Perkins 1004-40 Troubleshooting
| Engine Model: Perkins 1004-40 |
| Engine Type: 4-cycle vertical 4-cylinder direct injection liquid-cooled diesel |
| Total Displacement: 243 cu.in (3.99 L) |
| Rated Engine Power: 74.3 Hp (55 kW) at 2200 rpm |
| Aspiration Type: Naturally aspirated |
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| Engine starts hard or won't start |
Fuel filter plugging - Service the filter.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles are faulty or clogged - Test injection nozzles and change if necessary.
Fuel injection pump is faulty - Replace or repair injection pump.
Improper valve timing - Set the valve timing correctly.
Fuel pipes are clogged - Clean fuel pipes.
Injection timing is incorrect - Set up as recommended.
Damaged piston rings and cylinder - Replace faulty parts.
| Engine starts but then stops |
Fuel filter plugged - Clean the filter element.
Fuel injection pump is faulty - Change or repair the pump.
Intake air restriction - Air filter maintenance required.
Incorrect nozzle opening pressure - Set up as recommended.
| Engine shuts off suddenly during operation |
Incorrect adjustment of fuel injection pump timing - Set it up as required.
Dirty fuel filter - Change filter element.
Engine has not warmed up to the recommended temperature - Warm up the engine.
Injection nozzles sticking or clogged - Change or repair injection nozzles.
Incorrect low idle setting - Adjustment required.
Excessive valve clearance - Check and adjust.
Fuel injection pump damage - Rebuild or replace pump.
Fuel injection nozzles are clogged or faulty - Check and replace nozzles if required.
Dirt in the fuel hoses or lines - Service fuel lines and hoses.
Clogged air filter element - Clean or replace the element.
Cylinder head gasket is damaged - Replace the gasket as required.
Improper injection timing - Check injection timing adjustment.
Fuel injection pump is damaged - Rebuild or install a new injection pump.
One of moving engine components has failed - Repair or replace defective components.
Faulty radiator cap or dirty radiator fins - Clean radiator or install new cap.
Coolant level is low - Add coolant and check the components of cooling system.
Loose or defective fan belt - If necessary, replace the belt.
Low engine oil level - Check and refill engine oil.
Cylinder head gasket is worn - Replace cylinder head gasket.
Wrong injection timing - Check injection timing adjustment.
| Oil pressure is insufficient |
Oil level is insufficient - Checking oil level and add if necessary.
Oil pump is damaged - Repair or replace.
Oil filter is clogged - Service or change engine oil filter element.
Relief valve is stuck or broken - Change or clean relief valve.
Excessive crankshaft bearing clearance - Test and repair or replace worn parts.
Excessive oil clearance of crankpin bearing - Inspect and change or repair worn components.
| Engine using too much oil |
Oil leakage: Worn gaskets or seals - Change worn parts according to specifications.
Crankcase oil too light - Use oil of correct viscosity.
Piston rings are stuck or broken - Change piston rings.
Worn valve guides and valve stems - Install new valves.
Scored cylinder liners or pistons - Inspect liners and pistons, fit new parts as necessary.
Engine is not warmed up to the required temperature - Warm up engine as required.
Low engine oil level - Add oil to the engine crankcase.
Fuel injection pump timing is wrong - Adjust fuel injection pump as required.
Piston wear or scoring - Pistons replacement required.
Misaligned or faulty connecting rod - Connecting rod must be aligned or replaced.
Low battery capacity - Low battery charging, charge as required.
Battery runs out quickly - Service or change the battery.
Battery terminals are corroded or wires are disconnected - Check wire connections and change or service terminals.
Battery is discharged or worn - Need to charge or replace the battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Battery power is low - Battery is drained, recharge it.
Damaged starter motor - Repair or replace starter.
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