Perkins 404D-15 Troubleshooting
| Engine Model: Perkins 404D-15 |
| Engine Type: 4-cycle vertical 4-cylinder indirect injection liquid-cooled diesel |
| Total Displacement: 92 cu.in (1.51 L) |
| Rated Engine Power: 35.5 Hp (26.5 kW) at 3000 rpm |
| Aspiration Type: Naturally aspriated |
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| Engine difficult to start or won't start |
Fuel filter plugged - Install new filter element.
Air in the fuel pipes - Bleed the fuel pipes.
Damaged or dirty injection nozzles - Clean or replace injection nozzles.
Damaged fuel injection pump - Rebuild or replace pump.
Valve timing is incorrect - Set the valve timing correctly.
Fuel pipes clogging - Clean fuel pipes.
Improper injection timing - Use correct injection timing adjustment.
Cylinder or piston rings are worn - Change defective components.
| Diesel starts and suddenly stops |
Fuel filter plugged - Clean or change the filter.
Fuel injection pump is damaged - Replace or rebuild injection pump.
Dirty air filter element - Clean or change.
Incorrect nozzle opening pressure - Adjust according to specifications.
| Engine shuts off suddenly during operation |
Timing of fuel injection pump is incorrect - Adjust as recommended.
Fuel filter element clogging - Clean the filter element.
Engine is not warmed up to the required temperature - Engine is not warmed up to the required temperature.
Defective or stuck injection nozzles - Service or change injection nozzles.
| Engine stalls when idling |
Too low idle RPM - Adjust as required.
Valve out of adjustment - Adjust valve clearance.
Fuel injection pump is not operating properly - Rebuild or change fuel pump.
Dirty or damaged injection nozzles - If necessary, replace with a new nozzle.
Fuel hoses or lines clogging - Clean fuel hoses and lines.
Air filter is clogged - Change air filter element.
Defective cylinder head gasket - Install new cylinder head gasket.
Wrong injection timing - Check injection timing adjustment.
Faulty fuel injection pump - Replacement or repair required.
One of moving engine components is worn - Replace or repair damaged components.
Radiator core is dirty or radiator cap is damaged - Clean radiator or replace cap.
Low coolant level - Add coolant and check the components of cooling system.
Loose or defective fan belt - Change as required.
Lack of engine oil - Check oil level and add oil as required.
Blown cylinder head gasket - Install new cylinder head gasket.
Wrong injection timing - Adjust according to specifications.
Engine oil level low - Need to add oil.
Worn oil pump - Remove and inspect oil pump.
Oil filter is dirty - Service or change engine oil filter element.
Stuck or worn relief valve - Replace or clean relief valve.
Excessive crankshaft bearing clearance - Test and replace or repair worn components.
Crankpin bearing clearance is excessive - Inspect and replace or repair faulty parts.
| High engine oil consumption |
Oil leakage: Worn gaskets or seals - Defective components must be replaced.
Wrong oil viscosity - Use proper viscosity oil.
Piston rings are seized or worn - Change piston rings.
Damaged valve stems or valve guides - Valves must be replaced.
Damaged cylinder liners or pistons - Check liners and pistons, replace as required.
| Abnormal engine noise or knocking |
Engine is not fully warmed up - Warm up the engine.
Lack of engine oil - Checking oil level and add if necessary.
Fuel injection pump timing is wrong - Set up as recommended.
Pistons are broken or worn - Pistons need to be replaced.
Faulty or misaligned connecting rod - Connecting rod needs to be replaced or aligned.
Low battery voltage - Battery is drained, recharge it.
Battery is draining quickly - Service or change the battery.
Battery terminals are corroded or wires are disconnected - Connect wires properly or change terminals.
Battery is low or faulty - Recharge or replace battery.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Low battery capacity - Battery needs to be recharged.
Starter motor failing - Starter should be changed.
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