4/29/2016

924HZWheelLoaderJZZ00001UP(MACHINE)POWEREDBYC6.6Engine(SEBP513119)Systems&Components

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Welcome:m620mam5
Product:WHEELLOADER
Model:924HZWHEELLOADERJZZ
Configuration:924HZWheelLoaderJZZ00001UP(MACHINE)POWEREDBY
C6.6Engine

Troubleshooting
C6.6EnginesForCaterpillarBuiltMachines
MediaNumberKENR539206

PublicationDate01/03/2014

DateUpdated26/03/2014
i03633565

EngineCranksbutWillNotStart
SMCS1000035

ProbableCauses
Machinefaults
Diagnosticcodes
Visiblefaults
Airintakeandexhaustsystem
Primaryspeed/timingsensor
Lowpressurefuelsystem
Secondaryspeed/timingsensor
Highpressurefuelsystem
Glowplugs
Etherinjectionsystem
Valvelash
Lowcompression(cylinderpressure)

RecommendedActions
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924HZWheelLoaderJZZ00001UP(MACHINE)POWEREDBYC6.6Engine(SEBP513119)Systems&Components

NOTICE
Donotcranktheenginecontinuouslyformorethan30seconds.Allow
thestartingmotortocoolfortwominutesbeforecrankingtheengine
again.

MachineFaults
1.MakesurethattheMachineSecuritySystemisnotpreventingtheenginefromstarting.
2.Checkforanyfaultsonthemachinethatcouldpreventtheenginefromstarting.
3.Ifafaultisfoundonthemachine,rectifythefault.
4.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"DiagnosticCodes".

DiagnosticCodes
Useoneofthefollowingmethodstocheckforactivediagnosticcodes:
Thedisplayonthecontrolpanel
Theelectronicservicetool
DisplayontheControlPanel
Note:Thefollowingprocedureisonlyapplicableiftheapplicationisequippedwithadisplayonthe
controlpanel.
1.Checkthedisplayonthecontrolpanelforactivediagnosticcodes.
2.Troubleshootanyactivecodesbeforecontinuingwiththisprocedure.RefertoTroubleshooting,
"TroubleshootingwithaDiagnosticCode".
3.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"VisibleFaults".
ElectronicServiceTool
1.Connecttheelectronicservicetooltothediagnosticconnector.
2.Checkforactivediagnosticcodesontheelectronicservicetool.
3.Investigateanyactivecodesbeforecontinuingwiththisprocedure.RefertoTroubleshooting,
"TroubleshootingwithaDiagnosticCode".
4.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"VisibleFaults".

VisibleFaults
1.Visuallyinspecttheengineforthefollowingfaults:
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924HZWheelLoaderJZZ00001UP(MACHINE)POWEREDBYC6.6Engine(SEBP513119)Systems&Components

Missingcomponents
Damagedcomponents
Damagedelectricalcablesorlooseelectricalcables
Oilleaks
Fuelleaks
2.Checkthefollowingitems:
Checkforsmokefromtheexhaustwhentheengineiscranking.Ifsmokeisseenduring
cranking,theremaybeamechanicalfaultintheengine.Referto"LowCompression
(CylinderPressure)".
Checkfortheproperleveloffuel,oilandcoolant.
Ensurethatthefuelsupplyvalve(ifequipped)isinthefullOPENposition.
Iftheambienttemperatureisbelow0C(32F),makesurethatthecorrectspecificationof
engineoilandoilforthemachineisused.
Checkthatthebatteryvoltageiscorrect.
Usetheelectronicservicetooltochecktheaveragecrankingspeedoftheengine.Ifthe
crankingspeedislessthan150rpm,investigatethecauseofthelowcrankingspeed.
Makesurethatallfuelfiltersarecorrectlyinstalled.
Drainanywaterfromtheprimaryfuelfilter/waterseparator.
3.Rectifyanyfaultsthatarefoundduringthevisualchecks.
4.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"AirIntakeandExhaust
System".

AirIntakeandExhaustSystem
1.Usetheelectronicservicetooltocheckforanairfilterrestriction.
2.Ensurethattheairfilteriscleanandserviceable.
3.Checktheairintakeandexhaustsystemsforthefollowingdefects:
Blockages
Restrictions
Damagetolinesorhoses
4.Repairanydefectsbeforeattemptingtorestarttheengine.
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924HZWheelLoaderJZZ00001UP(MACHINE)POWEREDBYC6.6Engine(SEBP513119)Systems&Components

5.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"PrimarySpeed/timingSensor".

