10/21/22, 7:15 PM SIS 2.

2022/07/29 Engine Cranks but Does Not Start (M0153279-00)

SMCS - 1000, 1450 i09402449

Probable Causes
Diagnostic codes

Visible faults

Air intake and exhaust system

Speed/timing sensors

Low-pressure fuel system

High-pressure fuel system

Glow Plugs

Valve Lash

Low compression (cylinder pressure)

Recommended Actions

NOTICE
Do not crank the engine continuously for more than 30 seconds.
Allow the starting motor to cool for two minutes before cranking
the engine again.

Note: The procedures have been listed in order of probability. Complete the procedures in order.

Troubleshooting Test Steps Values Results

1. Diagnostic Codes

A. Download the Warranty Report and the Product Status Report with Result: A diagnostic code is present.
Histograms before performing any troubleshooting or clearing any diagnostic
codes. Repair: Troubleshoot the code and then reset the
Diagnostic
histogram.
codes
Note: The downloaded information will be required by the Dealer Solutions
Network (DSN) if troubleshooting assistance is needed. Result: A diagnostic code is not present.
Proceed to Test Step 2.

B. Use the electronic service tool to check for active or logged codes.

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Result: The fuel supply valve (if equipped) is not

in the OPEN position.

Repair: Move the fuel supply valve to the OPEN

position.

Result: The level of fuel, oil, or coolant is not

2. Visible Faults
correct.
A. Check that the fuel supply valve (if equipped) is in the OPEN position.
Repair: Replenish any fluids with an incorrect
level.
B. Check for the correct level of fuel, oil, and coolant.
Result: Water is present in the primary fuel
C. Check for water in the primary fuel filter/water separator.
filter/water separator.
D. If the ambient temperature is below 0 °C (32 °F), check the specification of
Repair: Drain any water from the primary fuel
engine oil and oil for the machine.
filter/water separator.
E. Visually inspect the engine for the following faults:
Visible faults Result: The correct specification of engine oil
and oil for the machine is not in use.
· Missing components
· Damaged components
Repair: Replenish the system with oil of the
· Damaged electrical cables or loose electrical cables
correct specification for the ambient conditions.
· Oil leaks
· Fuel leaks
Result: Battery voltage is low.
· All fuel filters are correctly installed.
Repair: Check the batteries. Refer to
F. Check that the battery voltage is correct.
Troubleshooting, "Battery Problem".
G. Use the electronic service tool to check the average cranking speed of the
Result: The cranking speed is less than 150 rpm.
engine.
Repair: Investigate the cause of the low cranking
speed and rectify, as necessary.

Result: All checks are OK.

Proceed to Test Step 3.

Result: The air filter is restricted.

Repair: Replace the air filter.

3. Air Intake and Exhaust System
Result: There are system restrictions.
A. Check the air filter restriction indicator, if equipped. Air and
Refer to Systems Operation/Testing and
Exhaust
Adjusting, "Air Inlet and Exhaust System" for
B. Check the air intake and exhaust systems for the following defects: System
additional information on the air inlet and exhaust
restrictions
systems.
· Blockages
· Restrictions
Result: The air intake and exhaust system are
· Damage to lines or hoses
OK.

Proceed to Test Step 4.

4. Speed/Timing Sensors Result: The speed/timing sensors are not

operating correctly.

A. Crank the engine and observe the engine speed on the electronic service Repair: Test the speed/timing sensors. Refer to
tool status screen. Refer to Troubleshooting, "Speed/Timing - Test" for Speed/timing Troubleshooting, "Speed/Timing - Test".
additional information. sensor
Result: The speed/timing sensors are operating
Note: Upon initial cranking, the status for engine speed may indicate that the correctly.
engine speed signal is abnormal. This message will be replaced with an engine
speed once the ECM is able to calculate a speed from the signal. Proceed to Test Step 5.

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Result: The fuel tank level is low.

Repair: Fill the fuel tank.

Result: The fuel contains solidified wax.

Repair: Replace the fuel with fuel of the correct

specification for the ambient conditions.

Result: There are fuel supply lines that are

restricted or not correctly installed.

