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Topic: U-225 Cummins 5.9 fuel solenoid relay - does not start (Read 949 times) previous topic - next topic

U-225 Cummins 5.9 fuel solenoid relay - does not start

She turns over but no fuel.  It appears that either the Fusible Link or the 70 amp relay for my fuel cut off solenoid has kicked the dust.  My understanding is the the fuel solenoid seldom goes bad, and it is usually the link or relay.  So I called around all the local parts stores to locate a new relay and everyone gave me the old runaround.  Could not find anything locally and most had no idea of what I was talking about.  Even the local Dodge parts desk drew a blank.  Cummins Northeast in Buffalo would not even talk to me without the engine number.  Only place I can find the relay is on line at speciality diesel shops.  Prices for the relay run from $14 to $19 on line.  Read on one of the diesel forums that we 5.9 owners should carry a spare relay (SS70A Fuel Shutoff relay).  The Cummins 5.9 is the same engine that was in all the old Dodge diesel pickups that are still running around out there.  They use the same relay.  One would think that this would be very easy to find?
Here is Barry Leavitt's write up concerning a similar problem with his Cummins 8.3 with one of the parts suppliers:  Fuel Shut Off Solenoid Replacement.  Parts are similar.
1994 U225
build #4514

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #1 –
Pat, That is a standard Cummins Fuel shut off in the post that you referenced.  Does engine start when you manually pull up on fuel shut off lever ? If so wire it open to start it and take It to a shop or take it off and go to parts house.
I had to replace mine, it died, I wired it open and got home so I could replace it.
Be aware that the older models have a different bolt pattern and the new kit will have a new bracket that fits the new shutoff.  Its in a tight place and the rear bolt is a b... to get to but it can be done.
Gary B

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #2 –
Shutoff is okay.  Its the relay and fusible link I need for the shutoff which operates the shutoff.  Had to order it all the way from Wisconsin. 
1994 U225
build #4514

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #3 –
OK, Sounds like something went to ground if fusible link is bad.
Is the relay the standard little cube like relay used in several places in the coach ?  If so you can probably switch one out.  I have these at AC condensor fan, AC Compressor and at other points.
Good luck
Gary B

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #4 –
Parts should be here tomorrow.  And to think, I know folks at the Jamestown Cummins Plant and can't get this stupid relay locally :-[ .
1994 U225
build #4514

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #5 –
I think you'll find it's a standard Bosch relay you can find at any parts house.  Just take yours in.
Regards,
Brett

'99 42' Foretravel Xtreme
'14 Brown Motorsports Stacker
'05 Chevy SSR
'02 BMW R1150R

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #6 –
If it is a Bosch relay, the best price I found was Pep Boys, $5.75 each.
The selected media item is not currently available.Kent Speers
Locust Grove, OK
1993 U300 SSE 40' (Restored at FOT 2009) Build 4323
720 watts Solar
6V92TA DDEC Silver Engine
2014 Subaru Outback

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #7 –
I guess I should swallow my pride and call Foretravel first.  Would you believe that there is not a relay to operate that fuel shut off solenoid.  It powers off the ignation solenoid under the dash.  So it looks like I am going to have to get a new shut off solenoid.  Low voltage is the enemy of those shut off solenoids, and by the time the juice goes from the back of the coach to the front of the coach, and to the back again, one would think that they would have ran a relay to draw power from the batteries that are within 4 foot of that solenoid!  Think seeing that I now have a relay, that I will have to do some re-wiring and add it to the system.
1994 U225
build #4514

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #8 –
Pat,

How much current does the fuel solenoid draw?  Might make a difference as to what relay you use.  If I understand the way it works the solenoid is powered all the time, correct?
John Cooper
'91 GV 36'
Oshkosh chassis
Cat 3208T 300HP

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #9 –
Quote from: John Cooper –
Pat,

How much current does the fuel solenoid draw?  Might make a difference as to what relay you use.  If I understand the way it works the solenoid is powered all the time, correct?
The regular Cummins relay is rated at 70 amp and the fusable link is rated at 65 amp.  That is what is relayed from the battery.  The power that trips it would come from the starter motor relay according to the diagram I have from "LarryB's", a supplier.  The way it is currently wired is direct off the ignition solenoid at the dash without the relay.  I would have to guess that it would be under 65 amps.



It is my understanding that low voltage is the so called killer of the  Cummins Fuel Shut Off solenoid according to all  I have read on the web.  And that is why the relay is used.  Don't know why Foretravel saw fit to go without it considering the distance run and its effect on voltage.
1994 U225
build #4514

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #10 –
PatC,  It might be a case that 18  years  ago before all the corrosion and dirty contacts involoved in the circuit became a problem along with battery age & condition, a relay was not required. I only know the current required to pull the solenoid in is about 15 amps, then the hold in current is about .4 amp, two coils a pull in and a hold in coil.
I know my lil Freightliner FL60 with the 5.9 uses a pull cable to shut down, no electrical solenoid.
Cheers
Dave M

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #11 –
Quote from: Dave M –
I know my lil Freightliner FL60 with the 5.9 uses a pull cable to shut down, no electrical solenoid.
I've considered that, but with a 30 plus foot run, it just does not seem like a simple or cost effective idea.  All the Detroits I've ever driven had a pull cable.  Did the buses have the cable too??
1994 U225
build #4514

Re: U-225 Cummins 5.9 fuel solenoid relay - does not start

Reply #12 –
PatC
Bus setup used a small air solenoid, maybe two depending on what you were trying to do.  A 24 v control, everything was air controlled, fast idle & shutdown.
You think a  Foretravel has a lot of air leak possibilities, Ha Ha, a MCI uses about 6 pages of air drawings for engine control, tag axle, brakes used the DD3 system (Weird system), door lock, wipers, shutters, (you remember shutters?), and the normal compressor, alcohol injection or dryer, wet tank, air tensioners on the belts for alternator and the 9 ton A/C compressor, etc etc and lots more etc.
Very educational with air, electrical, plumbing, a real play house for fools like me, after 20 years, not many surprises left.
Still miss it.
Dave M