Engine Cranks but Will Not Start

SMCS - 1000-035; 1400-035

Probable Causes
The ignition shutdown switch is in the OFF position.
Electrical connectors or power supply
Fuel supply or carburetor
No signal from the speed/timing sensor
EIS control module
Ignition system

Recommended Repairs
Ignition Shutdown Switch

Refer to Troubleshooting, "Ignition Shutdown Circuit".

Electrical Connectors or Power Supply

There may be an intermittent interruption of power. Check the wiring harnesses and
the connectors. Inspect the connectors in the terminal box. Inspect the power supply
connections and the ground.

Inspect the wiring from the power supply to the EIS control module. Check the power
and ground connections. Refer to Troubleshooting, "Electrical Power Supply".

Fuel Supply

Make sure that fuel is supplied at a sufficient pressure that is stable. Make sure that
the size of the fuel line is sufficient. Inspect the fuel system for leaks.

The following conditions can cause the engine to malfunction:

Low fuel pressure

High fuel pressure
Poor fuel quality
Make sure that the fuel pressure is correct. When possible, interview the operator in
order to determine if fuel quality is in question. Try to determine if the source of the
fuel was changed.

Inspect the fuel system components: fuel filter, gas pressure regulator, gas shutoff
valve and fuel metering valve. Verify that the system's components are operating
correctly.

Replace the fuel filter, if necessary.

No Signal from the Engine Speed/Timing Sensor

Make sure that the speed/timing sensor is installed correctly. Refer to

Troubleshooting, "Engine Speed/Timing Sensor".

Make sure that the timing wheel is correctly installed.

EIS Control Module

Verify that the control module is working properly. Refer to Troubleshooting,

"Control Module Self Test".

Electrical Connections to the Ignition System

Inspect the ignition transformers for the following conditions:

Loose connections
Moisture
Short circuits
Open circuits

Inspect the primary wiring and the secondary electrical connections.

Make sure that the correct transformers and spark plugs are installed. Inspect the
extenders for signs or pin holes and arcing.

Maintain the spark plug according to Operation and Maintenance Manual, "Ignition
System Spark Plugs - Check/Adjust/Replace".

Make sure that the ignition timing is correct.

Troubleshooting
G3400 Engines (EIS)

Media Number -SENR6535-06 Publication Date -01/10/2014 Date Updated -09/10/2014

i02320559

Engine Speed/Timing Sensor

SMCS - 1912-038

System Operation Description:

The speed/timing sensor provides information about engine speed and the position of
the crankshaft to the control module for the Electronic Ignition System (EIS). The
sensor is powered by a sensor supply (13 VDC) from the control module. A magnetic
pickup is located in the plastic sliphead of the sensor. The timing ring is mounted on
the governor drive shaft. As the teeth of the ring rotate past the sliphead of the sensor,
the sensor generates a signal that matches the pattern of the teeth.

The timing ring has a special tooth pattern that indicates the position of the camshaft
and the direction of rotation. When the engine rotates in the normal direction, the slots
pass the speed/timing sensor in a particular order.

With the information from the engine speed/timing sensor, the EIS control module is
able to calculate the positions of the pistons in the cylinders. The control module
determines the desired ignition timing according to the engine speed. If detonation is
detected, the control module retards the timing. The control module sends voltage
pulses to the ignition transformers for firing the spark plugs according to the desired
timing.

During engine operation, the control module will shut down the engine if the module
detects a problem with the signal from the speed/timing sensor. The control module
will also generate a diagnostic code.

If there is a problem with the engine speed/timing sensor's signal during start-up but
no diagnostic code is generated, the control module will not initiate the ignition. The
engine will not start. The corresponding diagnostic code is not generated.

The most likely causes of the diagnostic code are a poor electrical connection or a
problem in a wiring harness. The next likely cause is a problem with the engine
speed/timing sensor. The least likely cause is a problem with the EIS control module.
Test Step 1. Inspect the Electrical Connectors and Wiring.

A. Set the engine control to the OFF/RESET mode. Remove the electrical power
from the engine.

Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical

Connectors".

