go to step 6.
UNSUCCESSFUL, the electronic injection timing has not been set.
à Check that the engine rev/
l Re-check the tool installation and tool operation and try again min was stable during the
to calibrate electronic injection timing. If the crankshaft and testing (+/- 50 rev/min).
camshaft gears have been reassembled incorrectly (relative to If the engine rev/min was
each other), the engine will not calibrate. unstable or could not be
l If the timing calibration has been successfully completed, do controlled within +/- 50 rev/
not exit the Timing Calibration Screen on the electronic service min because of mechanical
tool until you have disconnected the timing probe from the or electrical factors, refer to
speed/timing calibration connector P400. Test 3: Engine misfires, runs
rough or is unstable on page
Was the timing calibration procedure completed
39.
successfully ?
If all of the checks are OK
but the timing still will not
calibrate, check the timing
probe cable and timing
probe to ensure it is not bent.
If it is not bent, restart this
procedure.
Step 6: Disconnect timing probe before exiting electronic service tool "Monitor/Calibrate Timing" screen
l Disconnect the timing probe from the speed/timing calibration á Go to step 7.
connector P400.
l Exit the electronic service tool "Timing Calibration" screen. à If the timing probe is still
installed following exit of the
electronic service tool
Timing Calibration Screen,
engine speed diagnostic
codes may be generated
and should be cleared.
STOP.
Step 7: Restore correct engine speed
l Use TIPSS-EST to restore the correct digital, analogue or á STOP.
PWM speed control.
l Run the engine to check the correct running speed. à Re-check speed control
selection.

Diagnostic Manual, TSD 3457E, Issue 1 137

4 2300 Series

Injector solenoids circuit test Test 48

Diagnostic codes Functional test

System operation
Use this procedure if a 1-11, 2-11, 3-11, 4-11, 5-11, 6-11 Cylinder Fault is present or is you have been referred
here after following the sequence of steps in Test 3: Engine misfires, runs rough or is unstable on page 39, or
Test 4: Low power/poor or no response to throttle on page 40.
It is important to perform this procedure when the injector is under identical conditions as when the problem
occurs. Typically, injector solenoid problems occur when the engine is warmed up and/or when the engine is
under vibration (heavy loads).
The 2300 and 2800 Series engines utilize electronic unit injectors that are mechanically actuated and
electronically energized.
The injectors can be individually cut out while the engine is running to check for weak cylinders, or tested
without the engine running to check for electrical circuit problems.
The injector solenoid is mounted on top of the fuel injector body along side the rocker arm return spring.
Injector Trim Codes provide a means to fine tune each individual injector for optimum performance. A 268-02
Check Programmable Parameters diagnostic code will be active if the injector codes are not programmed.
If the ECM is replaced, all six injector codes must be programmed into the new ECM.
Injector schematic
Note: Refer to the wiring diagrams for full connection details.

ECM

5 J2/44 Injector Common Cylinders 1 & 2

7 J2/45 Injector Common Cylinders 3 & 4
6 J2/46 Injector Common Cylinders 5 & 6
10 J2/55 Injector Cylinder 6
3 J2/54 Injector Cylinder 5
11 J2/39 Injector Cylinder 4
2 J2/38 Injector Cylinder 3
12 J2/37 Injector Cylinder 2
1 J2/36 Injector Cylinder 1
Injector Injector Injector Injector Injector Injector J300 P300
Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6 P2 J2

A HA0034

138 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Diagnostic codes

Diagnostic
Conditions that could cause the code System response To find the fault
fault code
1-11 Cylinder 1 Fault Electronic system response Proceed with Test
2-11 Cylinder 2 Fault The ECM will turn the diagnostic 48: Injector
lamp ON and log the diagnostic solenoids circuit
3-11 Cylinder 3 Fault test.
code. If the cause of the diagnostic
4-11 Cylinder 4 Fault code is a short circuit or an open
5-11 Cylinder 5 Fault circuit in the common line, two
cylinders will be affected because
6-11 Cylinder 6 Fault
of the shared common wiring for
The ECM detects one of the following after the injectors.
attempting to operate the injector
Engine response
l An open circuit in the injector wiring The injector may not operate while
l An internal open circuit in the injector the conditions exist.
wiring
l A electrical short circuit to ground (to the
engine iron)
l A internal injector solenoid electrical short
circuit
l A short circuit to battery voltage

Functional test
Test 48 - Injector solenoids circuit test
Test step Result Action
Step 1: Inspect electrical connectors and wiring
l Turn key switch OFF, engine OFF á Go to step 2.
Warning! Ensure that the key switch is OFF. Possible strong
electrical shock hazard if the key switch is not turned OFF.
à Repair or replace wiring or
connectors as necessary.
l Thoroughly inspect the ECM engine harness connector J2/P2 Ensure all seals are correctly
and the injector solenoids connector. installed and that connectors
l Perform a 45 N (10 lb) pull test on each of the wires in the ECM are completely mated.
connector and the injector solenoids connector. Check that the repair
l Check that the ECM connector Allen screw is correctly eliminates the fault.
tightened to not more than 3,0 Nm (2.2 lb ft) 0,31 kgf m. STOP.
l Check the injector solenoids connector to ensure that it is
correctly mated.
l Check the harness and wiring for abrasion and pinch points
from the injector(s) back to the ECM.
Are connectors/pins/sockets completely mated/inserted, and
the harness/wiring free of corrosion, abrasion or pinch
points ?
Step 2: Check for logged injector solenoid diagnostic codes
l Connect an electronic service tool to the data link connector. á Go to step 4.
l Turn the key switch ON, engine OFF
à Go to step 3.
l Access the screen displaying logged diagnostic codes
Does the service tool indicate a logged 1-11, 2-11, 3-11, 4-11,
5-11 or 6-11 cylinder fault ?

Diagnostic Manual, TSD 3457E, Issue 1 139

4 2300 Series
Test 48 - Injector solenoids circuit test (Continued)
Test step Result Action
Step 3: Check cylinder to cylinder variation of injectors
l Connect the TIPSS-EST to the data link connector. á All cylinders test OK.
l Start the engine. If a misfiring problem or low
l Allow the engine to warm up to normal operating temperature - power problem still exists
77 °C (171 °F). refer to Test 3: Engine
misfires, runs rough or is
l Access the Cylinder cut-out test located under the
unstable on page 39 or Test
"Diagnostics\Diagnostic Tests" menu.
4: Low power/poor or no
l Select the start button at the bottom of the "Cylinder cut-out" response to throttle on page
test screen. 40.
Do all cylinders indicate OK on the TIPSS-EST screen? If a diagnostic code results
from running the Cylinder
cut-out test then Go to step
4.

à Go to step 4.
Step 4: Check injector solenoids using the TIPSS-EST Injector Solenoid test
l Start the engine. á There is not an electronic
l Allow the engine to warm up to normal operating temperature - problem with the injectors at
77 °C (171 °F) this time.
l Turn the key switch OFF, engine OFF If the Cylinder cut-out test
returned a NOT OK for any
l Connect an electronic service tool at the data link connector.
injector, refer to Test 3:
l Turn the key switch ON, engine ON Engine misfires, runs rough
l After the engine is warmed to operating temperature, access or is unstable on page 39.
and begin the Injector Solenoid test located under the STOP.
"Diagnostics\Diagnostic Tests" menu of the electronic service
tool. à Note the cylinders that
indicate OPEN and/or
Note: Do not confuse the Injector Solenoid test with the Cylinder SHORT.
cut-out test. The Cylinder cut-out test is used to shut off fuel to a
Go to step 5.
specific cylinder while the engine is running. The Injector Solenoid
test is used in order to actuate the injector solenoids in order to
"hear" the injector solenoids click, when the engine is not running,
to determine that the circuit is functioning correctly.
l Perform the Injector Solenoid test two or three times.
Do all cylinders indicate OK ?
Step 5: Check engine harness from P2 to P300 for short circuits using the service tool injector solenoid test
l Turn key switch OFF, engine OFF á Go to step 7.
Warning! Ensure that the key switch is OFF. Possible strong
electrical shock hazard if the key switch is not turned OFF.
à Note which cylinders are
indicating the short circuit.
l Disconnect the injector solenoids connector J300/P300 Go to step 6.
l Turn the key switch ON, engine OFF
l Perform the Injector Solenoid test two or three times.
Do all cylinders indicate OPEN ?

140 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 48 - Injector solenoids circuit test (Continued)
Test step Result Action
Step 6: Check ECM for short circuits using service tool Injector Solenoid test
l Turn key switch OFF, engine OFF á The short circuit is in the
Warning! Ensure that the key switch is OFF. Possible strong engine harness.
electrical shock hazard if the key switch is not turned OFF. Repair or replace the engine
harness as required.
l Disconnect ECM engine harness connector J2/P2 from the
ECM and check for evidence of moisture entry. Clear all diagnostic codes
after completing this test
l Turn the key switch ON, engine OFF
step.
l Perform the Injector Solenoid test two or three times. STOP.
Note: With the engine harness disconnected all of the +5 V
supplied sensor open circuit diagnostic codes will be active. This is à Temporarily connect
another ECM.
normal. Clear all of these diagnostic codes after completing this
test step. Repeat this test step. If the
problem is resolved with the
Do all cylinders indicate OPEN with engine harness connector new ECM, reconnect the old
P2 disconnected from the ECM ? ECM to check that the
problem returns with the old
ECM.
If the new ECM works and
the old one did not, renew
the ECM.
STOP.
Step 7: Check engine harness from P2 to P300 for open circuits using service tool Injector Solenoid test
l Turn key switch OFF, engine OFF á If the previous step indicated
Warning! Ensure that the key switch is OFF. Possible strong only one injector has an
electrical shock hazard if the key switch is not turned OFF. open or short, or one
cylinder indicates an open
l Disconnect injector solenoids connector J300/P300. but the injector sharing the
l Turn the key switch ON, engine OFF injector common indicates a
l Make a jumper wire 100 mm (4 in) long with a Deutsch Pin on short.
both ends. Go to step 9.
l Insert the jumper wire between the injector common socket of If the previous step indicated
the problem injector, and the problem injector socket of the two injectors sharing an
injector solenoids connector P300. For example, if injector 5 is injector common are open.
the problem injector, insert the jumper from terminal-5 (injector Go to step 10.
5) to terminal-8 (injector common cylinders 5 & 6) of the injector
If the previous step indicated
solenoids connector P300.
two injectors sharing an
l Perform the Injector Solenoid test two or three times. injector common are short.
Does the cylinder with the jumper wire installed indicate Go to step 11.
SHORT ?
à Go to step 8.
l Repeat this test for each suspect injector. Ensure that the
Injector Solenoid test is disabled before handling the jumper
wires.

