Perkins 402D-05 Troubleshooting
| Engine Model: Perkins 402D-05 |
| Engine Type: 4-cycle 2-cylinder indirect injection liquid-cooled diesel |
| Total Displacement: 31 cu.in (0.51 L) |
| Rated Engine Power: 13.7 Hp (10.2 kW) at 3600 rpm |
| Aspiration Type: Naturally aspirated |
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| Engine hard to start or won't start |
Clogged fuel filter - Change filter element.
There is air in the fuel system - Bleed the system.
Dirty or damaged injection nozzles - Change fuel injection nozzles.
Fuel injection pump malfunctioning - Change pump or rebuild it.
Wrong valve timing - Correct or change timing gear.
Fuel pipes are clogged - Clean fuel pipes.
Wrong injection timing - Set the injection timing correctly.
Worn piston rings and cylinder - Replace faulty components.
| Diesel starts but stalls immediately |
Fuel filter element is clogged - Clean the filter or install new filter element.
Defective fuel injection pump - Repair or change injection pump.
Plugged air cleaner - Clean or change the filter.
Nozzle opening pressure is incorrect - Set it correctly.
| Engine stalls during operation |
Wrong setting of fuel injection pump timing - Adjust according to specifications.
Dirty fuel filter - Service the filter.
Coolant temperature is low - Warm up engine as required.
Injection nozzles are stuck or clogged - Clean or replace injection nozzles.
Incorrectly adjusted low idle speed - Need to adjust idle speed.
Incorrect valve clearance - Have it adjusted.
Faulty fuel injection pump - Repair or replace injection pump.
Fuel injection nozzles fault - Inspect nozzles and replace if necessary.
Fuel hoses or lines are clogged - Fuel lines and hoses need to be cleaned.
Air filter clogged - Replace air filter element.
Cylinder head gasket defective - Replace the gasket as required.
Incorrect injection timing - Adjust as recommended.
Fuel injection pump is faulty - Repair or change injection pump.
One of moving engine parts has broken - Change or repair damaged parts.
Defective radiator cap or clogged radiator core - Clean radiator or change cap.
Engine coolant is insufficient - Fill radiator to proper level and check components for faults.
Fan belt slipping or worn - The fan belt needs to be replaced.
Engine oil level is low - Check oil level and add oil as required.
Defective cylinder head gasket - Gasket should be replaced.
Injection timing is improper - Set the injection timing correctly.
Low crankcase oil level - Check oil level and add oil as required.
Oil pump is defective - Inspect and change as required.
Dirty oil filter element - Service or change engine oil filter element.
Relief valve is defective or dirty - Replace or service relief valve.
Clearance of crankshaft bearing is excessive - Inspect and replace or repair faulty parts.
Clearance of crankpin bearing is excessive - Inspect and replace or repair faulty components.
Oil leaking: Seals or gaskets are wearing excessively - Replace defective parts.
Incorrect oil viscosity - Use oil of correct viscosity.
Piston rings are seized or worn - Replace piston rings.
Worn valve stems and valve guides - Replace defective valves.
Scored cylinder liners or pistons - Check pistons and liners, replace as required.
| Engine knocking sound or abnormal noise |
Engine not warmed up - Warm up the engine.
Engine oil level is insufficient - Need to add engine oil.
Improper setting of fuel injection pump timing - Adjust the pump as required.
Worn or broken pistons - Replace the pistons as required.
Connecting rod is misaligned or worn - Need to change or align the connecting rod.
Battery power is low - Recharge the battery.
Battery won’t hold charge - Service battery or replace it.
Corroded battery terminals or disconnected wires - Check cable connections and change or clean terminals.
Battery is drained or worn - Charge or replace the battery.
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required.
Battery power is low - Low battery charging, charge as required.
Starter motor is damaged - Starter needs to be changed.
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