B. Thoroughly inspect the following connections:

o EIS connector
o Connectors for the speed/timing sensor\

Front view of the G3412C engine

(20) Speed/timing sensor

(21) 70 pin connector

 a. Check the harness and wiring for abrasion and for pinch points from the
speed/timing sensor to the control module.

b. Perform a 45 N (10 lb) pull test on each of the wires that are associated
with the circuit for the speed/timing sensor.

Expected Result:

The connectors, pins, and sockets are connected properly. The connectors and the
wiring do not have corrosion, abrasion, or pinch points.

Results:

OK - The components are in good condition with proper connections. Proceed

to Test Step 2.
Not OK - The components are not in good condition and/or at least one
connection is improper.

Repair: Perform the necessary repairs and/or replace parts, if necessary.

STOP

Test Step 2. Check for a Diagnostic Code

A. Restore the electrical power to the engine.

B. Connect the Digital Diagnostic Tool (DDT) or the Caterpillar Electronic

Technician (ET) to the service tool connector.

C. Clear any diagnostic codes.

D. Configure the electronic service tool to view the engine rpm.

E. Observe the engine rpm and set the engine control to the "START" mode.
Crank the engine.

F. Continue to observe the engine rpm and allow the engine rpm to stabilize at the
normal cranking speed.

G. Set the engine control to the "STOP" mode.

Expected Result:
Before the engine is cranked, the engine speed is "0". The engine speed increases until
the speed stabilizes at the normal cranking speed. When the engine is stopped, the
speed decreases back to "0". There are no diagnostic code for the engine speed/timing
sensor.

Results:

OK - The engine started and the engine ran properly. There are no diagnostic
code for the speed/timing sensor. The speed/timing sensor is operating
properly.
STOP
Not OK - The engine cranked. However, the electronic service tool did not
display the correct engine speed or a diagnostic code was activated. If the
engine speed is incorrect and there is no diagnostic code, proceed to Test Step
5. If a 320-05 diagnostic code or a 320-08 diagnostic code is activated, proceed
to Test Step 3. If a 320-07 diagnostic code is activated, proceed to Test Step 7.

Test Step 3. Check for an Open Circuit

A. Disconnect the following connectors:

o EIS connector
o Connector for the speed/timing sensor

B. Measure the resistance between the points that are listed in Table 1. During
each measurement, wiggle the wires in the harness in order to check for an
intermittent problem. Be sure to wiggle the wires near each of the connectors.

Table 1
Resistance Measurements for the Harness for the Speed/Timing Sensor
Terminal on the Connector for the
Terminal on the EIS Connector
Speed/Timing Sensor
EISC-Z (Ground for the speed/timing
B (Ground)
sensor)
EISC-J (13 VDC for the speed/timing A (13 VDC for the engine speed/timing
sensor) sensor)
EISC-O (Engine speed/timing
C (Engine speed/timing signal)
signal)

Expected Result:
Each check of the resistance is less than 2 Ohms.

Results:

OK - Each check of the resistance is less than 2 Ohms. The wiring does not
have an open circuit. Proceed to Test Step 4.
Not OK - At least one check of the resistance is greater than 2 Ohms. There is
an open in the wiring for the speed/timing sensor.

Repair: Repair the connection and/or the wire, when possible. Replace parts, if
necessary. Verify that the problem is resolved.

STOP

Test Step 4. Check for a Short Circuit

A. Measure the resistance between the points that are listed in Table 2. During
each measurement, wiggle the wires in the harness in order to check for an
intermittent problem. Be sure to wiggle the wires near each of the connectors.

Table 2
Resistance Measurements for the Speed/Timing Sensor
Terminals on the EIS Connector
All of the remaining terminals on the EIS
EIS-Z (Ground for the speed/timing connector
sensor)
The housing for the EIS connector
All of the remaining terminals on the EIS
EISC-J (13 VDC for the speed/timing connector
sensor)
The housing for the EIS connector
All of the remaining terminals on the EIS
EISC-O (Engine speed/timing signal) connector
The housing for the EIS connector

Expected Result:

Each check of the resistance is greater than 2 Ohms.

Results:
 OK - Each check of the resistance is greater than 2 Ohms. The wiring does not
have a short circuit. Proceed to Test Step 5.
Not OK - At least one check of the resistance is less than 2 Ohms. The wiring
for the speed/timing sensor has a short circuit.