Diagnostic Manual, TSD 3457E, Issue 1 141

4 2300 Series
Test 48 - Injector solenoids circuit test (Continued)
Test step Result Action
Step 8: Check ECM for open circuit
l Turn key switch OFF, engine OFF á The ECM is OK. Replace or
Warning! Ensure that the key switch is OFF. Possible strong repair the engine harness.
electrical shock hazard if the key switch is not turned OFF. STOP.
l Disconnect the engine harness from the ECM connector J2 à Temporarily connect
and connect a 70-terminal breakout T to the ECM (do not another ECM.
connect the engine harness to the breakout T). Repeat this test step. If the
l Use a jumper wire to short between the injector socket and the problem is resolved with the
injector common socket of the suspect injector. new ECM, reconnect the old
ECM to check that the
l Perform the Injector Solenoid test two or three times.
problem returns with the old
Note: With the engine harness disconnected all of the +5 V ECM.
supplied sensor open circuit diagnostic codes will be active. This is
If the new ECM works and
normal. Clear all of these diagnostic codes after completing this
the old one did not, renew
test step.
the ECM.
Does the cylinder with the jumper wire installed indicate STOP.
SHORT ?
Step 9: Check injector harness under valve cover
l Turn key switch OFF, engine OFF á Replace the faulty injector
Warning! Ensure that the key switch is OFF. Possible strong indicating the problem.
electrical shock hazard if the key switch is not turned OFF. Restore the wiring to the
correct injector(s).
l Remove the valve cover to gain access to the problem
STOP.
injector(s).
l Disconnect the harness from the problem injector and from the à Replace the injector harness
under the valve cover.
other injector sharing the same injector common.
STOP.
l Thoroughly clean the terminals of both injectors and the
harness. Exchange the harness between the two injectors
sharing the common.
l Turn key switch ON, engine OFF
l Perform the Injector Solenoid test two or three times.
Did the problem change to the other injector with the
movement (exchanging terminals) of the harness ?
Step 10: Check engine harness under valve cover for an open circuit in the common
l Turn key switch OFF, engine OFF á Replace the engine harness
Warning! Ensure that the key switch is OFF. Possible strong under the valve cover.
electrical shock hazard if the key switch is not turned OFF. Check new harness
installation using the Injector
l Remove the valve cover to gain access to the problem Solenoid test before
injector(s).
installing the valve covers.
l Disconnect each of the injectors indicating an OPEN from the
STOP.
wiring harness. Ensure that each of the connectors from the
disconnected injector harness does not touch other à BOTH injectors indicate
components and short to ground. SHORT.
l Attach a jumper wire to both terminals of the injector harness Replace BOTH injectors.
for the two injectors sharing an injector common. STOP.
l Turn key switch ON, engine OFF
l Perform the Injector Solenoid test two or three times.
Do both cylinders with the short in place indicate an OPEN ?

142 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Test 48 - Injector solenoids circuit test (Continued)
Test step Result Action
Step 11: Check engine harness under valve cover for short circuits in the injector wires
l Turn key switch OFF, engine OFF á Leave the injector wires
Warning! Ensure that the key switch is OFF. Possible strong disconnected.
electrical shock hazard if the key switch is not turned OFF. Neither of the injector wires
are shorted to the engine.
l Remove the valve cover to gain access to the problem
injector(s). Go to step 12.
l Disconnect each of the injectors indicating an SHORT from the à Replace the injector harness
wiring harness. Ensure that each of the connectors from the under the valve cover.
disconnected injector harness does not touch other STOP.
components and short to ground.
l Turn key switch ON, engine OFF
l Perform the Injector Solenoid test two or three times.
Do both cylinders indicate an OPEN ?
Step 12: Check for a short circuit in the injector common to the engine
l Turn key switch OFF, engine OFF á Reconnect the engine
Warning! Ensure that the key switch is OFF. Possible strong harness to the ECM.
electrical shock hazard if the key switch is not turned OFF. Go to step 13.
l Disconnect the ECM engine harness connector J2/P2. à Replace the injector harness
under the valve cover.
l Measure the resistance from the problem injector common
terminal of connector P2 to the engine ground stud. STOP.
Does the multimeter indicates resistance greater than 10
Ohms ?
Step 13: Check for a short circuit in the injector
l Turn key switch OFF, engine OFF á Replace the injector.
Warning! Ensure that the key switch is OFF. Possible strong STOP.
electrical shock hazard if the key switch is not turned OFF.
à This injector is OK.
l Reconnect one of the two disconnected injectors. Go to step 14.
l Turn key switch ON, engine OFF
l Perform the Injector Solenoid test two or three times.
Does the reconnected injector indicates a SHORT ?
Step 14: Check for a short circuit in the other injector
l Turn key switch OFF, engine OFF á Replace the injector.
Warning! Ensure that the key switch is OFF. Possible strong STOP.
electrical shock hazard if the key switch is not turned OFF.
à This injector is OK.
l Reconnect the other disconnected injector. STOP.
l Turn key switch ON, engine OFF
l Perform the Injector Solenoid test two or three times.
Does the reconnected injector indicates a SHORT ?

Diagnostic Manual, TSD 3457E, Issue 1 143

4 2300 Series
ECM terminal connections
Note: Using ECM connector P2.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 Injector Common Cyls 1 & 2 44
31 30 29 28 27 26 25 24 Injector Common Cyls 3 & 4 45
39 38 37 36 35 34 33 32
Injector Common Cyls 5 & 6 46
47 46 45 44 43 42 41 40
Injector Cylinder 1 36
57 56 55 54 53 52 51 50 49 48
Injector Cylinder 2 37
70 69 68 67 66 65 64 63 62 61 60 59 58
Injector Cylinder 3 38
Injector Cylinder 4 39
Terminal side Injector Cylinder 5 54
Injector Cylinder 6 55

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
B HA0036

144 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Engine harness injector connector
Pin No. Function
1 Injector Cylinder No. 1
2 Injector Cylinder No. 3
3 Injector Cylinder No. 5
5 Injector Common Cylinders 1 and 2
6 Injector Common Cylinders 5 and 6
7 Injector Common Cylinders 3 and 4
10 Injector Cylinder No. 6
11 Injector Cylinder No. 4
12 Injector Cylinder No. 2

12 11 10 9 8 7

1 2 3 4 5 6

C HA0037

Electronic unit injector harness terminals

D HA0038

1 Attach jumper wire #1 here

2 Attach jumper wire #2 here

Diagnostic Manual, TSD 3457E, Issue 1 145

4 2300 Series

Analogue sensor abnormal test Test 49

Diagnostic codes Functional test

System operation
Use this procedure to diagnose an "Abnormal" diagnostic code for the analogue speed control.
The analogue speed control may be a simple potentiometer or may be a signal from a device such as a load
sharing/synchronising controller. The actual analogue speed control device is not supplied by Perkins, it is an
optional control supplied by the OEM.
Analogue speed control schematic
Note: Refer to the wiring diagrams for full connection details.

ECM
J1/67 - Battery
680R
5K Analogue J1/3 Analogue Ground
Speed Setting
Potentiometer or J1/15 Analogue Speed Input
Input from Load 680R
Sharer/Synchroniser J1/2 +5V

A HA0039

Diagnostic codes

Diagnostic
Conditions that could cause the code System response To find the fault
fault code
1690-08 Analogue Throttle Signal Abnormal Engine response Proceed with Test
The analogue throttle control signal (optional, Engine runs at 1100 rev/min. 49: Analogue
supplied by OEM) is greater than 4.8 volt or sensor abnormal
less than 0.2 volt test.
AND
Analogue speed control is selected
AND
A +5 V Sensor Supply diagnostic code (262-
03 or 262-04) is NOT active.

146 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series 4
Functional test
Test step Result Action
Step 1: Check for active +5 V Sensor Supply codes
l Connect the TIPSS-EST service tool to the service tool á This procedure will not work
connector. if a sensor supply diagnostic
l Turn the key switch to the ON position. Wait at least 10 code is active. Refer to Test
seconds for codes to become active. 43: +5 V Sensor voltage
supply circuit test on page
l Check if any of the following diagnostic codes are active: 107.
l 262-03 +5 V Supply Above Normal
STOP.
l 262-04 +5 V Supply Below Normal
Are any diagnostic codes listed above active ?
à Go to step 2.

Step 2: Check for active analogue throttle diagnostic codes

l Check if the following diagnostic code is active: 1690-08. á Go to step 3.
Note: Diagnostic code 262-03 +5 V Supply Above Normal or 262-
04 +5 V Supply Below Normal should not be active.
à If the codes listed are logged
only and the engine is
Is the diagnostic code listed above active ? currently NOT running
correctly, refer to
"Diagnostic procedures
without a diagnostic fault
code" on page 36.
If the engine is running
correctly at this time, there
may be an intermittent
problem in the harness
causing the logged code.
Refer to Test 39: Inspecting
electrical connectors on
page 82.
STOP.
Step 3: Check that supply voltage is present at the throttle control
l Measure the supply voltage at the speed control potentiometer á Supply voltage is present.
or device. Go to step 5.
Does the voltage should measure between 4.5 and 5.5 Volts
DC ? à Go to step 4.

Step 4: Check that supply voltage is present on the engine

l Measure the voltage between pin-19 (+5 V) and pin-20 á Supply voltage is present.
(Return) on the engine customer interface connector (if fitted) Go to step 5.
or J1 pin 2 (+5V) and J1 pin 3 (Return) if a customer interface
connector is not fitted. à The supply voltage is not
present.
Does the voltage should measure between 4.5 and 5.5 Volts
DC ? Most likely there is an OPEN
circuit in either the common
or supply wire between the
engine harness and the
OEM control.
Refer to Test 39: Inspecting
electrical connectors on
page 82.
STOP.

Diagnostic Manual, TSD 3457E, Issue 1 147

4 2300 Series
Test step Result Action
Step 5: Check that control voltage is present on the engine
l Measure the voltage between pin-24 (+5 V) and pin-20 á The electrical circuit is
(Return) on the engine customer interface connector (if fitted) correct.
or J1 pin 15 (+5V) and J1 pin 3 (Return) if a customer interface Check that the configuration
connector is not fitted. parameters in the service
The voltage should measure between 0.5 and 4.5 Volts DC. tool have analogue speed
control selected and that the
correct speed range is set.
STOP.

à Go to step 6.
Step 6: Check that control voltage is present on the external speed control
l Measure the signal voltage at the slider of the potentiometer or á There is a fault in the wiring
the output of the speed control device. between the speed control
and the engine.
Investigate and repair as
necessary.
STOP.

à There is a fault in the speed

control potentiometer or
device.
Repair or renew as
necessary.
STOP.
ECM terminal connections
Note: Using ECM connector P1.

13 12 11 10 9 8 7 6 5 4 3 2 1 Function Pin Location

23 22 21 20 19 18 17 16 15 14 +5 V 2
31 30 29 28 27 26 25 24 Analogue Speed Input 15
39 38 37 36 35 34 33 32
Analogue Ground 3
47 46 45 44 43 42 41 40
- Battery (Cable Screen) 67
57 56 55 54 53 52 51 50 49 48
70 69 68 67 66 65 64 63 62 61 60 59 58

Terminal side

70 69 68 67 66 65 64 63 62 61 60 59 58

57 48
47 40
36
31 24
23 >PEI< 14

13 12 11 10 9 8 7 6 5 4 3 2 1

Wire side
B HA0022

148 Diagnostic Manual, TSD 3457E, Issue 1

2300 Series

5
Special tools 5

Required service tools

Part No. Description

- IBM PC compatible
Minimum - Pentium 100 MHz processor or greater, 32 Mb RAM, 200 Mb of available hard disk
space, VGA monitor or display, CD-ROM, 3.5 in 1.44 Mb diskette drive, Windows 95 or greater,
Windows NT, Windows 2000, RS232 port with 16550AF UART, Built in pointing device or mouse.
Recommended - Pentium 200 MHz processor, 64 Mb RAM, 1Gb of available hard disk space,
Super VGA monitor or display, 12X CD-ROM, 3.5 in 1.44 Mb diskette drive, Windows 95 or greater,
Windows NT, Windows 2000, RS232 port with 16550AF UART, Built in pointing device or mouse.
Single user license for TIPSS
-
All engine data subscription
Communication adapter II group
27610164
(Communication adapter II, harness cables, software program, users manual and storage case)
27610165 Communication adapter
27610167 Communication adapter software
27610168 Connector cable (connects communication adapter to diagnostic connector)
27610169 RS232 cable (connects communication adapter to PC)
CH11169 Terminal removal tool (16 and 18 AWG wire) used for removing pin and socket terminals
GE50036 Service tool bypass harness
GE50037 70-terminal “AMP” breakout T
GE50038 Engine timing probe
GE50039 Timing probe adapter
GE50040 Deutsch “DT” timing probe cable

Diagnostic Manual, TSD 3457E, Issue 1 149

5 2300 Series
Optional service tools

Part No. Description

27610181 Harness repair tool kit (includes crimping tool)
27610182 Harness repair tool kit top-up
GE50041 3-Pin "DT" breakout T (breakout T harness is inserted in series between a harness jack and plug to
permit voltage measurement on an operating system)
GE50042 Signal reading probes
CH11148 Turning tool permits turning engine by hand

150 Diagnostic Manual, TSD 3457E, Issue 1

 Perkins 2300 Series
Models 2306A-E14 and 2306C-E14

USER’S HANDBOOK

6 cylinder turbocharged diesel engines for industrial

applications

Publication TSD 3454E, issue 2.

© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in December 2006 by Technical Publications,
Perkins Engines Company Limited, Peterborough PE1 5NA England.

This document is printed from SPI². Not for RESALE

 This publication is divided into six chapters:

1 General information

2 Engine views

3 Operation instructions

4 Preventive maintenance

5 Engine fluids

6 Fault diagnosis

The pages which follow contain a detailed table of contents

ii

This document is printed from SPI². Not for RESALE

 2300 Series

Contents

1 General information
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1
Safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2
How to care for your engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Engine lift equipment .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Welding ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Engine preservation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Parts and service ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Service literature . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Training ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Engine identification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 5
Engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 6

2 Engine views
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 7
Location of engine parts .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 7

3 Operation instructions
How to start the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 9
How to start a new, an overhauled engine or an engine which has been in storage .. ... .. 9
How to start a cold engine in cold conditions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11
After the engine has started ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12
Engine emergency stop .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12
Manual stop procedure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12

User’s Handbook, TSD3454E, Issue 2 iii

This document is printed from SPI². Not for RESALE

 2300 Series
Engine diagnostics .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13

4 Preventive maintenance
Preventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15
Schedule .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
How to check the amount of the coolant . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
How to check the air cleaner service indicator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
How to check the amount of lubricating oil .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18
How to drain the primary fuel filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18
Visual inspection .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
Diagnostics check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20
How to renew the element of the primary fuel filter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
How to renew the element of the secondary fuel filter . ... ... ... ... ... ... ... ... ... ... ... ... ... 24
How to check the specific gravity of the coolant .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26
How to obtain an oil sample ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
How to renew the engine lubricating oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
How to renew the element of the lubricating oil filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
How to renew the air cleaner element . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
How to check the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
How to adjust the tension of the fan belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
How to adjust the tension of the alternator belt ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32
How to renew the fan belts .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
How to renew the alternator belt .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
How to inspect the crankshaft vibration damper .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
Earth stud ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
Hoses and hose clips .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
How to clean the radiator . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36
How to inspect the engine mountings .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36
How to drain the coolant system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to clean the coolant system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to fill the coolant system .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to check the tappet clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
How to check/adjust the electronic unit injectors . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41
Engine protection devices ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42
How to renew the thermostats of the coolant system .. ... ... ... ... ... ... ... ... ... ... ... ... ... 43
How to clean and to calibrate the engine speed/timing sensors . ... ... ... ... ... ... ... ... ... 45
iv User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series
How to inspect the turbocharger . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46
How to inspect the battery charging alternator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46
How to inspect the starter motor . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47
How to inspect the coolant pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47
How to eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48

5 Engine fluids
Fuel specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49
Coolant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49
Lubricating oil specification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50
Warranty . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50

6 Fault diagnosis
Problems and possible causes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51
List of possible causes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52

User’s Handbook, TSD3454E, Issue 2 v

This document is printed from SPI². Not for RESALE

 2300 Series

vi User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series

1
General information 1

Introduction
The 2306 diesel engine is the latest development from Perkins Engines Company Limited, a world leader in
the design and manufacture of high performance diesel engines. More than fifty years of diesel production
experience, together with the use of the latest technology, have been used in the manufacture of your engine
to give you reliable and economic power.
To ensure that you use the relevant information for your specific engine type, refer to "Engine identification"
on page 5.
The terms "left side" and "right side" apply when the engine is seen from the rear end, the flywheel end.
Number one cylinder is at the front end of the engine
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.

User’s Handbook, TSD3454E, Issue 2 1

This document is printed from SPI². Not for RESALE

 1 2300 Series
Safety precautions
These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only apply to specific applications.
Always refer to the text of this handbook for specific warnings and cautions.
Only use these engines in the type of application for which they have been designed.
Do not change the specification of the engine.
Do not make adjustments that you do not understand.
Do not allow the engine to stand on its sump.
Do not smoke when you put fuel in the tank.
Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme caution must be used to prevent injury).
Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
Do not permit loose clothing or long hair near moving parts.
Warning! Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly
while the engine runs.
Do not operate the engine if a safety guard has been removed.
Do not remove the filler cap or any component of the coolant system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
Disconnect the battery terminals before a repair is made to the electrical system. Always disconnect the
negative terminal first.
Only one person must control the engine.
Ensure that the engine is operated only from the control panel or from the operator's position.
If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets.
Discard used lubricating oil and coolant in accordance with local regulations to prevent contamination.
The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
Continued

2 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 1
Always use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.
Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
Some components are not waterproof and should not be washed with a high-pressure water jet or steam.
Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine,
certain components on the engine could be damaged.
Fit only genuine Perkins parts.

User’s Handbook, TSD3454E, Issue 2 3

This document is printed from SPI². Not for RESALE

 1 2300 Series
How to care for your engine
Warning! Read the "Safety precautions" and remember them. They are given for your protection and must be
applied at all times.
Caution: Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain
components on the engine may be damaged.
To obtain the best performance and the longest life from your engine, you must ensure that the maintenance
operations are done at the correct intervals, refer to "Preventive maintenance periods" on page 15.
Ensure that all adjustments and repairs are done by personnel who have had the correct training.

Engine lift equipment

Warning! The lifting eyes which are fitted to the engine must be used for lifting only the engine. Do NOT use
them to lift the engine if it is still attached to its driven unit.

Welding
Welding can cause damage to the electronic components fitted to the engine. If welding is necessary, the
precautions which follow must be undertaken before and during the welding operation.

Cautions:
Switch off the engine.
Disconnect the cable from the negative terminal of the battery. If the machine is fitted with a battery
disconnect the switch then open the switch.
If welding to the engine, remove the ECM (electronic control module).
If welding onto the machine chassis, ensure that the earth clamp is attached as close to the welding point
as possible and NOT near to the ECM.
If it is necessary to weld near to the ECM, remove the ECM from the engine.

Engine preservation
Details not available at time of print.

Parts and service

If problems occur with your engine or with the components fitted to it, your authorised distributor can make the
necessary repairs and will ensure that only the correct parts are fitted and that the work is done correctly.

Service literature
Workshop manuals and other service publications are available from your authorised distributor.

Training
Courses on the service and overhaul of the 2306 engine are available at the Factory. For details apply to: The
Product Training Centre, Perkins Engines Company Limited, Peterborough, PE1 5NA, England.

4 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 1
Engine identification
If you need parts, service or information for your engine, you must give the complete engine number. The
engine number is stamped on a data plate which is fastened to the right side of the engine.
A typical engine number is: FGB060125U 2905J, which consists of these codes:
F Code for engine capacity
G Engine application
B Engine type
06 Number of engine cylinders
0125 Engine specification number
U The country of manufacture
2905 Build line number
J Year of manufacture

User’s Handbook, TSD3454E, Issue 2 5

This document is printed from SPI². Not for RESALE

 1 2300 Series
Engine data
Number of cylinders ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..6
Cylinder arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. In line
Cycle .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Four stroke
Induction system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Turbocharged
Combustion system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Direct injection
Nominal bore.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...137 mm (5.394 in)
Nominal stroke .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...165 mm (6.496 in)
Compression ratio.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 16:1
Cubic capacity ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14,6 litres (893 in3)
Firing order. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1, 5, 3, 6, 2, 4
Direction of rotation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Anti-clockwise viewed on flywheel
Lubricating oil capacity:
Total system... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 68 litres (120 UK pints)
Sump maximum . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 60 litres (106 UK pints)
Sump minimum .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 45 litres (79 UK pints)
Lubricating oil pressure:
At rated speed ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .4,5 bar
Typical coolant capacity of engine . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 20,8 litres (4.6 UK gallons)
Typical coolant capacity of engine and radiator. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 47 litres (10.3 UK gallons)

6 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series

2
Engine views 2

Introduction
Perkins engines are built for specific applications and the views which follow do not necessarily match your
engine specification.

Location of engine parts

Front and left side view of engine (A)
1 Radiator 7 Electronic Control Module (ECM)
2 Radiator filler cap 8 Earth stud
3 Speed/timing sensor 9 Sump drain plug
4 Hand priming pump 10 Secondary fuel filter
5 Rocker cover 11 Primary fuel filter
6 Starter motor 12 Speed/timing sensor

User’s Handbook, TSD3454E, Issue 2 7

This document is printed from SPI². Not for RESALE

 2 2300 Series
Rear and right side view of engine (B)
1 Radiator 7 Thermostat housing
2 Restriction indicator 8 Dipstick
3 Air cleaner 9 Lubricating oil filter
4 Turbocharger 10 Sump drain plug
5 Exhaust manifold 11 Flywheel housing
6 Filler cap for lubricating oil 12 Flywheel

8 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series

3
Operation instructions 3

How to start the engine

Before the engine is started
Perform the required daily maintenance and other periodic maintenance before the engine is started. Refer to
"Preventive maintenance periods" on page 15.
Check the fuel supply. Drain water from the water separator. Open the fuel supply valve.
Caution: All valves in the fuel return line must be open before and during engine operation to help prevent
high fuel pressure. High fuel pressure can cause failure of the filter housing or other damage.
Note: If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air
may have entered the filter housing. Also, when fuel filters have been changed, some air pockets will be
trapped in the engine. If necessary refer to "How to eliminate air from the fuel system" on page 48.
Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” label or similar
warning label attached to the start switch or to the controls.
Ensure that the areas around rotating parts are clear.
Reset all of the shutdown devices or alarm components.
Check the level of the engine lubricating oil. Maintain the oil level between the “L” and the “H” marks on the
dipstick.
Check the level of the coolant. Maintain the level of coolant within 13 mm (0.5 inch) of the bottom of the
filler pipe. If the engine is fitted with a sight glass, maintain the coolant level in the sight glass.
Check the service indicator for the air cleaner. When the red warning indicator is seen through the clear
panel after the engine has stopped, the air filter element must be renewed.
Ensure that any driven equipment has been disengaged. Remove any electrical loads.

How to start a new, an overhauled engine or an engine which has been in storage
Prime the turbocharger. This can be achieved by cranking the engine briefly with no fuel.
When a new engine, or an engine which has been serviced, is first started, prepare to stop the engine if an
overspeed condition occurs. Use the quickest method available, for example: Emergency Stop button.

User’s Handbook, TSD3454E, Issue 2 9

This document is printed from SPI². Not for RESALE

 3 2300 Series
Start procedure
This start procedure may be used for all engines which are not fitted with an air inlet heater.
Refer to the Owner's Manual of the OEM for your type of controls. Use this procedure to start the engine:
1 Move the ignition switch to the ON position. If a system fault is indicated by, for example a panel light,
investigate the cause. If necessary use the Perkins Electronic Service Tool, EST.
2 Push the start button or turn the ignition switch to the START position to crank the engine.
3 If the engine fails to start within 30 seconds, release the start button or ignition switch. Wait for 30 seconds
to allow the starter motor to cool before attempting to start the engine again.
Note: A system fault may be indicated after the engine is started. If this occurs the ECM has detected a
problem with the system. Investigate the cause, if necessary use the Perkins service tool EST.
Caution: Oil pressure should rise within 15 seconds after the engine starts. The electronic engine controls
monitor the oil pressure and will stop the engine if the oil pressure is below normal.
4 If possible, allow the engine to run at no load for approximately three minutes. Run the engine at no load
until the water temperature gauge has started to rise. Check all gauges during the warm-up period.