PrimarySpeed/timingSensor
1.DisconnectconnectorP401fromtheprimaryspeed/timingsensor.
2.Attempttostarttheengine.
3.Iftheenginestarts,checkforafaultinthecircuitfortheprimaryspeed/timingsensor.Referto
Troubleshooting,"EngineSpeed/TimingSensorCircuitTest".
4.Iftheenginedoesnotstart,inspectthetimingringonthecrankshaftformisalignment.
5.Ifnecessary,repairthetimingring.RefertoDisassemblyandAssembly,"CrankshaftTimingRing
RemoveandInstall".
6.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"LowPressureFuelSystem".

LowPressureFuelSystem
1.Ifthetemperatureisbelow0C(32F),checkforsolidifiedfuel(wax).
2.Checkforfuelsupplylinesthatarerestricted.
3.Checkthatthelowpressurefuellinesarecorrectlyinstalled.
4.Checkthedieselfuelforcontamination.RefertoSystemsOperation,TestingandAdjusting,"Fuel
QualityTest".
5.Checkforairinthefuelsystem.RefertoSystemsOperation,TestingandAdjusting,"AirinFuel
Test".
6.Ensurethatthefuelsystemhasbeenprimed.RefertoSystemsOperation,TestingandAdjusting,
"FuelSystemPrime".
7.Attempttostarttheengine.Iftheenginewillnotstart,continuewiththisprocedure.
8.Replacetheprimaryfuelfilterandthesecondaryfuelfilter.RefertotheOperationand
MaintenanceManual,"FuelSystemPrimaryFilter(WaterSeparator)ElementReplace".
9.Attempttostarttheengine.Iftheenginewillnotstart,continuewiththisprocedure.
10.Checktheflowoffuelthroughthetransferpump.Iftheflowoffuelthroughthetransferpumpis
lessthan250mLperminuteat150rpm,replacethetransferpump.RefertoDisassemblyand
Assembly,"FuelTransferPumpRemove"andDisassemblyandAssembly,"FuelTransferPump
Install".
11.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"SecondarySpeed/timing
Sensor".

SecondarySpeed/timingSensor
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924HZWheelLoaderJZZ00001UP(MACHINE)POWEREDBYC6.6Engine(SEBP513119)Systems&Components

1.Connecttheelectronicservicetooltothediagnosticconnector.
2.Checkthatthedesiredfuelrailpressureisatleast25MPa(3625psi)whentheengineiscranking.
3.Ifthedesiredfuelrailpressureislessthan25MPa(3625psi),performthefollowingprocedure:
a.Usetheelectronicservicetooltocheckthesignalfromthesecondaryspeed/timingsensor
whiletheengineiscranking.
b.Ifthesignalfromthesecondaryspeed/timingsensoris0rpm,investigatethesecondary
speed/timingsensor.RefertoTroubleshooting,"EngineSpeed/TimingSensorCircuitTest".
c.Ifafaultisidentifiedinthecircuitforthesecondaryspeed/timingsensor,repairthefaultand
thenattempttostarttheengine.Iftheenginewillnotstart,proceedto"HighPressureFuel
System".
d.Ifthesignalfromthesecondaryspeed/timingsensorisgreaterthan0rpmandtheengine
willnotstart,proceedto"HighPressureFuelSystem".

HighPressureFuelSystem
1.Usetheelectronicservicetooltochecktheabsolutefuelrailpressurewhiletheengineiscranking
ataminimumspeedof150rpm.
2.Iftheabsolutefuelrailpressureislessthan25MPa(3625psi),performthefollowingprocedure:
a.Checkthattheinletpressureatthefuelrailpumpisgreaterthan50kPa(7.25psi).Ifthe
inletpressureislessthan50kPa(7.25psi),repeatthediagnosticprocessfrom"Low
PressureFuelSystem".
b.Checkforfuelleaksinthehighpressurefuelsystem.Rectifyanyfuelleaksandthenrecheck
thepressureinthefuelrail.Ifthefuelrailpressureisgreaterthan25MPa(3625psi),
proceedtoteststep3.
c.Usetheelectronicservicetooltoperformasolenoidtestonthefuelrailpump.Referto
Troubleshooting,"FuelRailPumpSolenoidTest".
d.IfanyservicehasbeenperformedasaresultofStep2.c,attempttostarttheengine.Ifthe
enginewillnotstart,repeatthediagnosticprocessfrom"DiagnosticCodes".
e.Checkthepressurereliefvalveinthefuelrailforleakage.Ifthepressurereliefvalveis
leaking,replacethevalveandrecheckthepressureinthefuelrail.
f.Ifthepressurereliefvalveinthefuelrailisnotleaking,checkforfuelintheengineoil
system.Iffuelissuspectedintheoilsystem,takeanengineoilsampleforanalysis.Referto
theOperationandMaintenanceManual,"EngineOilSampleObtain".Iftheanalysis
confirmsthatthereisfuelintheengineoilsystem,investigatethecause.
g.Iffuelisnotfoundintheoilsystem,checktheelectronicunitinjectorsforexcessivefuel
leakoff.RefertoSpecialInstructionKENR6938,"HighLeakoffoftheElectronicUnit
Injector".
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924HZWheelLoaderJZZ00001UP(MACHINE)POWEREDBYC6.6Engine(SEBP513119)Systems&Components

