Perkins 1004-4T Troubleshooting
| Engine Model: Perkins 1004-4T |
| Engine Type: 4-cycle vertical 4-cylinder direct injection liquid-cooled diesel |
| Total Displacement: 243 cu.in (3.99 L) |
| Rated Engine Power: 115.4 Hp (85.5 kW) at 2200 rpm |
| Aspiration Type: Turbocharged |
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| Engine hard to start or won't start |
Fuel filter element clogging - Install new filter element.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles are clogged or faulty - Replace injection nozzles.
Fuel injection pump is defective - Change or repair the pump.
Incorrect valve timing - Use correct valve timing adjustment.
Dirty fuel pipes - Clean fuel pipes.
Unadjusted injection timing - Set up as recommended.
Damaged piston rings and cylinder - Change defective parts.
| Engine starts and immediately shuts off |
Fuel filter plugging - Filter maintenance required.
Fuel injection pump is not working correctly - Rebuild or install a new injection pump.
Dirty air filter element - Replace air filter element.
Nozzle opening pressure is not adjusted - Set up as recommended.
| Engine stalls during operation |
Improper fuel injection timing - Set up as recommended.
Fuel filter plugging - Clean or replace the filter.
Low coolant temperature - Engine is not warmed up to the required temperature.
Injection nozzles are burnt or jammed - Check injection nozzles and replace if required.
Incorrectly adjusted low idle speed - Normalize low idle speed.
Valve clearance is wrong - Correct valve clearance.
Fuel injection pump is not working correctly - Replace or repair injection pump.
Faulty or dirty injection nozzles - Change fuel injection nozzles.
Clogged fuel hoses or lines - Service fuel hoses and lines.
Restricted intake air - Replace air filter element.
Worn cylinder head gasket - Change cylinder head gasket.
Incorrect injection timing - Set up as recommended.
Fuel injection pump is defective - Rebuild or change fuel pump.
One of moving engine parts has broken - Change or repair damaged parts.
Dirty radiator fins or faulty radiator cap - Install new cap or clean radiator.
Insufficient coolant fluid - Add coolant fluid and inspect the cooling system for leaks.
Fan belt is loose or defective - Belt replacement is recommended.
Engine oil insufficient - Fill up the oil to required level.
Damaged cylinder-head gasket - Replace the gasket as required.
Improper injection timing - Set up as recommended.
Engine oil level low - Check and refill the oil.
Oil pump is damaged - Install a new pump.
Oil filter element clogged - Clean or change engine oil filter.
Stuck or worn relief valve - Replace or service relief valve.
Excessive oil clearance of crankshaft bearing - Test and repair or replace worn parts.
Clearance of crankpin bearing is excessive - Check and change or repair defective parts.
| Diesel engine consuming too much oil |
Oil leaking: Gaskets or seals are excessively worn - New components need to be installed.
Improper oil viscosity - Use oil of proper viscosity.
Piston rings are defective or worn - Install new piston rings.
Valve guides or stems are damaged - Replace the valves.
Scuffed cylinder liners or pistons - Check pistons and liners, replace as required.
| Abnormal engine noise or knocking |
Engine not warmed up - Warm up to required temperature.
Engine oil level is insufficient - Need to add engine oil.
Improper setting of fuel injection pump timing - Check the fuel injection pump timing adjustment.
Scored or worn pistons - Have pistons replaced.
Connecting rod failure or misalignment - Replace or align connecting rod.
Low battery output - Low battery charging, charge as required.
Battery does not hold charge - Service battery or change it.
Disconnected cables or faulty battery terminals - Check wiring and clean or replace terminals.
Battery is discharged or worn - Charge or replace the battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery output - Battery is drained, charge it.
Starter motor failure - Starter needs to be changed.
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