10 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 3
How to start a cold engine in cold conditions
Refer to the Owner's Manual of the OEM for your type of controls. Use the procedure which follows to start the
engine.
Warning! DO NOT USE ETHER. The use of ether could result in engine damage and/or personal injury.
The engine will start without aids down to a temperature of -10 °C (14 °F), but the ability to start at temperatures
below 10 °C (50 °F) will improve by the use of a cylinder block coolant heater or a device which heats the
crankcase oil. This will help to reduce white smoke and misfires when the engine is started in cold weather.
Note: If the engine has not been run for several weeks, fuel may have drained. Air may have moved into the
filter housing. Also, when fuel filters have been changed, some air will be left in the filter housing. Refer to "How
to eliminate air from the fuel system" on page 48.
1 Move the ignition switch to the ON position. If a system fault is indicated by, for example a panel light,
investigate the cause. If necessary use the Perkins Electronic Service Tool, EST.
2 Push the start button or turn the ignition switch to the START position to crank the engine.
3 If the engine fails to start within 30 seconds, release the start button or ignition switch. Wait for 30 seconds
to allow the starter motor to cool before attempting to start the engine again. Repeat for a maximum of three
times; if the engine fails to start investigate the cause,
4 A system fault may be indicated after the engine is started. If this occurs the ECM has detected a problem
with the system. Investigate the cause, if necessary use the Perkins service tool EST. Refer to the Diagnostic
Manual for more information on engine diagnostics.
Note: Oil pressure should rise within 15 seconds after the engine starts. The electronic engine controls monitor
the oil pressure and will stop the engine if the oil pressure is below normal.
5 If possible, allow the engine to run at no load for approximately three minutes. Run the engine at no load
until the coolant temperature gauge starts to rise. Check all gauges during the warm-up period.
Caution: The oil pressures and fuel pressures should be in the normal range on the instrument panel. Do not
apply a load to the engine until the oil pressure gauge indicates at least normal pressure. Inspect the engine
for leaks and/or unusual noises.
Important notes
The cold start strategy will be activated when the coolant temperature is below 17 °C (63 °F). The cold start
strategy will continue until the coolant temperature reaches 28 °C (82 °F), or until the engine has been running
for 14 minutes. A timer will disable the cold start strategy after a maximum time of 14 minutes.
If the cold start strategy is active and if the ECM measures engine speed, the engine power that is available is
reduced.
After the ECM has completed the cold mode (or the cold mode is disabled), it cannot be enabled again until
the ECM is switched OFF.
If an engine has been stopped, for example after a fault has been indicated, do not attempt to restart the engine
until it has fully stopped.

User’s Handbook, TSD3454E, Issue 2 11

This document is printed from SPI². Not for RESALE

 3 2300 Series
After the engine has started
1 Check all of the gauges during the warm-up period.
2 Perform another walk-around inspection. Check the engine for fluid leaks and air leaks.
Note: Gauge readings should be observed and the data should be recorded frequently while the engine runs.
A comparison of the data over time will help to determine normal readings for each gauge, it will also help to
detect abnormal conditions of operation. Significant changes in the readings should be investigated.

Engine emergency stop

Caution: Emergency shut-off controls are for EMERGENCY use ONLY. For the normal stop procedure DO
NOT use emergency shut-off devices or controls.
Ensure that any components for the external system that support the engine operation are secured after the
engine is stopped.

Manual stop procedure

Individual applications will have different control systems. Ensure that the engine shut-down procedures are
understood. To stop the engine, use the general guidelines which follow:
1 Run the engine with no load for five minutes to allow it to cool.
2 After the cool-down period, turn the start switch to the OFF position.

12 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 3
Engine diagnostics
Self-diagnostics
Perkins electronic engines can perform a self-diagnostics test. Diagnostic codes are stored in the permanent
memory of the Electronic Control Module (ECM) and can be retrieved by use of the Perkins electronic service
tool, EST. A list of diagnostic codes is given in the table under "Diagnostic codes" on page 20.
Some installations have electronic displays that provide a direct reading of the engine diagnostic codes. Refer
to the manual that is provided by the OEM for more information on retrieving engine diagnostic codes.
Active codes, indicated by a warning lamp or similar device (depending on application), represent problems
that currently exist. These problems should be investigated first.
Logged codes represent:
Intermittent problems
Recorded events
Performance history
The problems may have been repaired since the code was logged. These codes do not indicate that a repair
is needed; the codes are guides or signals when a situation exists. Codes may be helpful to diagnose
problems.
When the problems have been corrected, the corresponding logged fault codes should be cleared, where
possible.
Use the Perkins service tool EST to determine the diagnostic code.
Fault logging
The system provides the capability of fault logging. When the Electronic Control Module (ECM) generates a
diagnostic code, the code will be logged in the memory of the ECM. The codes that have been logged in the
memory of the ECM can be retrieved with Perkins electronic service tools. The codes that have been logged
can be cleared with Perkins electronic service tools. The codes that have been logged in the memory of the
ECM will be automatically cleared from the memory after 100 hours. If the engine is operated in protection
override mode, then low engine oil pressure and high engine coolant temperature events cannot be cleared
without a factory password.
Engine operation with active diagnostic codes
If a fault is indicated during normal engine operation, the system has identified a situation that is not within the
specification. Use Perkins electronic service tools to check the active diagnostic codes.
The active diagnostic code should be investigated. The cause of the problem should be corrected as soon as
possible. If the cause of the active diagnostic code is repaired, and there was only one active diagnostic code,
the warning lamp or similar device will turn off.

User’s Handbook, TSD3454E, Issue 2 13

This document is printed from SPI². Not for RESALE

 3 2300 Series
Engine operation with intermittent diagnostic codes
If during normal engine operation a fault is indicated by a fault lamp or similar device and the lamp or device
then returns to normal, an intermittent fault may have occurred. If a fault has occurred, the fault will be logged
in the memory of the Electronic Control Module (ECM).
In most cases, it is not necessary to stop the engine because of an intermittent code. However, the operator
should retrieve the codes and refer to the relevant information to identify the nature of the event. The operator
should note the circumstances that are involved during the time that the lamp was on:
Engine load
Limits of the engine speed
Excessive smoke, etc.
This information can be useful to help diagnose the situation. The information can also be used for future
reference. For more information on diagnostic codes, refer to the Diagnostic Manual for this engine.
Customer specified parameters
Customer specified parameters that will enhance the fuel efficiency and the operator's convenience can be
programmed into the Electronic Control Module (ECM). Some parameters may affect engine operation. This
may lead to complaints from the operator about power or performance. The engine related parameters which
follow may be programmed by the customer, by use of the Perkins electronic service tool, to influence the
operation of the engine:
Engine ratings selection, the ability to choose between the relevant torque maps (prime/stand-by, 50/
60 Hz)
Governor gain tuning parameters
Analogue throttle enable
Equipment identification
Droop set point
Engine acceleration rate
Enable speed selection by the use of an external switch
Enable droop/isochronous selection by the use of an external switch

14 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series

4
Preventive maintenance 4

Preventive maintenance periods

These preventive maintenance periods apply to average conditions of operation. Check the periods given by
the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When
the operation of the engine must conform to the local regulations these periods and procedures may need to
be adapted to ensure correct operation of the engine.
It is good preventive maintenance to check for leakage and loose fasteners at each service.
These maintenance periods apply only to engines that are operated with fuel and lubricating oil which conform
to the specifications given in this handbook.

User’s Handbook, TSD3454E, Issue 2 15

This document is printed from SPI². Not for RESALE

 4 2300 Series
Schedule
The operations which follow must be applied at the interval (hours or months) which occurs first.
A Daily D Every 12 months G Every 5000 hours
B Every 250 hours or 12 months E Every 1000 hours or 24 months
C Every 500 hours or 12 months F Every 3000 hours or 24 months

A B C D E F G Operation
Check the amount of coolant
Check the air cleaner service indicator
Check the amount of lubricating oil in the sump
Drain water/sediment from the primary fuel filter
Visual inspection
Check battery electrolyte level
Drain water/sediment from fuel tank
Perform diagnostics check
Renew the element of the primary fuel filter
Renew the element of the secondary fuel filter
Check the specific gravity and the pH value of the coolant
Renew the engine lubricating oil (1)(2)
Renew the element of the lubricating oil filter
Inspect/adjust/renew the alternator and fan belts
Inspect the crankshaft vibration damper
Inspect/clean/tighten the earth stud
Inspect/renew the coolant hoses, air hoses and hose clips
Inspect and, if necessary, clean the exterior of the radiator/charge cooler
Inspect the engine mountings
Drain and flush the coolant system and renew the coolant mixture
Check/adjust the tappet clearances and the electronic unit injectors (3)
Check the engine protection devices (3)
Renew the thermostats of the coolant system
Check/clean/calibrate the engine speed/timing sensors
Inspect the turbocharger (3)
Inspect the battery charging alternator (3)
Inspect the starter motor (3)
Inspect the coolant pump

(1) The life of the engine lubricating oil may be extended by the use of an oil sample analysis programme.
(2) For TAG2 engines, with the 1/2 TA luft option, which operate at standby duty with an average load factor of 80%, the lubricating oil
MUST be changed at 250 hour intervals.
(3) By a person who has had the correct training.

16 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to check the amount of the coolant
Check the coolant level when the engine is stopped and cool.
Warning! On a hot engine release the filler cap carefully as the system will be under pressure.
1 Remove the filler cap from the expansion tank slowly to relieve the pressure.
2 Maintain the coolant level at the bottom of the filler pipe.
3 Clean the filler cap and check the condition of the filler cap gaskets. Renew the filler cap if the gaskets are
damaged. Fit the filler cap.
4 Inspect the coolant system for leaks.

How to check the air cleaner service indicator

Caution: Do not operate the engine if there is a blockage in the air filter or the air ducts. This can cause
lubricating oil to enter the cylinders through the engine breather valve.
The air filter is fitted with a restriction indicator (A) which gives a visual warning when the filter needs a service.
When the red warning indicator is seen through the clear panel after the engine has stopped, the air filter
element must be renewed.
After a clean element has been fitted, press the reset button on the restriction indicator.
Environmental conditions have an important effect on the frequency at which the air filter needs to be serviced.

User’s Handbook, TSD3454E, Issue 2 17

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to check the amount of lubricating oil
Warning! Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to
contact the skin.
At the periods given in the service schedule use the dipstick to check the amount of lubricating oil in the sump.
1 Check the oil level with the engine stopped. The level must be maintained between the “L” mark and “H”
mark on the dipstick.
2 If necessary, remove the oil filler cap and add more oil of the same grade and specification as that which is
already in the system. Do not overfill.
3 Clean and fit the oil filler cap.

How to drain the primary fuel filter

At the periods given in the service schedule, the bowl of the primary fuel filter must be checked and, if
necessary, drained.
1 Open the drain; the drain is self-ventilated. Use a suitable container to collect the water drained from the
filter housing. Dispose of the water safely.
2 Close the drain. Tighten the drain valve securely to prevent air from entering the fuel system.

