C175-16 Locomotive Engine Caterpillar

Engine Cranks but Does Not Start

Usage:

Use this procedure to troubleshoot an engine that cranks but does not start. Also, use this procedure if the following event code is active or logged.

Show/hide table

Table 1
J1939 Code and Description	CDL Code and Description	Comments
1664-31 Engine Automatic Start Failed	E225 (3) Engine Overcrank	The engine has cranked for a duration of 30 seconds and failed to start after 3 attempts. The code is logged.

Show/hide table

Table 2
Associated Codes
J1939	CDL	Troubleshooting Procedure
157-17	E398 (1)	Troubleshooting, Fuel Flow Is High
157-18	E398 (2)	Troubleshooting, Fuel Flow Is High
1440-0	E1106 (3)	Troubleshooting, Fuel Flow Is High
1440-15	E1106 (1)	Troubleshooting, Fuel Flow Is High
1440-16	E1106 (2)	Troubleshooting, Fuel Flow Is High
5578-14	E390 (3)	Troubleshooting, Fuel Filter Is Restricted
5584-0	E390 (1)	Troubleshooting, Fuel Filter Is Restricted
5584-16	E390 (2)	Troubleshooting, Fuel Filter Is Restricted
5585-17	E1220 (1)	Troubleshooting, Fuel Flow Is High

Probable Causes

Codes
Driven equipment
Batteries
Cranking speed
Starting aids (if equipped)
Voltage
Fuel system
Fuel priming system
Fuel pressure
High-pressure fuel line

Recommended Actions

Show/hide table

Table 3
Troubleshooting Test Steps	Values	Results
1. Check for Codes A. Connect Cat^® Electronic Technician (ET) to the service tool connector. B. Look for active codes that are associated with the system for the event code.	Codes	Result: An associated code is active. Repair: Troubleshoot any associated codes before continuing with this test. Result: A code is active or logged. Proceed to Test Step 2.
2. Inspect the Driven Equipment	Driven Equipment	Result: The driven equipment is OK. Proceed to Test Step 3. Result: The driven equipment is NOT OK. Repair: Repair or replace damaged driven equipment. Proceed to Test Step 3.
3. Inspect the Batteries A. Charge the batteries, if necessary. Refer to Special Instruction, SEHS7633, "Battery Test Procedure" for additional information. B. Load-test the batteries. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 V and 12 V Lead Acid Batteries" for additional information.	Batteries	Result: The batteries are OK. Proceed to Test Step 4. Result: The batteries are NOT OK. Repair: Repair or replace the batteries. Proceed to Test Step 4.
4. Check for Slow Cranking Speed A. Connect Cat ET. B. Use Cat ET to monitor the following while cranking the engine: - Engine speed Note: If the engine cranks too slowly, the engine will not start. C. Check for the following problems: - Low voltage for an electric starting system - Excess parasitic load - Engagement all starters on a multiple starting motor system - Starting signal being sent from controller	Cranking Speed	Result: The engine speed is greater than 100 rpm for a duration of four revolutions. Proceed to Test Step 5. Result: The engine speed is not greater than 100 rpm for a duration of four revolutions. Repair: Repair or replace the damaged components. Proceed to Test Step 5.
5. Check the Starting Aids (if Equipped) A. Ensure that the ether canister is not empty or low. B. Check for proper operation of the jacket water heater.	Ether and Heater	Result: All starting aids checked out OK. Proceed to Test Step 6. Result: A starting aid checked out NOT OK. Repair: Repair or replace damaged starting aid components. Proceed to Test Step 6.
6. Check the Keyswitch Power to the Electronic Control Module (ECM) A. Turn the power supply ON. B. Check the voltage supply to the engine ECM on the keyswitch circuit. Refer to the appropriate wiring schematic for details on the pins.	18 V	Result: The keyswitch power is greater than 18 VDC. Proceed to Test Step 7. Result: The keyswitch power is less than 18 VDC. Repair: Refer to Troubleshooting, "Electrical Power Supply - Test" for additional information. Proceed to Test Step 7.
7. Check the ECM Supply Voltage A. Check the battery supply voltage between each ECM battery + pin and each ECM battery – pin on the engine ECM. Refer to the appropriate wiring schematic for details on the pins.	18 V	Result: The supply voltages are greater than 18 VDC. Proceed to Test Step 8. Result: The supply voltages are less than 18 VDC. Repair: Refer to Troubleshooting, "Electrical Power Supply - Test" for additional information. Proceed to Test Step 8.
8. Inspect the Fuel System A. Visually check the fuel level in the tank. Do not rely on the fuel gauge only. B. Ensure that the fuel vent is not filled with debris. C. Ensure that the fuel supply valve (if equipped) is in the OPEN. Note: Cold weather adversely affects the characteristics of fuel. Refer to Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold-weather operation. D. Check the fuel quality. Check the fuel tank for debris or foreign objects which may block the fuel supply. E. Check for external fuel leaks. F. Check all fuel fittings to ensure the correct torque values.	Fuel System	Result: The fuel system is OK. Proceed to Test Step 9. Result: There was a problem found during the fuel system inspection. Repair: Repair or replace the damaged fuel system components. Proceed to Test Step 9.
9. Check the Fuel Priming System A. Connect Cat ET. B. Prime the fuel system. Refer to the Original Equipment Manufacturers (OEM) and Operation and Maintenance Manual (OMM) for additional information. C. Verify the "Fuel Transfer Pump Intake Pressure" is reading greater than 400 kPa (58 psi) after 30 seconds of priming.	400 kPa (58 psi)	Result: The "Fuel Transfer Pump Intake Pressure" is greater than 400 kPa (58 psi). Proceed to Test Step 10. Result: The "Fuel Transfer Pump Intake Pressure" is less than 400 kPa (58 psi). Repair: Low fuel pressure during priming has been detected. The electrical circuit to the priming pump may be damaged, or the priming pump has failed. Refer to Troubleshooting, "Fuel Priming Pump - Test" for additional information.