Repair: Install the fuel lines correctly. Replace

any damaged or restricted fuel lines.
5. Low-Pressure Fuel System
Replace the primary fuel filter and the secondary
A. Visually check the fuel tank for fuel.
fuel filters. Refer to the Operation and
Note: The fuel gauge may be faulty.
Maintenance Manual for further information.
B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
Result: There is air in the fuel system.
C. Check the primary filter/water separator for water in the fuel.
Repair: Prime the fuel system. Refer to Systems
Low-
Operation, Testing, and Adjusting, "Fuel System -
D. Check for fuel supply lines that are restricted or not correctly installed. pressure fuel
Prime".
system
E. Check for air in the fuel system and that the fuel system is primed. Refer to
Result: The diesel fuel is contaminated.
Systems Operation Testing and Adjusting , Air in Fuel - Test and Systems
Operation Testing and Adjusting , Fuel System - Prime.
Repair: Drain the fuel tank and the fuel system.
G. Check the diesel fuel for contamination. Refer to Systems Operation,
Replace the primary fuel filter and the secondary
Testing, and Adjusting, "Fuel Quality - Test".
fuel filters. Refer to the Operation and
Maintenance Manual for further information.
H. Check the flow of fuel though the transfer pump.
Fill and prime the fuel system with fuel of the
correct specification. Refer to Systems Operation,
Testing, and Adjusting, "Fuel System - Prime".

Result: The flow of fuel through the transfer

pump is less than 250ml at 150rpm.

Repair: Replace the transfer pump. Refer to

Disassembly and Assembly , Fuel Transfer Pump
- Remove and Fuel Transfer Pump - Install.

Result: The low-pressure fuel system is OK.

Proceed to Test Step 6.

Table 1

Contact with high pressure fuel may cause fluid penetration and
burn hazards. High pressure fuel spray may cause a fire hazard.
Failure to follow these inspection, maintenance and service
instructions may cause personal injury or death.

NOTICE
Ensure that the pressure in the high-pressure fuel system has
been purged before any service or repair is performed on the
high-pressure fuel system.
Refer to Operation and Maintenance Manual, High-Pressure Fuel
Lines for the time taken for the high-pressure fuel system to be
purged.

Troubleshooting Test
Values Results
Steps

6. High-Pressure Fuel System High- Result: The absolute fuel rail pressure is less than 25 MPa (3625 psi).
pressure
A. Use the electronic service tool fuel system Repair: Perform the following procedure:
to check the absolute fuel rail

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pressure while the engine is Check that the inlet pressure at the fuel rail pump is greater than 50 kPa (7.25 psi). If the inlet
cranking at a minimum speed of pressure is less than 50 kPa (7.25 psi), repeat the diagnostic process from Test Step 5.
150 rpm.
Check for fuel leaks in the high-pressure fuel system. Rectify any fuel leaks and then recheck
the pressure in the fuel rail. If the fuel rail pressure is greater than 25 MPa (3625 psi), refer to
the troubleshooting steps below.

Use the electronic service tool to perform a solenoid test on the fuel rail pump. Refer to
Troubleshooting, "Solenoid Valve - Test".

If any service has been performed as a result of referring to the "Solenoid Valve - Test" above,
attempt to start the engine. If the engine will not start, return to Test Step 1.

Check the pressure relief valve in the fuel rail for leakage. If the pressure relief valve is leaking,
replace the valve and recheck the pressure in the fuel rail.

If the pressure relief valve in the fuel rail is not leaking, check for fuel in the engine oil system. If
fuel is suspected in the oil system, take an engine oil sample for analysis. Refer to the
Operation and Maintenance Manual, "Engine Oil Sample - Obtain". If the analysis confirms that
there is fuel in the engine oil system, investigate the cause.

If fuel is not found in the oil system, check the electronic unit injectors for excessive fuel leak
off. Refer to Special Instruction , KENR6938 , "High Leakoff of the Electronic Unit Injector".

If the leak off is greater than 38 mL (1.3 oz) in 30 seconds for a 6 cylinder engine or the leak off
is greater than 25 mL (0.85 oz) in 30 seconds for a 4 cylinder engine, replace the electronic unit
injectors

Note: The fault is not in the fuel rail pump. Do not replace the pump.

If the leak off is less than specified, ensure that the latest flash file for the application is installed
in the ECM. Refer to Troubleshooting, "ECM Software - Install".