Repair: Repair the connection and/or the wire, when possible. Replace parts, if
necessary. Verify that the original problem is resolved.

STOP

Test Step 5. Check the Sensor

A. Remove the speed/timing sensor.

B. Inspect the condition of the plastic sliphead. Look for signs of wear and for
contaminants. Clean any debris from the plastic sliphead.

C. Check the tension of the plastic sliphead. Gently extend the plastic sliphead for
a minimum of 4 mm (0.16 inch). Then push back the plastic sliphead.

Expected Result:

The sensor is in good condition. At least 22 N (5 lb) of force is required to push in the
plastic sliphead from the extended position.

Results:

OK - The sensor is not damaged. The tension of the plastic sliphead is correct.
 Repair: Install the sensor.

NOTICE
The plastic sliphead must be fully extended when the speed/timing
sensor is installed so that the sensor maintains the correct clearance
with the timing ring. If the correct clearance is not maintained, the
signal from the sensor will not be generated.

Do not install the sensor's plastic sliphead between the teeth of the
timing ring. Damage to the plasic sliphead will result. Before installing
the sensor, ensure that a tooth of the ring is visible in the mounting
hole for the sensor.

1. Use the following steps to install the speed/timing sensor:

a. Ensure that a tooth on the timing ring is visible in the mounting
hole for the sensor.

b. Fully extend the sliphead.

Note: The plastic sliphead is designed to contact the tooth of the

timing ring during installation. As the timing ring begins to turn,
the radial runout of the timing ring will push the plastic sliphead
into the sensor body slightly. This provides the plastic sliphead's
air gap with a self-adjusting function. The maximum allowable
clearance between the sliphead and a tooth on the timing ring is
0.5 mm (0.02 inch).

c. Coat the threads of the sensor with 4C-5597 Anti-Seize

Compound .

d. Install the sensor. Tighten the sensor to 40 5 Nm (30 4 lb ft).

STOP

Not OK - The plastic sliphead is damaged and/or the tension of the sliphead is
insufficient.

Repair: Install a new sensor. Calibrate the sensor. Refer to Troubleshooting,

"Engine Speed/Timing Sensor - Calibrate".

If the condition is not resolved, proceed to Test Step 6.

Test Step 6. Perform a Self Test of the EIS Control Module

A. Perform the self test for the EIS control module. Refer to Troubleshooting,
"Control Module Self Test".

Expected Result:

The self test was successful.

Test Step 7. Check that the Timing Ring is Installed Correctly

A. Manually rotate the engine in the direction of normal rotation until the 7/16
inch timing bolt can be threaded into the timing ring.

Note: If the timing bolts fits into the threads of the timing ring it is very likely
that the timing ring is installed correctly. The threads do not extend past the
timing ring. When the timing bolt is threaded into the timing ring, cylinder 1 is
at the top center position.

If the timing bolt does not fit into the threads of the timing ring perform the
following steps.

B. Check the timing ring.

C. Remove the magneto and remove the cover for the governor drive housing.
Ensure that the timing ring is installed and/or installed correctly.
Expected Result:

The timing bolt fits into the threads of the timing ring.

Results:

OK - The timing ring is installed correctly.

Repair: The 320-07 diagnostic code was caused by one of the following
conditions:

o The engine was cranking in the reverse direction.

o The engine was running in the reverse direction.

Check the driven equipment and make repairs. Verify that the original problem
is resolved.

STOP

Not OK - The timing ring is installed incorrectly.

Repair: Install the timing ring correctly. Refer to the engine's Disassembly and
Assembly manual for the correct procedure for installation of timing ring.

Connecting the Digital Diagnostic Tool (DDT) to the

Junction Box
1. Connect cable (1) to the service tool connector on the engine mounted
junction box.

2. Connect cable (2) to cable (1) .

3. Connect DDT (3) to cable (2) .

The other connector on cable (2) is not used.

4. Set the engine control to the STOP mode.

If the DDT does not communicate with the EIS control module, refer to
Troubleshooting, "Electronic Service Tool Will Not Communicate With ECM".