Show/hide table




Illustration 1	g06213432
(1) Starting priority valve (2) System pressure regulator

Show/hide table

Table 4
Troubleshooting Test Steps	Values	Results
10. Check the Fuel Pressure A. Connect Cat ET. B. Use Cat ET to monitor the following while cranking the engine: - "Fuel Pressure" Note: The "Fuel Pressure" should read greater than 250 kPa (36 psi).	Fuel Pressure	Result: The "Fuel Pressure" is greater than 250 kPa (36 psi). Proceed to Test Step 11. Result: The "Fuel Pressure" is less than 250 kPa (36 psi). Repair: Inspect the starting priority valve and the low-pressure fuel system pressure regulator valve. 1. Remove the low-pressure fuel system pressure regulator from the secondary fuel filter auxiliary manifold and actuate the spool of the cartridge assembly. 2. Remove the starting priority valve from the secondary fuel filter head and actuate the spool of the cartridge assembly. Both of the valves should move freely through the full travel: - If one or both of the valves do not move freely through the full travel, replace the failed valves. - If both valves move freely through the full travel, then replace the fuel transfer pump. Verify that the repair eliminated the problem.
11. Check for Internal High-Pressure Fuel Line Leaks A. Turn the keyswitch to OFF. B. Remove the cap assembly from the tee adapter attached to the double wall fuel return line. C. Catch fuel into a suitable container. D. Crank/Start the engine and check for fuel leakage.	Fuel Volume	Result: There was leakage from the fuel return line. Leave the cap assembly off the tee adapter attached to the double wall fuel return line. Proceed to Test Step 12. Result: There was no leakage from the fuel return line. Proceed to Test Step 14.
12. Check the Torque on the High-Pressure Lines and Accumulator Quill Tube Connections A. Turn the keyswitch to OFF. B. Check the torque on each one of the high-pressure fuel lines and accumulator quill tube connections. C. Check the torque on the high-pressure fuel accumulator quill tube studs.	Torque	Result: All torque values were within specification. Proceed to Test Step 13. Result: The torque values were not all within specification. Repair: Tighten the lines and/or accumulator quills that were not properly torqued. Proceed to Test Step 16.

