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Old 06-15-2018, 01:07 PM   #1
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Cummins 5.9 12v crank no start no fuel

Ok so here is my dilemma.
Bus has been sitting for a couple of months while I work on it. I have started it periodically just to make sure everything was working. I attempt to start it now and it cranks over but doesn't start.

Through my troubleshooting I discovered there's no fuel going to the injectors I loosened up an injector line and cranked but ....no fuel I tried the manual pump pushed that thing about a hundred times.... no fuel. I loosened up the bleed valve on the fuel filter again .....no fuel. I had my wife try to turn over the engine while I went underneath next to the tank to see if the fuel pump was even kicking on. I could not hear anything no humming so it sound like there was no power to the pump.

I trace the wires back and found that the fuel pump wires was fused to the muffler I cut them and repaired the wires I took a voltmeter and as I had the ignition on there was 7 volts going to the wires where they were fused I went to the top of the tank in that little access hole and the voltmeter read 4 volts which to me seems very low to power a fuel pump. I don't see a way to remove the fuel pump either it looks like it's built into the tank.

Anyway I'm at a loss any brainstorming ideas would help, thanks.
Tom
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Old 06-15-2018, 01:14 PM   #2
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Seven (or four) volts isn't gonna get it. Have you checked the grounds on the pump? And where exactly are you measuring, across the incoming wires or ???

Sounds to me like the circuit is floating, with a high resistance or open circuit on the ground.
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Old 06-15-2018, 01:42 PM   #3
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So this is the top of my tank through the access panel. These wires are the only to wires going to the tank so I figured these are the wires to the pump but again I'm guessing. The configuration is odd to me I expected to see a larger pump head that can be removed.

I put voltmeter on those wiresIMG_20180615_113830.jpeg
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Old 06-15-2018, 01:53 PM   #4
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Ok. Check each wire's voltage to a clean spot on the bus frame where you can get a good ground. 4v across the pump means, in a 12v system, you have 8 volts going somewhere else. If the voltages measured to frame are 12 and 8, you have a bad ground. If they're 4 and zero, you have a bad circuit feeding the pump.
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Old 06-15-2018, 02:07 PM   #5
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Guys, that's not a pump. That's the fuel sender. It's what tells the gauge the fuel level.
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Old 06-15-2018, 02:09 PM   #6
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The lift pump on a 6bt is mechanical and is located on the side of the block.
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Old 06-15-2018, 02:24 PM   #7
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Ok well I'm learning stuff so this is good. So there is no electrical fuel pump in 96 Cummins 5.9 12v

So that pump with a manual plunger appears to be the lift pump. This is what I was manually pumping in effort to get fuel to the injectors. IMG_20180615_122013.jpeg
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Old 06-15-2018, 02:29 PM   #8
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If there is one, it's aftermarket.

It's hard to tell from your picture but I would assume that that is the lift pump.

Open the bleed at the filter and pump that until you get fuel.

If you don't get fuel, either the tank is empty, fuel line between the tank and pump is leaking, or the pump is junk.
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Old 06-15-2018, 03:05 PM   #9
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Well then. So much for that troubleshooting sequence.
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Old 06-15-2018, 03:57 PM   #10
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Okay I ran to the gas station and filled up all the fuel cans I had and put 10 gallons in. I opened up the bleeder valve on top of the fuel filter..... I tried turning it over and manually pumping the transfer pump again no fuel. I follow the lines from the tank all the way to the engine and I did not see any leaks or wet spots so I think they're good.

So process of elimination I should try to replace the lift pump? And cross my fingers?
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