18 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
Visual inspection
A visual inspection should take only a few minutes and can prevent costly repairs and accidents.
For maximum engine life, inspect the engine compartment before the engine is started. Look for items such
as oil or coolant leaks, loose fastenings, worn belts or loose connections. Repair as necessary.
The guards must be at the correct positions. Repair damaged guards or renew missing guards.
Wipe all caps and plugs before the engine is serviced to reduce the chance of system contamination.
For any type of leak (coolant, lubricating oil or fuel), clean away the fluid. If a leak is observed, find the
source and correct the leak. If a leak is suspected, check the fluid levels frequently until the leak is found
and repaired.
Accumulated grease and/or oil on an engine is a fire hazard. Remove it by steam cleaning or by the use of
a high pressure water jet.
Ensure that the coolant pipes are fitted correctly and that they are secure. Check for leaks. Check the
condition of all pipes.
Inspect the coolant pump for leaks.
Note: The coolant pump seal is lubricated by the coolant in the coolant system. It is normal for a small amount
of leakage to occur as the engine cools and the parts contract.
Excessive coolant leakage may indicate the need to renew the coolant pump seal. For the removal of the
coolant pump and the installation of the coolant pump and/or coolant pump seals, refer to the Workshop
Manual.
Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the sump, the
oil filter and the rocker cover. If many oil leaks are present, particularly on an old engine, there could be a
blockage of the engine breather.
Inspect the fuel system for leaks. Check for loose fuel line clamps or for loose ties on the fuel lines.
Inspect the ducts for the air inlet system and the elbows for cracks. Check also for loose clamps and check
the condition of mounting rubbers. Ensure that hoses and tubes are not in contact with other hoses, tubes,
wiring harnesses, etc.
Inspect the fan belts and the alternator belt for cracks, breaks or other damage. Where more than one belt
is used between two pulleys, all of the belts must be renewed together. Maximum belt life will only be
obtained if the belts are maintained at the correct tension.
Drain the water and sediment from fuel tanks on a daily basis to ensure that only clean fuel enters the fuel
system.
Inspect the wiring and the wiring harnesses for loose connections and for worn or frayed wires.
Inspect the earth strap for a good connection and for good condition.
Inspect the ECM-to-cylinder head earth strap for a good connection and for good condition.
Disconnect any battery chargers which are not protected against the current drain of the starter motor.
Check the condition and the electrolyte level of the batteries, unless the engine is fitted with a maintenance
free battery.
Check the condition of the gauges. Renew any gauges that are cracked. Renew any gauge that cannot be
calibrated.

User’s Handbook, TSD3454E, Issue 2 19

This document is printed from SPI². Not for RESALE

 4 2300 Series
Diagnostics check
At the periods specified in the service schedule, use the Perkins Electronic Service Tool to retrieve the
diagnostic codes. A key to the codes is given below. Refer to the relevant Diagnostic Manual for further details.
Diagnostic codes
CID-FMI Diagnostic code description
1-11 Injector cylinder No. 1 fault
2-11 Injector cylinder No. 2 fault
3-11 Injector cylinder No. 3 fault
4-11 Injector cylinder No. 4 fault
5-11 Injector cylinder No. 5 fault
6-11 Injector cylinder No. 6 fault
41-03 8 volt Sensor power supply open/short to B+
41-04 8 volt Sensor power supply short to ground
91-08 PWM Speed control abnormal
100-03 Engine oil pressure sensor open/short to B+
100-04 Engine oil pressure sensor short to ground
110-03 Engine coolant temp sensor open/short to B+
110-04 Engine coolant temp sensor short to ground
168-02 Intermittent battery power to the ECM
172-03 Intake manifold temperature sensor open/short to B+
172-04 Intake manifold temperature sensor short to ground
174-03 Fuel temperature sensor open/short to B+
174-04 Fuel temperature sensor short to ground
190-02 Engine speed sensor data intermittent
190-09 Engine speed sensor abnormal update
190-11, 12 Engine speed sensor mechanical fault
248-09 Perkins data link communications abnormal
253-02 Check customer or system parameters
254-12 ECM Fault
261-13 Engine timing calibration required
262-03 5 volt Sensor power supply open/short to B+
262-04 5 volt Sensor power supply short to ground
268-02 Check programmable parameters
273-03 Turbo outlet pressure sensor open/short to B+
273-04 Turbo outlet pressure sensor short to ground
274-03 Atmospheric pressure sensor open/short to B+
274-04 Atmospheric pressure sensor short to ground
281-03 Action alert lamp open/short to B+
281-04 Action alert lamp short to ground
281-05 Action alert lamp open circuit
282-03 Engine overspeed lamp open/short to B+
282-04 Engine overspeed lamp short to ground
285-03 Engine coolant temperature lamp open/short to B+
285-04 Engine coolant temperature lamp short to ground
286-03 Engine lubricating oil pressure lamp open/short to B+
286-04 Engine lubricating oil pressure lamp short to ground
286-05 Engine lubricating oil pressure lamp open circuit
323-03 Engine shutdown lamp open/short to B+
323-04 Engine shutdown lamp short to ground
323-05 Engine shutdown lamp open circuit

20 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
CID-FMI Diagnostic code description
324-03 Engine warning lamp open/short to B+
324-04 Engine warning lamp short to ground
324-05 Engine warning lamp open circuit
342-02 Engine speed sensor No. 2 data intermittent
342-11, 12 Engine speed sensor No. 2 mechanical fault
443-03 Crank terminate relay open/short to B+
799-12 Service tool fault
1266-03 Diagnostic lamp open/short to B+
1266-04 Diagnostic lamp short to ground
1690-8 Analogue throttle signal abnormal

User’s Handbook, TSD3454E, Issue 2 21

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to renew the element of the primary fuel filter

Cautions:
Do not allow dirt to enter the fuel system. Clean thoroughly the area around a fuel system component that
will be disconnected. Fit a suitable cover to any disconnected component of the fuel system.
Do not loosen fuel pipes or fittings except where indicated in this handbook.
1 Stop the engine. Turn the start switch to the “OFF” position. Disconnect the battery.
2 Close the fuel tank supply valve. Remove the drain plug from the base of the filter housing (A2) and drain
the water and fuel into a suitable container. Dispose of the mixture safely.
3 Remove the filter housing, remove the ‘O’ ring seal from the housing and withdraw the filter element (A1).
Warning! Discard the used filter element and ‘O’ ring seal in a safe place and in accordance with local
regulations.
4 Clean the inside of the housing and the housing thread with clean fuel oil and clean the contact face of the
filter head. Clean the drain plug and fit it to the housing.

Notes:
If a degreasing agent has been used to clean the housing, a special lubricant, CV60896, must be applied
to the threads before the housing is fitted.
The correct filter element will be marked with the symbol shown (B).

Continued

22 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
5 Fit a new element (A1) into the housing (A2), ensure that it engages fully with the guide in the base of the
housing. Fit a new ‘O’ ring seal to the top of the housing.

Cautions:
It is important that only genuine Perkins parts are used. The use of wrong parts could damage the fuel
injection equipment.
Do not fill the primary fuel filter with fuel before installation. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause accelerated wear to components of the fuel system.
6 Fit the housing onto the filter head. Tighten the housing to a torque of 80 Nm (59 lbf ft). Do NOT overtighten.
Ensure that the drain plug is tightened securely.
7 Clean away any fuel which has been spilled.
8 Open the fuel tank supply valve and eliminate air from the fuel system as given in "How to eliminate air from
the fuel system" on page 48.
9 Check for leaks.

User’s Handbook, TSD3454E, Issue 2 23

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to renew the element of the secondary fuel filter

Cautions:
Do not allow dirt to enter the fuel system. Clean thoroughly the area around a fuel system component that
will be disconnected. Fit a suitable cover to any disconnected component of the fuel system.
Do not loosen fuel pipes or fittings except where indicated in this handbook.
1 Stop the engine.
2 Turn the start switch to the “OFF” position. Disconnect the battery.
3 Close the fuel tank supply valve. Remove the drain plug from the base of the filter housing (A2) and drain
the fuel into a suitable container.
4 Remove the filter housing, remove the ‘O’ ring seal from the housing and withdraw the filter element (A1).
Warning! Discard the used filter element and ‘O’ ring seal in a safe place and in accordance with local
regulations.
5 Clean the inside of the housing and the housing thread with clean fuel oil and clean the contact face of the
filter head. Clean the drain plug and fit it to the housing.

Notes:
If a degreasing agent has been used to clean the housing, a special lubricant, CV60896, must be applied
to the threads before the housing is fitted.
The correct filter element will be marked with the symbol shown (B).

Continued

24 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
6 Fit a new element (A1) into the housing (A2), ensure that it engages fully with the guide in the base of the
housing. Fit a new ‘O’ ring seal to the top of the housing.

Cautions:
It is important that only genuine parts are used. The use of wrong parts could damage the fuel injection
equipment.
Do not fill the secondary fuel filter with fuel before installation. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause accelerated wear to components of the fuel system.
7 Fit the housing onto the filter head. Tighten the housing to a torque of 80 Nm (59 lbf ft). Do NOT overtighten.
Ensure that the drain plug is tightened securely.
8 Clean away any fuel which has been spilled.
9 Open the fuel tank supply valve and eliminate air from the fuel system as given in "How to eliminate air from
the fuel system" on page 48.
10 Check for leaks.

User’s Handbook, TSD3454E, Issue 2 25

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to check the specific gravity of the coolant
Warning! Do not remove the radiator cap while the engine is still hot and the system is under pressure
because dangerous hot coolant can be discharged.
Drain some coolant from the coolant system after the engine has been stopped and before the formation of
sediment. Proceed as follows:
1 For mixtures which contain inhibited ethylene glycol:
Put a hydrometer, and a reliable thermometer, into the antifreeze mixture and check the readings on both
instruments.
Compare the readings obtained with the chart and adjust the strength of the mixture as necessary.
2 For mixtures which contain inhibited propylene glycol:
Open the cover of the refractometer, check that the clear panel is clean and use a small syringe to apply
three or four drops of the coolant mixture to the clear panel.
Spread the coolant over the full area of the clear panel and close the cover. Hold the refractometer
horizontally with the clear panel at the top and inspect the sample through the viewer.
Compare the reading with the chart in the instructions; adjust the strength of the mixture as necessary.
Caution: The clear panel must be cleaned thoroughly before use. Some of the fluid which was tested earlier
can remain on the clear panel and this will affect the reading of the sample.
Protection against frost is as follows:
Antifreeze/water Protection down to
(% by volume) (°C)
50/50 -35
60/40 -40

A
40 45 50 55 60
60 140

50 122

40 104

C 30 86
D
20 68

10 50

0
1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11

Specific gravity chart

A = Percentage anti-freeze by volume
B = Specific gravity
C = Mixture temperature in Centigrade
D = Mixture temperature in Fahrenheit

26 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to obtain an oil sample
Warning! Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to
contact the skin.
This operation must only be performed by personnel with the correct training. To avoid contamination of the
oil sample, ensure that the tools and equipment used are clean.
An oil sample kit (part number KRP1572), which includes the relevant sample bottles, is available from Perkins
dealers. Certain engines are fitted with an oil sample valve, use the relevant procedure given below.
Engines fitted with an oil sample valve
1 Fit the vented cap to the sample bottle and insert the open end of the tube into the one of the holes in the cap.
Warning! Hot oil under pressure is present at the oil sample valve. Protective clothing must be worn during
this operation. Do not allow hot oil or hot components to contact the skin.
2 With the engine running at the normal temperature of operation, remove the dust cap from the sample valve
on the engine and insert the nozzle of the tube into the sample valve. Press the nozzle against the valve, the
valve will open and allow the oil to flow. Ensure that the sample bottle remains upright and withdraw the nozzle
when the correct amount of oil is obtained; a mark on the bottle indicates the correct level for the oil sample.
3 Fit the dust cap to the sample valve.
4 Remove the vented cap from the sample bottle and fit the sealed cap. Dispose of the tube, nozzle and vented
cap in accordance with local regulations.
5 Complete the adhesive label and attach it to the sample bottle. Send the oil sample to a reputable oil analysis
laboratory to provide a recommendations report.
Engines without an oil sample valve
1 Run the engine until the normal temperature of operation is achieved, stop the engine and proceed with the
operation immediately.
2 Use a vacuum pump and a long flexible tube: remove the engine oil dipstick, insert the flexible tube into the
dipstick tube and withdraw the oil sample. Fit the dipstick to the dipstick tube.
3 Complete an adhesive label and attach it to the sample bottle. Send the oil sample to a reputable oil analysis
laboratory to provide a recommendations report.
4 Ensure that all equipment used is cleaned or, if relevant, disposed of in accordance with local regulations.

