Perkins 403D-15 Troubleshooting
| Engine Model: Perkins 403D-15 |
| Engine Type: 4-cycle vertical 3-cylinder indirect injection liquid-cooled diesel |
| Total Displacement: 91 cu.in (1.49 L) |
| Rated Engine Power: 33.7 Hp (25.1 kW) at 3000 rpm |
| Aspiration Type: Naturally aspirated |
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| Engine hard to start or doesn't start |
Fuel filter element is clogged - Service the filter.
Air in fuel tank - Bleed fuel tank.
Dirty or faulty injection nozzles - Check injection nozzles and replace if required.
Fuel injection pump malfunction - Replace injection pump or repair it.
Unadjusted valve timing - Adjust or replace timing gear.
Fuel pipes are dirty - Clean fuel pipes.
Injection timing is incorrect - Use correct injection timing adjustment.
Worn piston rings and cylinder - Replace defective components.
| Diesel starts but then stops |
Fuel filter plugged - Replace the filter element.
Fuel injection pump malfunctioning - Replace or repair injection pump.
Air filter is clogged - Clean air cleaner element.
Nozzle opening pressure is improper - Adjust as recommended.
| Engine stalls while running |
Improper setting of fuel injection pump timing - Adjust according to specifications.
Fuel filter element clogging - Filter maintenance required.
Engine not warmed up - Warm up the engine.
Injection nozzles are stuck or clogged - Change or repair injection nozzles.
| Engine stalls while idling |
Incorrectly set low idle speed - Test and adjust.
Incorrect valve clearance - Correct valve clearance.
Damaged fuel injection pump - Change or repair the pump.
| Diesel engine loses power |
Fuel injection nozzles are clogged or faulty - Check injection nozzles and replace if required.
Fuel hoses or lines are clogged - Fuel hoses and lines must be clean.
Air filter is dirty - Clean air cleaner element.
Damaged cylinder-head gasket - Gasket should be replaced.
Incorrect injection timing - Adjust according to specifications.
Faulty fuel injection pump - Rebuild or change fuel pump.
One of moving engine components has failed - Repair or replace defective components.
Radiator core is clogged or radiator cap is leaking - Replace cap or clean radiator.
Engine has a lack of coolant - Fill radiator to proper level and check components for faults.
Fan belt is loose or defective - Install new fan belt.
Engine oil level is insufficient - Check oil level and add oil as required.
Cylinder head gasket is damaged - Install new cylinder head gasket.
Injection timing is incorrect - Set up as recommended.
Low oil level - Checking oil level and add if necessary.
Oil pump failure - Inspect and change as required.
Dirty oil filter - Service or replace engine oil filter.
Relief valve is seized or worn - Relief valve need to be replaced or cleaned.
Excessive crankshaft bearing clearance - Check and replace or repair defective parts.
Clearance of crankpin bearing is excessive - Inspect and change or repair worn components.
| Diesel engine consuming too much oil |
Oil leaking: Damaged gaskets or seals - Replace to repair leaks.
Crankcase oil too light - Fill up with the proper oil viscosity.
Piston rings are stuck or broken - Piston rings replacement required.
Valve stems or guides are damaged - Replace the valves.
Damaged pistons or cylinder liners - Check pistons and liners, install new parts as required.
Engine is not warmed up to the required temperature - Engine is not warmed up to the required temperature.
Not enough engine oil - Check oil level and add oil as required.
Improper fuel injection timing - Adjust according to specifications.
Pistons are scored or worn - Replace the pistons as required.
Connecting rod is defective or misaligned - Connecting rod must be aligned or replaced.
Low battery output voltage - Charge the battery.
Battery will not hold charge - Service battery or change it.
Disconnected cables or faulty battery terminals - Check wire connections and change or service terminals.
Battery is low or faulty - Replace or charge as required.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Battery capacity is low - Battery is drained, recharge it.
Starter motor failing - Starter needs to be changed.
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