Perkins 404D-22T Troubleshooting
| Engine Model: Perkins 404D-22T |
| Engine Type: 4-cycle vertical 4-cylinder indirect injection liquid-cooled diesel |
| Total Displacement: 135 cu.in (2.22 L) |
| Rated Engine Power: 61 Hp (45.5 kW) at 3000 rpm |
| Aspiration Type: Turbocharged |
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| Diesel engine hard to start or doesn't start |
Fuel filter element clogging - Clean the filter element.
There is air in the fuel system - Bleed the system.
Faulty fuel injection nozzles - Check injection nozzles and replace if required.
Damaged fuel injection pump - Change or repair the pump.
Valve timing is improper - Adjust or change timing gear.
Restricted fuel pipes - Clean or replace fuel pipes.
Unadjusted injection timing - Use correct injection timing adjustment.
Piston rings and cylinder are worn - Change defective parts.
| Diesel starts but stalls immediately |
Fuel filter element is clogged - Filter maintenance required.
Fuel injection pump is not operating properly - Change or repair the pump.
Air filter clogged - Air filter maintenance required.
Improper nozzle opening pressure - Adjust as recommended.
| Engine stops suddenly during operation |
Timing of fuel injection pump is incorrect - Adjust fuel injection pump as required.
Fuel filter plugged - Service the filter.
Engine not warmed up - Warm up the engine.
Stuck or burnt injection nozzle - Clean or replace injection nozzles.
Incorrect low idle setting - Need to adjust idle speed.
The valve clearance is incorrect - Check and adjust.
Fuel injection pump failure - Rebuild or replace pump.
| Engine is not running at maximum power |
Clogged or burnt injection nozzle - Check injection nozzles and replace if required.
Restricted fuel hoses or lines - Clean fuel lines and hoses.
Air filter plugged - Clean or change.
Damaged cylinder-head gasket - Change cylinder head gasket.
Unadjusted injection timing - Check injection timing adjustment.
Fuel injection pump is faulty - Change pump or rebuild it.
One of moving engine components has failed - Repair or replace defective components.
Defective radiator cap or clogged radiator core - Clean radiator or replace cap.
Insufficient coolant - Top up coolant fluid and check system for leaks.
Loose or damaged fan belt - Change as required.
Low engine oil level - Need to add engine oil.
Damaged cylinder-head gasket - Change cylinder head gasket.
Unadjusted injection timing - Set the injection timing correctly.
| Oil pressure is insufficient |
Engine oil level low - Add oil as required.
Oil pump failure - Repair or change.
Oil filter is clogged - Change or service engine oil filter.
Worn or dirty relief valve - Replace or clean relief valve.
Crankshaft bearing clearance is excessive - Inspect and replace or repair faulty components.
Excessive crankpin bearing clearance - Inspect and change or repair worn components.
External oil leaks: Gaskets or seals can be faulty - Replace to repair leaks.
Oil viscosity is incorrect - Use proper viscosity oil.
Piston rings are seized or worn - Piston rings replacement required.
Damaged valve guides or valve stems - Change the valves.
Cylinder liners or pistons are scored - Inspect liners and pistons, fit new parts as necessary.
| Engine knocking sound or abnormal noise |
Engine is cold - Warm up to required temperature.
Engine oil insufficient - Check oil level and add oil as required.
Improper setting of fuel injection pump timing - Adjust fuel injection pump as required.
Pistons are broken or worn - Pistons need to be replaced.
Connecting rod is worn or not aligned - Connecting rod needs to be replaced or aligned.
Low battery power - Battery needs to be recharged.
Battery drains quickly - Service or change the battery.
Bad terminals or disconnected battery cables - Connect wires properly or change terminals.
Battery is discharged or defective - Charge or change the battery.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Low battery voltage - Battery needs to be recharged.
Starter motor is defective - Replace or repair starter.
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