Cummins 5.9 stalled and wont start. Injector pump?

[clayhubler]

Hi all,

Need a little help on this one. 1994 Safari Sahara with the magnum chassis. Cummins 5.9 230 HP and the Allison MD 3060 tranny. Engine stopped on a hill, would not restart. I feel like it didn't have full power right before it died, but that may just be in my head.
This coach is new to us.
Everything is working, engine cranks, just doesn't fire, so I suspected it wasn't getting fuel. After some time, I have determined that fuel is getting to the injector pump, but not going to the cylinders. I cracked the inlet line on the injector and fuel is pumped out when cranking engine. When I loosened the fitting on the injector itself, I don't get any fuel.
I know very little about troubleshooting the pump itself. The next thing I am going to try is to check the fuel shutoff solenoid. I'm hoping that is it, but I won't know until friday when I have time to look into it.
Does anybody have any other suggestions? Also, I would like to confirm the purpose of the shutoff solenoid. My understanding is that it shuts off when the ignition circuit is shut off. Therefore I should get 12v at the terminals when the key is on, correct? If I have 12v there, then I need to determine if the solenoid is actually operating, which I should hear or feel. If not I will have to pull it to visually verify that it is operating. Can somebody please confirm this process for me?
FYI I have above average mechanical skills, but little experience with engines, especially diesels.

Thanks in advance, any help is greatly appreciated.

[Ava]

Hi, gswcgi I was looking up lift pumps on eBay for my 5.9 Cummins. They were all about $50.00. On mine there are a couple of bolts and the fuel line to remove and replace. That would take a mechanic less than an hour to do. I hope they did other work for the $1800.

[gswcgi]

It just happened to my Cummins 5.9 with 167,000 miles on it. It was a lift pump. Cost $1,800. to fix !!

[wolfe10]

path1 wrote:
Copied from 1994 service manual.


ENGINE CRANKS, BUT WILL NOT START and NO SMOKE FROM EXHAUST
No fuel in supply tank.
Electrical fuel shutdown solenoid not open.
Air intake or exhaust plugged.
Fuel filter plugged.
Excessive fuel inlet restriction.
Injection pump not getting fuel or fuel is aerated.
Inoperative lift pump.
One or more injectors worn or not operating properly.
Worn or inoperative injection pump.
Internal pump timing incorrect.
Camshaft out of time.

THIS is where to start.

[path1]

Copied from 1994 service manual.


ENGINE CRANKS, BUT WILL NOT START and NO SMOKE FROM EXHAUST
No fuel in supply tank.
Electrical fuel shutdown solenoid not open.
Air intake or exhaust plugged.
Fuel filter plugged.
Excessive fuel inlet restriction.
Injection pump not getting fuel or fuel is aerated.
Inoperative lift pump.
One or more injectors worn or not operating properly.
Worn or inoperative injection pump.
Internal pump timing incorrect.
Camshaft out of time.

[1320Fastback]

Fuel Stop Solenoids are famous for having the rubber tip break off and plug up a passage somewhere.

On my truck I gutted it long go and run a manual shut down cable.

Also check power to solenoid is there, a faulty ignition or wire could de activate it.

[Ava]

I hope it is just plugged filters. We had a loss of power recently going up hill or when pushing the throttle down hard. Changed out the two fuel filters, one on engine and one bigger one in the back and all was well again after system was bled. I have a 5.9 Cummins / Allison trans as well. Good luck

[MrWizard]

leave the ignition off
slide underneath
look at the injector pump
while someone steps on the throttle
is the cable linkage to the input control valve moving ?

IF no cheap fix
IF yes, then the injector pump may have died
or the lift pump died, its a lot cheaper to replace

i had the injector pump replaced this time last year, late may 2016
they cost about $4500 for a rebuild, here in L.A. and that is just the pump, not the labor

there are some on ebay a LOT cheaper, the trouble is Matching it up with what you have
its the same pump body, but different (parts/plungers?) depending on which version of the 5.9 you have
the 190hp 230Hp, or larger
mine is the 230hp

hope it is one of the cheaper fixes