User’s Handbook, TSD3454E, Issue 2 27

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to renew the engine lubricating oil
Warning! Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to
contact the skin.
1 Operate the engine until it is warm, then stop the engine.
2 A drain plug is fitted to both sides of the sump, remove one of the sump drain plugs (A1) and drain the
lubricating oil into a suitable container. Clean the drain plug and fit a new sealing washer. Fit the drain plug
and tighten it to a torque of 45 Nm (33 lbf ft).
Warning! Discard the used filter element and used engine oil in a safe place and in accordance with local
regulations.
3 Renew the element of the lubricating oil filter as given in "How to renew the element of the lubricating oil
filter" on page 29.
4 Clean the area around the oil filler cap (B1) and remove the cap. Fill the sump to the “H” mark on the dipstick
(B2) with clean new lubricating oil of the correct grade as given in "Lubricating oil specification" on page 50.
Do NOT overfill.
To prevent damage to the crankshaft bearings, crank the engine with the fuel OFF. This will fill the oil filters
before the engine is started. Do NOT crank the engine continuously for more than 30 seconds. Ensure that oil
pressure is indicated on the oil pressure gauge, or the service tool, before the engine is started.
5 Operate the engine at low idle speed for two minutes and check for leakage from the oil filter assembly.
6 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes. Check the oil level
on the dipstick and, if necessary, add more oil. The oil level must be between the “L” and “H” marks on the
dipstick.

28 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to renew the element of the lubricating oil filter
1 Stop the engine.
2 Turn the start switch to the “OFF” position. Disconnect the battery.
3 Remove the drain plug (A2) from the base of the oil filter housing (A1) and drain the oil into a suitable
container.
4 Remove the filter housing, remove the ‘O’ ring seal from the housing and withdraw the filter element.
Warning! Discard the used filter element, ‘O’ ring seal and used engine oil in a safe place and in accordance
with local regulations.
5 Clean the housing and clean the contact face of the filter head. Clean the drain plug (A2) and fit it to the
housing.
Note: If a degreasing agent has been used to clean the housing, a special lubricant, CV60896, must be applied
to the threads before the housing is fitted.
6 Fit a new element into the housing, ensure that it engages fully with the guide in the base of the housing. Fit
a new ‘O’ ring seal around the top of the housing.
Caution: It is important that only genuine Perkins parts are used. The use of incorrect parts could damage the
engine. The correct filter element will be marked with the symbol shown (B).
7 Fit the housing onto the filter head and tighten by use of a socket and torque wrench on the hexagon (A1).
Tighten the housing to a torque of 80 Nm (59 lbf ft). Do NOT overtighten. Ensure that the drain plug is tightened
securely.
8 Check the amount of engine oil in the sump. If necessary, add more oil of the correct grade and specification.
Refer to "Lubricating oil specification" on page 50.
9 Run the engine and check for leaks.

User’s Handbook, TSD3454E, Issue 2 29

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to renew the air cleaner element
The air filter contains a paper element. This must not be washed. Renew the paper element as follows:
1 Loosen the clamp and remove the end cover (A1). Withdraw and discard the filter element (A2).
2 Clean, thoroughly, the inside of the casing (A3). Fit a new filter element and fit the end cover.
3 Reset the restriction indicator.

30 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to check the drive belts
Check all drive belts and renew a belt if it is worn or damaged. Where more than one belt is used between two
pulleys, all of the belts must be renewed together. Maximum belt life will be obtained only if the belts are kept
at the correct tensions. Where more than one belt is used, check/adjust the tension on the tightest belt.

How to adjust the tension of the fan belts

Remove the fan guards and proceed as follows.
Use a Borroughs belt tension gauge. Check the tension at the position shown (A1). It should be 800 N, which
is equivalent to 4,0 mm of movement when a force of 33 N is applied. To adjust the tension, proceed as follows:
1 Loosen the lock nuts on the adjustment bolt (A2), loosen the large lock nut on the belt tensioner and turn
the adjustment bolt (A2) until the correct tension is obtained. Fully tighten the large lock nut and check the
tension of the belts again. If the tension is correct, loosen the adjustment bolt (A2) just enough to release its
tension, then tighten its lock nuts.
2 Fit the fan guards and run the engine for 15 minutes. Remove the guards and check again the tension.
For new fan belts, set the tension to 868 N, which is equivalent to 4,0 mm of movement when a force of 35,7 N
is applied. After the engine has been run for 15 minutes, check the tension and adjust it to 800 N; equivalent
to 4,0 mm of movement when a force of 33 N is applied.
3 When the correct tension is obtained, fit the fan guards.

User’s Handbook, TSD3454E, Issue 2 31

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to adjust the tension of the alternator belt
Remove the access panel in the fan guard and proceed as follows.
Use a Borroughs belt tension gauge. Check the tension at the position shown (A5). It should be 267 N, which
is equivalent to 2,5 mm of movement when a force of 11,3 N is applied. To adjust the tension, proceed as
follows:
1 Loosen the alternator pivot bolt (A3), the adjustment link bolt which is behind the fan pulley and the
adjustment bolt (A4). Move the alternator to obtain the correct belt tension and tighten the bolts.
2 Fit the access panel to the fan guard and run the engine for 15 minutes. Remove the access panel and check
again the tension.
If a new alternator belt is fitted, set the tension to 400 N, which is equivalent to 2,5 mm of movement when a
force of 16,6 N is applied. After the engine has been run for 15 minutes, check the tension and adjust it to
267 N; equivalent to 2,5 mm of movement when a force of 11,3 N is applied.
3 When the correct tension is obtained, fit the access panel to the fan guard.

32 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to renew the fan belts
1 Remove the fan guards.
2 Remove the six bolts which secure the fan and hub assembly to the pulley and remove the assembly.
Caution: Take care during the removal of the fan; ensure that the radiator does not become damaged.
3 Loosen the belt tensioner and remove the old belts. Ensure that the grooves of the pulley are free from
grease and dirt and fit a new set of belts.
4 Fit the fan and tighten the bolts securely. Adjust the fan belts to the correct tension, as given in "How to
adjust the tension of the fan belts" on page 31, and fit the fan guards.

How to renew the alternator belt

1 Remove the fan guards.
2 Remove the six bolts which secure the fan and hub assembly to the pulley and remove the assembly.
Caution: Take care during the removal of the fan; ensure that the radiator does not become damaged.
3 Loosen the adjustment bolts to release the tension on the alternator belt and remove the old belt. Check that
the pulley grooves are clean and fit a new belt.
4 Fit the fan and tighten the bolts securely. Adjust the alternator belt to the correct tension, as given in "How
to adjust the tension of the alternator belt" on page 32, and fit the fan guards.

How to inspect the crankshaft vibration damper

The viscous damper has a weight that is located inside a case filled with fluid. The weight moves in the case
to limit torsional vibration. Inspect the damper for evidence of dents, cracks or leaks of the fluid.
Renew the damper if it is dented, cracked or leaking.
The damper is mounted on the crankshaft and is located behind the belt guard at the front of the engine. Refer
to the Workshop Manual for the correct procedure to remove and to fit the damper.

User’s Handbook, TSD3454E, Issue 2 33

This document is printed from SPI². Not for RESALE

 4 2300 Series
Earth stud
Inspect the wiring harness for good connections and inspect the condition of the harness. Check the tightness
of the earth stud (A1) at the periods specified in the service schedule. The earth stud is fitted below the ECM
at the left side of the crankcase. The earth strap is fitted between the earth stud and a terminal on the starter
motor (A2). For engines which have the starter motor fitted to the right side, or engines not fitted with an electric
starter motor, the earth strap is fitted between the earth stud and the negative terminal of the starter battery.
1 Disconnect the batteries before any service work is attempted.
2 Remove the nut which retains the earth strap on the earth stud (A1) and remove the earth strap.
3 Remove the washer and use a torque wrench and suitable socket to check the tightness of the earth stud.
The earth stud must be tightened to a torque of 47 Nm (35 lbf ft).

Notes:
If the earth stud is removed, the short end must be fitted into the crankcase.
If the earth strap is disconnected from the starter motor, it must be connected again and the nut which
retains it must be tightened to a torque of 30,5 +/- 3,5 Nm (22.5 +/- 2.5 lbf ft).
4 Clean the earth stud and the earth strap with a clean cloth. If the connections are corroded, clean them with
a solution of sodium bicarbonate and water.
5 Fit the washer and the earth strap. Fit the retaining nut and tighten to a torque of 47 Nm (35 lbf ft).
6 Keep the earth stud and the strap clean and coated with petroleum jelly.
7 Connect the batteries.

34 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
Hoses and hose clips
Inspect all hoses for leaks which may be caused by:
Cracks
Softness
Loose clips
Renew hoses that are cracked or soft. Tighten any loose clips.
Check for these conditions:
End fittings that are damaged or leaking
Outer covering that is chafed or cut
Exposed wire that is used for reinforcement
Outer covering that is ballooning locally
Flexible part of the hose that is kinked or crushed
Armour that is embedded in the outer covering
To renew a hose
Warning! Take care during removal of the filler cap as the coolant system may be under pressure.
1 Stop the engine. Allow the engine to cool.
2 Loosen the filler cap of the coolant system slowly to relieve any pressure. Remove the filler cap.
Note: Drain the coolant into a suitable, clean container. The coolant can be used again.
3 Drain the coolant to a level below the hose which is to be renewed.
4 Remove the hose clips and remove the old hose.
5 Fit the new hose.
6 Fill the coolant system to the correct level with the specified coolant mixture.
7 Clean the filler cap and inspect the gaskets. Renew the filler cap if the gaskets are damaged. Fit the filler cap.
8 Start the engine. Inspect the coolant system for leaks.

User’s Handbook, TSD3454E, Issue 2 35

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to clean the radiator
Inspect the radiator for damaged fins, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the
exterior of the radiator, if necessary.

Warnings!
During the use of high pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
Use a high pressure air jet to remove loose debris. Direct the air in the opposite direction to the fan's air flow.
Hold the nozzle approximately 6 mm (0.25 in) away from the fins. Move the air nozzle slowly in a direction that
is parallel with the tubes to remove debris from between them.
A high pressure water jet may also be used to clean the radiator. The maximum water pressure for cleaning
purposes must be less than 275 kPa (40 psi). Do not hold the nozzle too close to the radiator as the fins can
be damaged. Use pressurized water to soften mud. Clean the core from both sides.
Use a degreaser and steam for the removal of oil and grease. Clean both sides of the core. Wash the core with
detergent and hot water. Rinse thoroughly with clean water.
After the radiator has been cleaned, start the engine and run it at high idle speed. This will help to dry the core
and remove debris. Stop the engine and use a light bulb, held behind the core, to inspect for cleanliness. Clean
again, if necessary.
Inspect the fins for damage. Check the condition of the welds, the mounting brackets, the connections and
seals. Arrange for repairs as necessary.

How to inspect the engine mountings

Inspect the engine mountings. Check for damage or deterioration and check that the bolts are tightened to the
correct torque. Note that engine vibration can be caused by:
Incorrect mounting of the engine.
Deterioration of the engine mounts.
If an engine mount shows signs of deterioration, it must be renewed.

