C175 Tier 4 Final Engines for Off-Highway Trucks Caterpillar

Engine Cranks but Does Not Start

Usage:

793F D3T

Use this procedure to troubleshoot an engine that cranks but does not start.

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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.

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Table 2
Associated Codes
J1939	CDL	Procedure
1382-15	E1129 (1)	Fuel Filter Is Restricted
1382-16	E1129 (2)	Fuel Filter Is Restricted
157-18	E398 (1)	Fuel Flow Is High
157-18	E398 (2)	Fuel Flow Is High
1440-0	E1106 (3)	Fuel Flow Is High
1440-15	E1106 (1)	Fuel Flow Is High
1440-16	E1106 (2)	Fuel Flow Is High
3551-0	N/A	Oil Pressure Is Low
5584-0	N/A	Fuel Pressure Is Low
5578-14	E390 (3)	Fuel Filter Is Restricted
5584-15	E390 (1)	Fuel Filter Is Restricted
5584-16	E390 (2)	Fuel Filter Is Restricted
5585-17	E1220 (1)	Fuel Flow Is High

Probable Causes

Codes
Driven Equipment
Batteries
Slow Cranking Speed
Starting Aids (if equipped)
Keyswitch Power
ECM Power Supply
Fuel System
Fuel Priming System
Fuel Pressure
Internal High-Pressure Fuel Line

Recommended Actions

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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 A. Inspect the equipment being driven by the engine. B. Check any damage to the components or the linkage between the engine and 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. If the problem is not resolved, 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. Inspect the charging system circuit to verify that the charging system is working. Verify that the alternator is working charging the batteries. If the problem is not resolved, proceed to Test Step 4.
4. Check for Slow Cranking Speed A. Connect Cat ET to the service tool connector. B. Use Cat ET to monitor the following when cranking the engine: - Engine speed Check to make sure that the engine cranking speed is greater than 100 RPM.	Engine speed	Result: The engine speed is greater than 100 RPM. Proceed to Test Step 5. Result: The engine speed is less than 100 RPM. Check for the following problems: - Low voltage for an electric starting system - Low air pressure for an air start system - Excess parasitic load - Engagement all starters on a multiple starting motor system - Hydraulic starters and the supply pump - Starting signal being sent from controller Repair: Repair or replace the damaged components. If the problem is not resolved, 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 are functioning. Proceed to Test Step 6. Result: One or more of the starting aids is not functioning correctly. Repair: Repair or replace damaged starting aid components. If the problem is not resolved, 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. If the problem is not resolved, 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.	ECM Power Supply	Result: The battery supply power is greater than 18 VDC to all ECM pins. Proceed to Test Step 8. Result: The battery supply power is less than 18 VDC on one or more pins. Repair: Refer to Troubleshooting, "Electrical Power Supply - Test" for additional information.
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 full OPEN position. 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. Remove the accumulator plugs at the joints that were serviced. Perform a "Fuel System Function Test" in Cat ET. If the problem is not resolved, proceed to Test Step 9.
9. Check the Fuel Priming System A. Connect Cat ET to the service tool connector. B. Prime the fuel system. Refer to the OEM / OMM for additional information. C. Verify the "Fuel Transfer Pump Intake Pressure" is reading greater than 300 kPa (43.5 psi).	300 kPa (43.5 psi)	Result: The "Fuel Transfer Pump Intake Pressure" is greater than 300 kPa (43.5 psi). Proceed to Test Step 10. Result: The "Fuel Transfer Pump Intake Pressure" is less than 300 kPa (43.5 psi). Low fuel pressure during priming has been detected. Refer to Troubleshooting, "Fuel Priming Pump - Test" for additional information. The electrical circuit to the priming pump may be damaged, or the priming pump has failed.