Show/hide table




Illustration 2	g06213409
HP accumulator-quill (3) Leak detection plug/port

Show/hide table

Table 5
Troubleshooting Test Steps	Values	Results
13. Check the Leak Detection Ports on the Fuel Accumulator Quill Tubes A. Turn the keyswitch to OFF. B. Remove all the leak detection port on each of the fuel accumulator quill tubes. C. Crank/Start the engine. D. If the engine can be started. Operate the engine at low idle and high idle. E. Inspect each of the leak detection ports for signs of fuel leakage. Note: Fuel leakage may occur, be prepared to collect leaking fuel.	Fuel Leak	Result: A leak was detected on the accumulator quill tube leak port. Repair: A leak at the high-pressure fuel supply line on each side of the leaking accumulator quill tube has been detected. Perform the following procedure: 1. Release the pressure in the high-pressure rail by loosening the end plug on one of the last 2 fuel accumulators. Refer to Testing and Adjusting, "Fuel Rail Pressure - Release" for instructions on how to release the pressurized fuel. 2. Verify that the "Fuel Rail Pressure" reading in Cat ET is 0 ± 8 MPa (1160 psi) prior to servicing the fuel system. 3. Replace the high-pressure fuel supply line on each side of the leaking accumulator quill tube. Proceed to Test Step 13. Result: A leak was detected on the high-pressure return line. Repair: Perform the following procedure: 1. Release the pressure in the high-pressure rail by loosening the end plug on one of the last 2 fuel accumulators. Refer to Testing and Adjusting, "Fuel Rail Pressure - Release" for instructions on how to release the pressurized fuel. 2. Verify that the "Fuel Rail Pressure" reading in Cat ET is 0 ± 8 MPa (1160 psi) prior to servicing the fuel system. 3. Replace the high-pressure fuel return line. Proceed to Test Step 16. Result: There were no leaks detected. Repair: There is a high-pressure fuel leak before the injector bank. Perform the following procedure: 1. Release the pressure in the high-pressure rail by loosening the end plug on one of the last 2 fuel accumulators. Refer to Testing and Adjusting, "Fuel Rail Pressure - Release" for instructions on how to release the pressurized fuel. 2. Verify that the "Fuel Rail Pressure" reading in Cat ET is 0 ± 8 MPa (1160 psi) prior to servicing the fuel system. 3. Remove and inspect all the high-pressure lines between the high-pressure fuel pump and each injector bank. Replace the lines if necessary. Torque the lines to the proper value upon reinstallation. Proceed to Test Step 16.
14. Check the Torque on the High-Pressure Lines and Quill Tubes A. Turn the keyswitch to OFF. B. Check the torque on each one of the high-pressure fuel lines and accumulator quill tubes.	Torque	Result: All torque values were within specification. Proceed to Test Step 15. Result: The torque values were not all within specification. Repair: Tighten the lines and/or accumulator quills that were not properly torqued. Proceed to Test Step 16.

Show/hide table




Illustration 3	g06213414
Secondary filter assembly (4) Injector cooling orifice fitting

Show/hide table

Table 6
Troubleshooting Test Steps	Values	Results
15. Check for a Leak into the Injector Cooling Circuit A. Turn the keyswitch to ON. B. Connect Cat ET. C. Disable fuel injection by going to Configuration > System Settings> Fuel Injection Enable Status and set the parameter to "Disabled". D. Turn the keyswitch to OFF. E. Disconnect the injector cooling circuit supply line from the injector cooling supply orifice fitting. F. Cap the injector cooling supply line end with contamination control part number 9U-7079 Tapered Cap/Plug. G. Install a threaded plug on the injector cooling circuit orifice fitting to seal orifice so no fuel comes from the manifold during cranking. Use 6V-9831 Cap As. H. Disconnect the injector cooling circuit fuel return lines from the cylinder heads. The injector cooling circuit return line is on the left side of the cylinder head and connects to the lower injector cooling fuel rail J. Turn the keyswitch to ON. K. Connect Cat ET. L. Crank the engine for 30 seconds for 3 cycles. Note: A prelube cycle must complete prior to allowing the engine to crank on some engines. The prelube cycle could take up to 30 seconds. The engine will only crank for 30 seconds at a time to protect the starter. Then the engine will require 30 seconds to cool back down. M. Inspect each of the injector cooling circuit return ports on the cylinder head for signs of fuel leakage. Note: Fuel leakage may occur, be prepared to collect leaking fuel.	Fuel Leak	Result: There was no fuel leakage detected. Enable fuel injection by going to Configuration > System Settings> Fuel Injection Enable Status and set the parameter to "Enabled". Reconnect all the injector cooling circuit return lines that were removed. Proceed to Test Step 16. Result: A fuel leak from the injector cooling circuit return port was detected. Repair: A quill tube leaking into the injector cooling circuit has been detected. Perform the following procedure: 1. Release the pressure in the high-pressure rail by loosening the end plug on one of the last 2 fuel accumulators. Refer to Testing and Adjusting, "Fuel Rail Pressure - Release" for instructions on how to release the pressurized fuel. 2. Verify that the "Fuel Rail Pressure" reading in Cat ET is 0 ± 8 MPa (1160 psi) prior to servicing the fuel system. 3. Remove the quill tube and the injector and inspect the mating surfaces for signs of damage. Replace if necessary. 4. Reassemble the fuel system. Connect both speed/timing sensors. Proceed to Test Step 16.
16. Perform a "Fuel System Functional Test" A. Connect Cat ET. B. Start the engine. C. Use Cat ET to perform the following test: - "Fuel System Functional Test" D. Once the test has completed, turn the keyswitch to the OFF position. E. Wait for 2 minutes to allow the pump diagnostics to run. F. Connect Cat ET. G. Use Cat ET to monitor the following: - Codes	Test	Result: The test was successful. Return to service.

If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).