36 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to drain the coolant system

Warnings!
Do not remove the coolant filler cap while the engine is still hot and the system is under pressure because
dangerous hot coolant can be discharged.
Discard used coolant in a safe place and in accordance with local regulations.
1 Stop the engine and allow the engine to cool. Loosen slowly the filler cap of the coolant system to relieve
any pressure. Remove the filler cap.
2 Open the drain valve of the coolant system (if fitted). If the coolant system is not fitted with a drain valve,
disconnect the lowest coolant hose.
Allow the coolant to drain.

How to clean the coolant system

1 Flush the coolant system with clean water.
2 Close the drain valve (if fitted), or connect the coolant hose used to drain the system.
Note: To avoid air locks, fill the coolant system no faster than 19 L (4.2 UK gal) per minute.
3 Fill the coolant system with a mixture of clean water and Holts Fast Acting Cooling System Cleaner or
equivalent. Refer to the manufacturer’s instructions. Fit the filler cap.
4 Start and run the engine at low idle speed for a minimum of 30 minutes. The coolant temperature should be
at least 82 °C (180 °F).
5 Stop the engine and allow the engine to cool. Loosen the filler cap of the coolant system slowly to relieve
any pressure. Remove the filler cap. Open the drain valve (if fitted) or disconnect the lowest coolant hose.
Allow the cleaning mixture to drain. Flush the coolant system with clean water. Close the drain valve (if fitted),
or connect the coolant hose used to drain the system.

How to fill the coolant system

1 Fill the coolant system with the correct coolant mixture, refer to "Coolant mixture" on page 49. Do not fit the
filler cap.
2 Start and run the engine at idle for 1 minute to eliminate air from the cavities of the engine block. Stop the
engine.
3 Check the coolant level. Maintain the coolant level at the bottom of the filler pipe in the expansion tank.
4 Clean the filler cap of the coolant system. Inspect the gasket on the filler cap. If the gasket is damaged,
renew the filler cap. If the gasket is not damaged, use a proprietary pressure test kit to perform a test on the
filler cap. The correct pressure for the filler cap is stamped on its face. If the filler cap does not retain the correct
pressure, fit a new filler cap.
5 Start the engine. Inspect the coolant system for leaks and for correct temperature of operation.

User’s Handbook, TSD3454E, Issue 2 37

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to check the tappet clearances

Tappet clearances
Inlet 0,38 +/- 0,08 mm (0.015 +/- 0.003 in)
Exhaust 0,76 +/- 0,08 mm (0.030 +/- 0.003 in)

The tappet clearance is measured between the rocker levers and the top of the valve bridge pieces. The
operation must be done with the engine cold and stopped. Refer also to "How to check/adjust the electronic
unit injectors" on page 41.
1 Remove the rocker cover.
2 Remove the top bolt (A1) from the cover (A2) on the flywheel housing and slacken the other cover bolt to
allow the cover to open. The top bolt (A1) is the timing bolt.
Caution: If a customer-fitted speed sensor is fitted to the flywheel housing, it must be removed before the
turning tool can be inserted.
3 Remove the plug (A3) from the timing bolt location in the flywheel housing and fit the timing bolt.
Note: There are two locations for the timing bolt, one at each side of the flywheel housing. Use the location
which is the most convenient.
4 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind the cover
(A2). Use a 1/2 inch drive ratchet with the turning tool to rotate the engine flywheel in the normal direction of
rotation (anti-clockwise when viewed on the flywheel) until the timing bolt engages with the threaded hole in
the flywheel. The piston of number 1 cylinder is now at TDC (top dead centre).
Caution: If the flywheel is turned past the threaded hole, the flywheel must be turned in the opposite direction
for approximately 45 degrees and then back in the normal direction of rotation until the timing bolt engages
with the threaded hole. This is to eliminate backlash.
5 Check the inlet and exhaust valves of the number 1 cylinder. If they are fully closed the piston is on its
compression stroke and the rocker levers can be moved by hand. If the rocker levers can not be moved
because the valves are slightly open, the piston is on its exhaust stroke. If it is on its exhaust stroke, withdraw
the timing bolt and turn the flywheel a further 360 degrees in the normal direction of rotation so that the number
1 cylinder is set to TDC on its compression stroke, then insert again the timing bolt.

Continued

38 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
6 Before each set of tappet clearances is adjusted, ensure that the roller of the rocker lever is fully against the
camshaft lobe.
7 Use a set of feeler gauges, inserted at the position shown (B3) between the valve bridge piece and the rocker
lever button, to check the tappet clearances for the inlet valves (C1) on cylinders 1, 2 and 4. Adjust the
clearances if necessary. Check the tappet clearance for the exhaust valves (C2) on cylinders 1, 3 and 5, and
adjust the clearances if necessary.

Notes:
Move each valve bridge piece before the feeler gauge is inserted to reduce the effect of the oil film.
During the procedure, ensure that the feeler gauge is fully inserted

Continued

User’s Handbook, TSD3454E, Issue 2 39

This document is printed from SPI². Not for RESALE

 4 2300 Series
8 After each unit has been adjusted, tighten the lock nut (B2) of the adjustment screw (B1) to a torque of 30 +/
- 4 Nm (22 +/- 3 lbf ft).
9 Withdraw the timing bolt and rotate the flywheel by 360 degrees so that the number 6 piston is at TDC on
its compression stroke. Insert again the timing bolt into the threaded hole.
10 Check the tappet clearances for the inlet valves (C1) on cylinders 3, 5 and 6. Adjust the clearances if
necessary. Check the tappet clearances for the exhaust valves (C2) on cylinders 2, 4 and 6, and adjust the
clearances if necessary.
11 After each unit has been adjusted, tighten the lock nut of the adjustment screw to a torque of 30 +/- 4 Nm
(22 +/- 3 lbf ft).
12 Check again the tappet clearances for all six cylinders.
13 Fit the rocker cover. Remove the engine turning tool and the timing bolt and fit the cover to the flywheel
housing.
14 Fit the plug to the timing bolt location.

40 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to check/adjust the electronic unit injectors
This operation should be performed at the same time as the operation to check the valve tappet clearances.
Warning! The electrical circuit for the fuel injector units operates on 110 volts. Do NOT work on the fuel injector
units unless the power supply to the ECM has been disconnected.
1 With the rocker covers removed, set the number 1 piston to TDC (top dead centre) on its compression
stroke. Check/adjust the height dimensions for the fuel injectors of cylinders 3, 5 and 6.
2 Use the fuel injector setting gauge, CH11149, to obtain the correct height for the fuel injector. The dimension
to be measured is from the top of the unit injector (A1) to the machined ledge on the fuel injector body (A2).
This dimension should be 78,0 +/- 0,2 mm (3.07 +/- 0.01 in). Slacken the lock nut and use the adjustment screw
of the rocker lever to obtain the correct dimension. Tighten the lock nut to a torque of 55 +/- 10 Nm (41 +/- 7
lbf ft).
3 Remove the timing bolt from the flywheel housing and rotate the flywheel by 360 degrees in the normal
direction of engine rotation until the timing bolt can be inserted into the threaded hole. This will put the number
1 piston at TDC in its exhaust stroke.
4 Check/adjust the height dimensions for the fuel injectors of cylinders 1, 2 and 4 as given in step 2.
5 When all adjustments have been made, remove the timing bolt, fit the cover to the flywheel housing, fit the
plug to the timing bolt position and fit the rocker covers.

User’s Handbook, TSD3454E, Issue 2 41

This document is printed from SPI². Not for RESALE

 4 2300 Series
Engine protection devices
The engine is fitted with an electronic management unit which monitors all critical engine temperatures and
pressures and will stop the engine if a critical fault occurs.
If any of the sensors fail, the diagnostics indicator will be activated and your Perkins dealer should be contacted
so that the fault can be identified by use of the Perkins Electronic Service Tool (EST).
Visual inspection
Check visually the condition of all gauges, sensors and wiring. Look for wiring and components that are loose,
broken, or damaged. Damaged wiring or components should be repaired or renewed immediately.

42 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to renew the thermostats of the coolant system
Renew the coolant thermostats at the periods given in the service schedule. This is recommended preventive
maintenance practice.

Cautions:
Failure to replace the thermostats at the periods given in the service schedule could cause severe engine
damage.
The engine MUST be operated with the thermostats installed. If a thermostat is fitted incorrectly the engine
may overheat.
1 Drain the coolant until the level is below the thermostat housing (A1).
Caution: Certain sensors fitted to the engine have a short lead which is part of the sensor unit. For this type
of sensor ensure that the wiring harness is disconnected from the end of the lead. Do NOT attempt to remove
the lead from the sensor unit.
2 Disconnect the cable (A3) from the coolant temperature sensor.
3 Release the hose clips (A2) and disconnect the pipe and hose clip from the top of the unit.
4 Slacken all five bolts of the thermostat housing; then remove fully the three bolts (A4) which retain the
thermostat housing on the cylinder head.
5 Lift carefully the assembly to separate it from the coolant bobbin (A5) at its base.
6 Remove the two short bolts which remain, separate the two halves of the assembly and remove the
thermostats.
7 Clean thoroughly both parts of the assembly and check the condition of the lip-type seals. Renew the seals
if they are worn or damaged.

Continued

User’s Handbook, TSD3454E, Issue 2 43

This document is printed from SPI². Not for RESALE

 4 2300 Series
8 Fit the new thermostats. Ensure that the new thermostats are fitted correctly. Fit a new ‘O’ ring type seal to
the groove in the thermostat housing, assemble the two halves of the unit and retain with two short bolts.
9 Ensure that the mating face on the cylinder head is clean. Fit new seals to the coolant bobbin (A5) which fits
into the base of the unit and lubricate the seals with a small amount of rubber lubricant. Fit a new ‘O’ ring type
seal to the groove in the mating face of the housing and fit the assembly over the coolant bobbin. Fit the three
bolts (A4) which retain the thermostat housing on the cylinder head and tighten fully all five bolts.
10 Connect the hose to the top of the housing and tighten the hose clip (A2).
11 Connect the cable (A3) to the coolant temperature sensor.
12 Fill the coolant system to the correct level with the approved coolant mixture.
13 Operate the engine until it reaches the normal temperature of operation and check for leaks. Stop the
engine, check the coolant level and, if necessary, add extra coolant.
Warning! Take care during removal of the filler cap as the coolant system will be under pressure.

44 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to clean and to calibrate the engine speed/timing sensors
1 Disconnect the wiring harness and remove the two speed-timing sensors from the left side of the engine at
the back of the gear case.
Caution: Certain sensors fitted to the engine have a short lead which is part of the sensor unit. For this type
of sensor ensure that the wiring harness is disconnected from the end of the lead. Do NOT attempt to remove
the lead from the sensor unit.
2 Check the condition of the plastic end of the sensors for wear and/or contaminants.
3 Clean the metal shavings and other debris from the face of the sensors.
4 Fit the sensors to the correct locations and connect the wiring harness.
Note: If a new ECM unit has been fitted, or the engine gear train has been renewed or dismantled and
assembled, the engine speed/timing sensors must be calibrated. Refer to engine timing calibration in the
Diagnostic Manual.

User’s Handbook, TSD3454E, Issue 2 45

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to inspect the turbocharger
At the periods given in the service schedule, with the engine switched off and cool, disconnect and remove the
pipe from between the air filter and the turbocharger. Turn, rapidly, the rotor assembly of the turbocharger,
check for freedom of movement and for sounds of interference. Contact your Perkins dealer if necessary.
Caution: Failure of the turbocharger bearings can cause large amounts of oil to enter the air inlet and exhaust
systems. Loss of engine lubricant can cause serious engine damage.
Minor leakage of a turbocharger housing under extended low load operation should not cause problems unless
turbocharger bearing failure has occurred.
Caution: When a turbocharger bearing failure is accompanied by a significant loss in engine performance
(exhaust smoke or engine speed up at no load), do not continue to operate the engine until the turbocharger
has been repaired or renewed.
Deposits must not be removed from the turbine wheels nor the compressor wheels or the balance of the
assembly will be adversely affected.
Check the oil supply and drain pipes for oil leaks.
Check for air leakage when the engine is run.
To remove and to fit the turbocharger
Refer the Workshop Manual for details of how to remove and to fit the turbocharger.