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Illustration 1	g06101717
(1) Starting priority valve (2) System pressure regulator

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Table 4
Troubleshooting Test Steps	Values	Results
10. Check the Fuel Pressure A. Connect Cat ET to the service tool connector. B. Monitor the "Fuel Pressure" when cranking. C. 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. Remove the low-pressure fuel system pressure regulator from the secondary fuel filter auxiliary manifold and actuate the spool of the cartridge assembly. 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 resolved the issue. Return to service.
11. Check Fuel Rail Pressure During Cranking A. Connect Cat ET to the service tool connector. B. Monitor the "Fuel Rail Pressure" while cranking. C. The "Fuel Rail Pressure" should read above 20 MPa (2900 psi).	Fuel Rail Pressure	Result: The "Fuel Rail Pressure" is above 20 MPa (2900 psi). Proceed to Test Step 15. Result: The "Fuel Rail Pressure" is below 20 MPa (2900 psi). Proceed to Test Step 12.
12. Check for Internal High-Pressure Fuel Line Leaks A. Turn the keyswitch to OFF. B. Disconnect the fuel double wall fuel return line between the check valve and the high-pressure junction block. C. Place the double wall fuel return line 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 high-pressure fuel return line disconnected from the check valve at the junction block. Proceed to Test Step 13. Result: There was no leakage from the fuel return line. Verify that the repair resolved the problem. Return to service.
13. 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 Value	Result: All torque values were within specification. Proceed to Test Step 14. Result: The torque values were not all within specification. Repair: Tighten the lines and/or accumulator quills that were not properly torqued. Remove the accumulator plugs at the joints that were serviced. Perform a "Fuel System Function Test" in Cat ET. Verify that the repair resolved the problem. Return to service.

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Illustration 2	g06041456
HP accumulator-quill (3) Leak detection plug/port

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Table 5
Troubleshooting Test Step	Value	Result
14. 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: There was no leak detected. Proceed to Test Step 15. Result: A leak was detected on the accumulator quill tube leak port. Repair: A high-pressure leak has been detected. Determine the cause if the leak. Refer to Step 8 in Troubleshooting, Fuel Flow Is High. Proceed with the troubleshooting procedure from Step 8 until the root cause is determined.
15. Check Fuel Rail Pressure During Cranking A. Connect Cat ET to the service tool connector. B. Monitor the "Fuel Rail Pressure" while cranking. C. The "Fuel Rail Pressure" should read above 20 MPa (2900 psi).	Fuel Rail Pressure	Result: The "Fuel Rail Pressure" is less than 20 MPa (2900 psi). Proceed to Test Step 16.

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Illustration 3	g06190342
(4) Injector Cooling Orifice Fitting

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Illustration 4	g06088551
(5) Return Lines (6) Supply Lines

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Table 6
Troubleshooting Test Step	Value	Result
16. Check for a Leak into the Injector Cooling Circuit A. Turn the keyswitch to the ON. B. Connect Cat ET. C. Disable the fuel injection using the procedure below: 1. Click "Configuration". 2. Click "System Settings". 3. Click "Fuel Injection Enable Status". 4. Set the parameter to "Disabled". D. Turn the keyswitch to the OFF. E. Cap the injector cooling supply line end with contamination control part number 9U-7079 Tapered Cap/Plug. F. 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. G. Disconnect the injector cooling circuit fuel return lines from the joints to 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 H. Turn the keyswitch to the ON position. I. Connect Cat ET. J. 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. K. 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 the fuel injection using the procedure below: 1. Click "Configuration". 2. Click "System Settings". 3. Click "Fuel Injection Enable Status". 4. Set the parameter to "Disabled". Reconnect all the injector cooling circuit return lines that were removed. Proceed to Test Step 17. 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. 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. Verify that the "Fuel Rail Pressure" reading in ET is 0 ± 8 MPa (1160 psi) prior to servicing the fuel system. Remove the quill tube and the injector and inspect the mating surfaces for signs of damage. Replace if necessary. Reassemble the fuel system. Connect both speed/timing sensors. Proceed to Test Step 17.
17. Perform a "Fuel System Functional Test" A. Remove the accumulator plugs at the repaired joints. B. Turn the keyswitch to the ON position. C. Connect Cat ET. D. Start the engine. E. Perform the "Fuel System Functional Test". F. Once the test has completed, turn the keyswitch to the OFF position to allow the pump diagnostics to run. G. Wait for 30 seconds once the engine has stopped, and then Turn the keyswitch to the ON position. H. Connect Cat ET. I. Check for active diagnostic codes.	Test Successful	Result: The "Fuel System Functional Test" passed successfully and there are no active codes. Repair complete.

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).