Result: The absolute fuel rail pressure is less than 25 MPa (3625 psi).

Repair: Perform the following procedure:

Use the electronic service tool to make sure that the status of the electronic unit injectors is not
"Disabled". If the injectors are disabled but the injectors were not intentionally disabled with the
electronic service tool, ensure that the latest flash file for the application is installed in the ECM.
Refer to Troubleshooting, "ECM Software - Install".

If the electronic unit injectors are not disabled, use the electronic service tool to perform an
injector solenoid test.

If any service has been performed as a result of referring to the "Solenoid Valve - Test" above,
attempt to start the engine. If the engine will not start, proceed to Test Step 7.

Ensure that the latest flash file for the application is installed in the ECM. Refer to
Troubleshooting, "ECM Software - Install".

Contact the Dealer Solutions Network (DSN).

If the DSN recommends the use of a test ECM, install a test ECM. Refer to Troubleshooting,
"ECM - Replace".

Attempt to start the engine. If the engine will not start, install the original ECM and then check
the timing of the fuel pump. To check the timing of the fuel rail pump with the pump installed on
the engine, refer to Special Instruction , M0130765 , Additional Troubleshooting for Engine
Cranks but Will Not Start on Certain C4.4 and C6.6 Engines. To check the timing of the fuel rail
pump not on the engine, refer to Testing and Adjusting , Fuel Injection Timing - Check.

If the engine starts normally, stop the engine and then attempt to start the engine again. If the
engine will not start at the second attempt, replace the ECM again and then replace the fuel rail
pump. Verify that the fault has been eliminated. If the engine will not start, proceed to Test Step
7.

If the engine starts normally, reconnect the suspect ECM and then verify that the fault returns
when the suspect ECM is installed.

If the engine will not start with the suspect ECM, replace the ECM. Check that the engine starts
normally. If the engine starts normally, no further testing is required.

Replace the ECM again and then replace the fuel rail pump. Verify that the fault has been
eliminated. If the engine will not start, proceed to Test Step 7.

Check the timing of the fuel pump. To check the timing of the fuel rail pump with the pump
installed on the engine, refer to Special Instruction , M0130765 , Additional Troubleshooting
for Engine Cranks but Will Not Start on Certain C4.4 and C6.6 Engines. To check the timing of
the fuel rail pump not on the engine, refer to Testing and Adjusting , Fuel Injection Timing -
Check.

If the timing of the fuel rail pump required adjustment and the engine will not start, proceed to

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Test Step 7.

If the timing of the fuel rail pump was correct, replace the fuel rail pump. If the engine will not
start, proceed to Test Step 7.

7. Glow Plugs

Note: Faulty glow plugs will only

affect the production of white
smoke when the ambient
temperature is between 5° C
Result: The glow plugs are not operating correctly.
(41° F) and −25° C (−13° F).
Repair: Make the necessary repairs. Verify that the repair corrected the fault.
A. Check operation of glow plugs.
Glow plugs
Verify that the glow plugs are
Result: The glow plugs are operating correctly.
operating correctly. Refer to
Systems Operation, Testing and
Proceed to Test Step 8.
Adjusting, "Glow Plugs - Test".

B. Check the configuration

screen on the electronic service
tool to verify that ether injection is
not enabled.

Result: The valve lash is not set correctly.

8. Valve Lash
Repair: Check the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Engine
Valve Lash - Inspect" for the correct procedure.
Note: The valve lash can affect Valve lash
the performance of the engine.
Result: The valve lash is correct.
A. Check the valve lash.
Proceed to Test Step 9.

Result: The results of the compression test are outside the specifications.

Repair: Investigate the cause and rectify any faults.

Note: Possible causes of low compression are shown in the following list:
9. Low Compression (Cylinder
Pressure) · Loose glow plugs
· Faulty piston
Cylinder
A. Perform a compression test. · Faulty piston rings
compression
Refer to Systems Operation, · Worn cylinder bores
Testing and Adjusting, · Worn valves
"Compression - Test". · Faulty cylinder head gasket
· Damaged cylinder head

Result: The results of the compression test are OK.

Contact the Dealer Solutions Network (DSN).

Table 2

PIP-11029688
2022/10/21
11:14:48+08:00
i09402449
© 2022 Caterpillar Inc.
Caterpillar:
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