How to inspect the battery charging alternator

Inspect the battery charging alternator, for loose connections. Inspect the ammeter (if fitted) during engine
operation to ensure correct battery performance and/or correct performance of the electrical system. Clean the
outside of the alternator and ensure that the ventilation holes are clear.
The alternator must be checked and corrected, if necessary, by a person who has had the correct training, at
the periods given in the service schedule.

46 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 4
How to inspect the starter motor
Check the electrical connections of the starter motor assembly and clean them. Check the starter motor for
correct operation.
The starter motor must be checked and corrected, if necessary, by a person who has had the correct training,
at the periods given in the service schedule.

How to inspect the coolant pump

Inspect the coolant pump for leaks. If leakage is observed, renew the coolant pump seal or the coolant pump
assembly. Refer to the Workshop Manual for the dismantle and assembly procedures.
Refer to the Workshop Manual or consult your Perkins dealer if any repair or replacement is needed.

Notes:
A small amount of leakage of coolant across the surface of the face seal in the water pump is normal. Its
purpose is to provide lubrication for the seal.
There is a hole in the water pump body to allow coolant to drain. Small amounts of coolant might be seen
to leak intermittently from the drain hole during the engine operation cycle.
Signs of a small leakage through the drain hole are not an indication that the pump is faulty. Coolant stains
or intermittent drops of coolant from the hole, indicate normal operation of the pump.

User’s Handbook, TSD3454E, Issue 2 47

This document is printed from SPI². Not for RESALE

 4 2300 Series
How to eliminate air from the fuel system
This procedure is used normally when the engine runs out of fuel.
1 Loosen the union of the fuel return pipe (A1). Unlock and operate the hand priming pump (A2) until fuel, free
from air, flows from the union; this procedure will require many strokes of the pump. Use a cloth or a container
to collect the excess fuel.
2 Tighten the union (A1). Operate the hand priming pump until a strong pressure is felt on the pump. Push the
priming pump plunger inward. Tighten the plunger by hand and continue immediately with the next stage.
3 Start the engine.
Caution: Do not crank the engine continuously for more than 30 seconds. Allow the starter motor to cool for
two minutes before the engine is cranked again.
4 If the engine will not start, allow the starter motor to cool for 2 minutes. Repeat steps 1 and 2 to start the
engine. Continue to eliminate air from the fuel system if:
The engine starts, but runs unevenly.
The engine starts, but continues to misfire or smoke.
5 Run the engine with no load until it runs smoothly.

48 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series

5
Engine fluids 5

Fuel specification
Diesel fuel must conform to one of these specifications:
ASTM D975 No 1-D or No 2-D
BS 2869: Part 2 1998 Class A2
BS EN 590 1997
General fuel requirements are: Maximum sulphur content 0.2%; minimum Cetane number 45.
Fuel cleanliness
The modern, high pressure fuel injection system used on the 2300 Series engine requires a high level of fuel
cleanliness to ensure correct operation and reliability.
The fuel must conform to all aspects of the ASTM D975 specification, but in particular to the requirement for
number 2-D to have less than 0.05% water and sediment. The fuel should also be free from biological growth.
If biological growth is suspected, contact Perkins to discuss a suitable measurement and course of action. For
long term storage of fuel, the recommendations given in ASTM D975 must be followed where appropriate.
The use of fuels which do not conform to the above standards can cause: difficulty with starting, poor
combustion, deposits in the fuel injectors or combustion chamber, reduced service life of the fuel system and
filters, reduced engine life and could affect the warranty. Further details can be obtained from the Service
Department at Perkins Engines Company Limited, Shrewsbury.

Coolant
Coolant mixture
The coolant approved for use in 2300 Series engines is a mixture of 50% heavy duty, commercially available,
ethylene glycol antifreeze and 50% clean soft water. The antifreeze must meet ASTM D5345 or ASTM D4985
specifications.
A 50/50 ethylene glycol antifreeze mixture gives protection against freezing down to -35 °C. A 60% glycol mix
gives protection down to -40 °C and should be used for Arctic conditions.
Propylene glycol antifreeze is an acceptable alternative to ethylene glycol but only in 50/50 mixture strength,
at which it will protect against freezing down to -29 °C.
Caution: Mixtures containing methanol are not approved.
If anti-freeze is not available, and the ambient temperature is not expected to fall below 10 °C, then clean soft
water, with 1% of Perkins corrosion inhibitor (part number 21825 735 - 1 litre), may be used. This ratio is
equivalent to 0,5 litres of corrosion inhibitor to 50 litres (11 UK gallons) of water. The use of this product should
be controlled in accordance with the manufacturer’s instructions.
Water quality
Soft water means de-ionised water, distilled water, rain water or water from a mains supply which has the
following requirements:
Chlorides - 40 mg/l max, sulphates - 100 mg/l max, total hardness 170 mg/l max, total solids 340 mg/l max and
pH of 5.5 to 9.0.
If in doubt consult the local water treatment and supply company.
If soft water is not used, the coolant system may be affected by the formation of hard deposits which can cause
the engine to overheat. This is especially important for engines which have coolant added frequently.

User’s Handbook, TSD3454E, Issue 2 49

This document is printed from SPI². Not for RESALE

 5 2300 Series
The use of products which are not approved for the coolant system may cause serious problems. Coolant
mixtures with insufficient corrosion inhibitor can cause erosion and/or corrosion of coolant system
components.

Lubricating oil specification

The lubricating oil used in the 2306 engine must be a 15W40 oil which conforms to the API CG-4 specification
as a minimum. Oil produced to the higher specification, API CH-4, has greater soot handling capability and
wear resistance leading to longer service intervals and/or engine life.
The recommendation is therefore API CG-4 acceptable oil and API CH-4 preferred oil.
Oil change period is 500 hours where fuel sulphur is less than 0.2%. Use of fuels having a higher sulphur level
than this will reduce the oil life, which will have to be determined by oil analysis conducted by the customer
and a reputable analysis service.

Warranty
The engine must be operated with the approved fuel, lubricant and coolant, and maintained in accordance with
the service schedule or the warranty can become invalid.

50 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series

6
Fault diagnosis 6

Problems and possible causes

Possible causes
Problem Checks by the workshop
Checks by the user
personnel
The starter motor turns the engine too slowly 1, 2, 3, 4
5, 6, 7, 8, 9, 10, 12, 13,
The engine does not start 34, 35, 36, 37, 38, 42, 43, 67
14, 15, 17
5, 7, 8, 9, 10, 11, 12, 13, 34, 36, 37, 38, 40, 42, 43, 44,
The engine is difficult to start
14, 15, 16, 17, 19 67
8, 9, 10, 11, 12, 13, 16, 34, 36, 37, 38, 39, 42, 43, 44,
Not enough power
8, 9, 20, 21 63, 64, 66, 67
8, 9, 10, 12, 13, 15, 20, 34, 36, 37, 38, 39, 40, 41, 43,
Misfire
22 67
11, 13, 15, 17, 18, 19, 34, 36, 37, 38, 39, 40, 42, 43,
High fuel consumption
23, 22 44, 63
34, 36, 37, 38, 39, 40, 42, 43,
Black exhaust smoke 11, 13, 15, 17, 19, 21, 22
44, 63, 64, 67
36, 37, 38, 39, 42, 44, 45, 52,
Blue or white exhaust smoke 4, 15, 21, 23
58, 61, 62
The pressure of the lubricating oil system is too low 4, 24, 25, 26 46, 47, 48, 50, 51, 59,
36, 37, 40, 42, 44, 46, 52, 53,
The engine knocks 9, 13, 15, 17, 20, 22, 23
60
8, 9, 10, 11, 12, 13, 15,
The engine runs erratically 34, 38, 40, 41, 44, 52, 60, 67
16, 18, 20, 22, 23
34, 38, 39, 40, 41, 44, 52, 54,
Vibration 13, 18, 20, 27, 28
67
The pressure of the lubricating oil system is too high 4, 25 49
11, 13, 15, 19, 27, 29, 34, 36, 37, 39, 52, 55, 56, 57,
The engine oil temperature is too high
30, 32, 65 66
Crankcase pressure 31, 33 39, 42, 44, 45, 52, 61
37, 39, 40, 42, 43, 44, 45, 53,
Bad compression 11, 22
60
The engine starts and stops 10, 11, 12 67

User’s Handbook, TSD3454E, Issue 2 51

This document is printed from SPI². Not for RESALE

 6 2300 Series
List of possible causes
1 Battery capacity low.
2 Bad electrical connections.
3 Fault in starter motor.
4 Wrong grade of lubricating oil.
5 Starter motor turns engine too slowly.
6 Fuel tank empty.
7 Fault in stop control.
8 Restriction in a fuel pipe.
9 Fault in fuel lift pump.
10 Dirty fuel filter element.
11 Restriction in air induction system.
12 Air in fuel system.
13 Fault in fuel injectors or fuel injectors of an incorrect type.
14 Cold start system used incorrectly.
15 Fault in cold start system.
16 Restriction in fuel tank vent.
17 Wrong type or grade of fuel used.
18 Restricted movement of engine speed control (not applicable to 2300 series engines).
19 Restriction in exhaust pipe.
20 Engine temperature is too high.
21 Engine temperature is too low.
22 Incorrect valve tip clearances.
23 Too much oil or oil of the wrong type is used in wet type air cleaner, if one is fitted.
24 Not enough lubricating oil in sump.
25 Defective gauge.
26 Dirty lubricating oil filter element.
27 Fan damaged.
28 Fault in engine mounting or flywheel housing.
29 Too much lubricating oil in sump.
30 Restriction in air or water passages of radiator.
31 Restriction in breather pipe.
32 Insufficient coolant in system.
33 Vacuum pipe leak or fault in exhauster (not applicable to 2300 series engines).
34 Fault in fuel injection pump.
35 Broken drive on fuel injection pump.
36 Timing of fuel injection pump incorrect.
37 Valve timing is incorrect.
38 Bad compression.
39 Cylinder head gasket leaks.
40 Valves are not free.
41 Wrong high-pressure pipes (not applicable to 2300 series engines).
42 Worn cylinder bores.
43 Leakage between valves and seats.
Continued

52 User’s Handbook, TSD3454E, Issue 2

This document is printed from SPI². Not for RESALE

 2300 Series 6
44 Piston rings are not free or they are worn or broken.
45 Valve stems and/or guides are worn.
46 Crankshaft bearings are worn or damaged.
47 Lubricating oil pump is worn.
48 Relief valve does not close.
49 Relief valve does not open.
50 Relief valve spring is broken.
51 Fault in suction pipe of lubricating oil pump.
52 Piston is damaged.
53 Piston height is incorrect.
54 Flywheel housing or flywheel is not aligned correctly.
55 Fault in thermostat or thermostat is of an incorrect type.
56 Restriction in coolant passages.
57 Fault in water pump.
58 Valve stem seal is damaged.
59 Restriction in sump strainer.
60 Valve spring is broken.
61 Turbocharger impeller is damaged or dirty.
62 Lubricating oil seal of turbocharger leaks.
63 Induction system leaks.
64 Turbocharger impeller is damaged or dirty.
65 Drive belt for water pump is loose.
66 Induction system leaks (turbocharged engines).
67 Faulty engine management system

User’s Handbook, TSD3454E, Issue 2 53

This document is printed from SPI². Not for RESALE

 This page is intentionally blank

This document is printed from SPI². Not for RESALE