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Product: EXCAVATOR
Model: 320D EXCAVATOR FAL
Configuration: 320D & 320D L Excavators FAL00001-UP (MACHINE)
POWERED BY C6.4 Engine

Troubleshooting
C4.2 and C6.4 Engines for Caterpillar Built Machines
Media Number -KENR5342-04 Publication Date -01/10/2007 Date Updated -08/10/2007

i02627534

Engine Cranks but Does ot Start

SMCS - 1000-035; 1450-035

Probable Causes

Diagnostic codes and event codes

Engine speed/timing

Electrical connectors

Air intake and exhaust system

Air inlet heater

Fuel supply

Cylinder performance

Electronic control system

High pressure fuel system

Recommended Actions

OTICE
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.

Diagnostic Codes and Event Codes

Certain diagnostic codes and/or event codes may prevent the engine from starting. Connect Caterpillar
Electronic Technician (ET) and check for active codes and/or for logged codes. Troubleshoot any active
codes that are present before continuing with this procedure.

ote: If there are any active diagnostic codes for the machine security system, verify that the lamp for the
machine security system is illuminated. If the lamp for the machine security system is illuminated, the
machine security system is armed. Deactivate the machine security system and try to start the engine.

ote: If a E390 Fuel Filter Restriction is logged and/or active, replace the fuel filters.

ote: If a E198 Low Fuel Pressure is logged and/or active, refer to the symptom Troubleshooting, "Fuel
Pressure Is Low".

Engine Speed/Timing

The diagnostic codes for the engine speed/timing are disabled during engine cranking. The status of the
engine speed/timing sensors can be viewed on the "No Start" parameters page while using Cat ET with the
engine cranking. The diagnostics for the engine speed/timing will be enabled after the engine is running.

If both speed sensors are detected, check the fuel rail pressure. Refer to Systems Operation/Testing and
Adjusting.

If the fuel rail pressure is less than 18000 kPa (2611 psi), use Cat ET to perform the"Fuel Pump Solenoid
Test". If the fuel pump fails the test, determine whether the fault is caused by the wiring, the ECM or the fuel
pump. .

Electrical Connectors

Check for correct installation of the J1/P1 and J2/P2 ECM connectors. Check for correct installation of all
other applicable connectors. Refer to service Troubleshooting, "Electrical Connectors - Inspect".

Air Intake and Exhaust System

1. Check the air filter restriction indicator, if equipped. Clean plugged air filters or replace plugged air
filters. Refer to the Operation and Maintenance Manual.

2. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting.

Air Inlet Heater

ote: A faulty air inlet heater will only affect engine starting when the ambient temperature is below 10 °C
(50 °F).

1. Check the operation of the air inlet heater. Refer to Systems Operation/Testing and Adjusting.

2. If necessary, replace the air inlet heater. Refer to Disassembly and Assembly.

Fuel Supply

1. Visually check the fuel level. Do not rely on the fuel gauge only. If necessary, add fuel. If the engine
 has been run out of fuel, it will be necessary to purge the air from the fuel system. Refer to Operation
and Maintenance Manual.

2. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.

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.

Do not loosen any high pressure fuel lines when the engine is running.
The high pressure in the fuel lines can cause personal injury or death.
Wait 60 seconds after the engine has stopped to allow pressure to purge
before any service or repair is performed on the engine fuel lines.

3. Check the fuel lines for the following problems: restrictions, collapsed lines, pinched lines and loose
connections. If problems are found with the low pressure fuel lines, repair the lines and/or replace the
lines. If the high pressure fuel lines have a leak, the high pressure fuel lines must be replaced. Refer to
the Disassembly and Assembly manual.

OTICE
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.

4. Prime the fuel system if any of the following procedures have been performed:

 Replacement of the fuel filters

 Service on the low pressure fuel supply circuit

 Replacement of unit injectors

ote: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer to
Testing and Adjusting.

5. Check the fuel tank for foreign objects which may block the fuel supply.

6. Check the fuel filters.

7. Check the diesel fuel for contamination. Refer to Systems Operation/Testing and Adjusting.
 8. Cold weather adversely affects the characteristics of the fuel. Refer to the Operation and Maintenance
Manual for information on improving the characteristics of the fuel during cold weather operation.

Cylinder Performance

1. Perform a compression test. Refer to Systems Operation/Testing and Adjusting. Possible causes of low
compression are shown in the following list:

 Faulty piston

 Faulty piston rings

 Worn cylinder bores

 Worn valves

 Faulty cylinder head gasket

 Damaged cylinder head

Electronic Control System

1. Use Cat ET to monitor the status of the parameters when the engine is cranking.

2. If a speed sensor is not detected, refer to the circuit test Troubleshooting, "Speed/Timing - Test".

Make sure that any repairs have eliminated the problem.

High Pressure Fuel System

Escaping fluid under pressure, even a pinhole size leak, can penetrate
body tissue, causing serious injury, and possible death. If fluid is
injected into your skin, it must be treated immediately by a doctor
familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

Do not loosen any high pressure fuel lines when the engine is running.
The high pressure in the fuel lines can cause personal injury or death.
Wait 60 seconds after the engine has stopped to allow pressure to purge
before any service or repair is performed on the engine fuel lines.

Use Cat ET to monitor a stable fuel rail pressure during engine cranking.
If the fuel rail pressure is less than 18000 kPa (2611 psi), perform the following procedure.

1. Use Cat ET to perform the"Fuel Pump Solenoid Test". If the fuel pump fails the test, determine
whether the fault is caused by the wiring, the ECM or the fuel pump.

2. Test the function of the fuel rail pressure sensor. Refer to the circuit test Troubleshooting Guide,
"Sensor Signal (Analog, Active) - Test".

3. Check the pressure relief valve in the fuel rail for leaks. If the pressure relief valve is leaking, replace
the fuel rail.

ote: Disconnect the return line to the fuel transfer pump from the cylinder head. It will be necessary
to plug the return line to the transfer pump before cranking the engine.

OTICE
If the return line off of the transfer pump is not plugged fuel will leak
out of the line.

4. Crank the engine and measure any leakage from the injectors at the cylinder head. If the leakage at a
minimum engine cranking speed of 150 RPM is greater than 0.1 L/min (0.2 Pints/min), replace all of
the electronic unit injectors.

5. Install a test ECM. Refer to service Troubleshooting, "Test ECM Mode".

6. Use Cat ET to perform the "Injector Solenoid Test". If necessary, refer to the circuit test
Troubleshooting, "Injector Solenoid - Test".

7. Check the timing from the fuel pump to the engine. Refer to Systems Operation/Testing and
Adjusting.

8. If the problem is still apparent, replace the fuel injection pump. Refer to Disassembly and Assembly.

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