Cat 3116 intermittent shutdown

EKM

EKM

Active Member
Feb 4, 2007
674
Beach Haven, NJ
Boat Info
2000 420AC
Engines
Cummins 6CTA
Took my first trip of the year and my port engine shutdown...all the gauges were left in the power position (tach at 2300rpm). The start rocker switch had no clunk (assume that is the fuel SV). First time, I when downstairs and turned off the master switch and it restarted. The second time, I did the same and it would not restart. I pulled the main rotary switch panel off and removed the cables and used 180 wet and dry to make a clean contact (they were not corroded). Put it back together and it started. Still don't think I found the real problem. The first shutdown was in some nasty seas, so that was a real break.

Next is to trace out all the leads and clean the terminals.
Thanks for the suggestions..Ed
 
I had the same problem. It was the relay that powers the fuel shutoff solenoid. It is located in the breaker box that sits on the engine above the transmission in my 99 400DA. Yours might be similar. Very easy to replace. I replaced them on both engines and bought a spare. If I remember correctly it was a Bosch relay that was discontinued but I was able to cross reference it to a tyco part.

Good luck

Pete
 
I'll give that a look....would the dash lose power with a relay failure (gages frozen)?
 
peterkvs said:
I had the same problem. It was the relay that powers the fuel shutoff solenoid. It is located in the breaker box that sits on the engine above the transmission in my 99 400DA. Yours might be similar. Very easy to replace. I replaced them on both engines and bought a spare. If I remember correctly it was a Bosch relay that was discontinued but I was able to cross reference it to a tyco part.
Good luck

Pete
Click to expand...

X2 I had the exact same thing happen! Luckily I was on the way to my dealership for a get together. Had it fixed quickly!
 
I looked at the schematic for the 97 and indeed it does not have this relay. Sorry for sending you on a wild goose chase. However, your intermittent failure may still be loss of power to the fuel solenoid. The power runs from battery to main bat disconnect, then to the starter solenoid, then to a 50 amp circuit breaker, to the dc panel to a 10 amp breaker and the ignition switch, then to the instrument panel and the ignition/start switch, then back to the engine to the fuel solenoid. Any bad connections or flaky components along that path can cause the problem you are seeing.

First check for loose or corroded connections.

While a bit painful, you could swap each switch and breaker from port to starboard and see which component causes the problem to move from one engine to the other.

You can see the schematics on page 112 and 113 here

http://www.searay.com/boat_graphics/electronic_brochure/Company1729/_23_917201090015AM.pdf

Hope this helps

Pete
 
I have a relay lurking at the back of my 3116 engines just above the trans oil cooler. I understand that this is the connection from the dash switch to the fuel solenoid which requires power to run. I am not a marine electrician but have had a harrowing experience from the failure of this relay. This failure causes engine shutdown without warning.
 
I assume you can power the relay with a jumper if you are in trouble and don't have time find the failure point.
 
The great thing about the 3116 is that the only electrical input required to operate the engine is the 12V supply to the Fuel Solenoid. I know of a few people (me included) that keep a wire with a battery clip on one end and an alligator clip (or push on terminal for screws) on the other that is long enough to reach from the battery to the solenoid. In the event that the circuit fails, this jumper wire can get you back up and running in minutes. You just need to know which terminal on the solenoid gets the 12V and which is ground, lest sparks fly.

Pete
 
That's the best thing about diesels; no electrical dependencies per se; just fuel and compression.... boy do I wish I had a diesel
 
The relay is fairly inexpensive. There was another thread here with the numbers.
 
there is a relay on top of the trans cooler (to the starboard side). I assume this is the relay to power the fuel SV (and yes, the fuel SV looks pretty pricey). I was thinking about picking up a replacement relay. Does anyone know the PN for a 97 vintage 3116. It is a larger relay than the 1998 and later 3116's.
I do have a wire on board just in case.
Thanks....Ed
 
It is not much more than a Ford starter solenoid rated for constant rather then intermittant use. They do not fail as frequently as the little molded relays do, but you should be able to cross one over at your local auto parts house.....or get to googling!
 
Yes....looks like a starter relay. It sounds like a connection problem to be tracked down.
 
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