h.Iftheleakoffisgreaterthan38mL(1.3oz)in30seconds,replacetheelectronicunit
injectors.
Note:Thefaultisnotinthefuelrailpump.Donotreplacethepump.
i.Iftheleakoffislessthan38mL(1.3oz)in30seconds,proceedtoTestStep3.d.
3.Iftheabsolutefuelrailpressureisgreaterthan25MPa(3625psi),performthefollowing
procedure:
a.Usetheelectronicservicetooltomakesurethatthestatusoftheelectronicunitinjectorsis
not"Disabled".Iftheinjectorsaredisabledbuttheinjectorswerenotintentionallydisabled
withtheelectronicservicetool,proceedtoteststep3.d.
b.Iftheelectronicunitinjectorsarenotdisabled,usetheelectronicservicetooltoperforman
injectorsolenoidtest.RefertoTroubleshooting,"InjectorSolenoidCircuitTest".
c.IfanyservicehasbeenperformedasaresultofStep3.b,attempttostarttheengine.Ifthe
enginewillnotstart,proceedto"GlowPlugs".
d.MakesurethatthelatestflashfilefortheapplicationisinstalledintheECM.Referto
Troubleshooting,"FlashProgramming".
e.ContactthetechnicalcommunicatorattheCaterpillardealer.
Note:Thisconsultationcangreatlyreducetherepairtime.
f.IfthetechnicalcommunicatorrecommendstheuseofatestECM,installatestECM.Refer
toTroubleshooting,"ReplacingtheECM".
g.Attempttostarttheengine.Iftheenginewillnotstart,installtheoriginalECMandthen
proceedtoTestStep3.l.
h.Iftheenginestartsnormally,stoptheengineandthenattempttostarttheengineagain.Ifthe
enginewillnotstartatthesecondattempt,proceedtoTestStep3.k.
i.Iftheenginestartsnormally,reconnectthesuspectECMandthenverifythatthefaultreturns
whenthesuspectECMisinstalled.
j.IftheenginewillnotstartwiththesuspectECM,replacetheECM.Checkthattheengine
startsnormally.Iftheenginestartsnormally,nofurthertestingisrequired.
k.ReplacetheECMagainandthenreplacethefuelrailpump.Verifythatthefaulthasbeen
eliminated.Iftheenginewillnotstart,proceedto"GlowPlugs".
l.Checkthetimingofthefuelrailpump.RefertoSystemsOperation,TestingandAdjusting,
"FuelInjectionTimingCheck".
m.Ifthetimingofthefuelrailpumprequiredadjustmentandtheenginewillnotstart,proceed
to"GlowPlugs".
n.Ifthetimingofthefuelrailpumpwascorrect,replacethefuelrailpump.Iftheenginewill
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notstart,proceedto"GlowPlugs".

GlowPlugs
Note:Faultyglowplugswillonlyaffectenginestartingwhentheambienttemperatureisbetween25C
(13F)and+10C(+50F).
1.Checktheoperationoftheglowplugs.RefertoSystemsOperation,TestingandAdjusting,"Glow
PlugsTest".
2.Ifnecessary,replacefaultyglowplugs.RefertoDisassemblyandAssembly,"GlowPlugRemove
andInstall".
3.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"EtherInjectionSystem".

EtherInjectionSystem
Note:Afaultintheetherinjectionsystemwillonlyaffectenginestartingwhentheambienttemperature
isbelow25C(13F).
1.Checktheoperationoftheetherinjectionsystem.RefertoTroubleshooting,"EtherInjection
SystemTest".
2.Ifnecessary,replacefaultycomponents.
3.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"ValveLash".

ValveLash
1.Checkthevalvelash.RefertoSystemsOperation,TestingandAdjusting,"EngineValveLash
Inspect/Adjust".
2.Attempttostarttheengine.Iftheenginewillnotstart,proceedto"LowCompression(Cylinder
Pressure)".

LowCompression(CylinderPressure)
1.Performacompressiontest.RefertoSystemsOperation,TestingandAdjusting,"Compression
Test".
2.Iflowcompressionisnotedonanycylinders,investigatethecauseandrectifythecause.
Possiblecausesoflowcompressionareshowninthefollowinglist:
Looseglowplugs
Faultypiston
Faultypistonrings
Worncylinderbores
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924HZWheelLoaderJZZ00001UP(MACHINE)POWEREDBYC6.6Engine(SEBP513119)Systems&Components

Wornvalves
Faultycylinderheadgasket
Damagedcylinderhead
3.Performallnecessaryrepairs.
4.Ensurethattherepairshaveeliminatedthefault.
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