Electrical problems, Need Assistance

[dobo17]

First post in a long time, but I've spent a long time lurking the steel soldiers forum to build my '84 M1009 to what it is today. I've searched the threads to make sure something like this hasn't already been solved, but I'm sorry if this repeats anything, here it goes...
So about a week ago my batteries were way overdue for replacement, and in my frustration of trying to start it with a dead battery, i turned it over way too many times and was afraid that i had burned out my starter. So i replaced my batteries, and tried to start it... nothing, so i took the starter out, tested it, and found it to be functioning fine, so i cleaned and replaced any corroded ends on all of the battery and starter wires and grounds, and hooked everything back up.
I turned it to the on position, and i didn't hear the click of the glow plug relay turn on, but it turned over fine and started right up, but when it started i could hear the glow plug relay on the fire wall clicking about a hundred times a minute, and then i smelled that familiar burning electronics smell coming from under the dash. So I quickly shut off the engine, and bought a new NAPA st-85 glow plug relay, which is the one recommended on the forum here as a good replacement for the stock one, so i hooked it up like the stock one, and the glow plug wait light took about 30 seconds to turn off, so i turned it over, and after a good bit of turning it finally started, but then the wait light turned back on and stayed on until i turned the truck off.
So I left it for an hour and came back to it to see if it would do it again, and now the wait light just stays on for about a minute, and when i tried to start it, It will not start, no matter how many times the wait light cycles. And I did the doghead starter relay mod when I first got the truck. My question is, do you think that I burned out my new glow plug relay, the starter relay, or my glow plug card is fried, or what else would you suggest that I do next? I figured the collective knowledge of the people of this site would be the best place to turn, and any help would be greatly appreciated.

 

[cpf240]

Sounds like the problem is in the GP system. I would suggest following the GP system trouble shooting section of the -20 TM. A bit of reading, some measurements with a DVM, and the problem should be clear. If that checks out ok per the TM, I'd take a look at the 'cranks but does not start" section of the trouble shooting section.

 

[antennaclimber]

Pull the GP card out of the holder and inspect it for any burned components or burnt traces. Sounds like it may be damaged or defective.

As stated above, read and use the troubleshooting section of the TM.
Karl

 

[doghead]

Test your GPs, fast cycling is often a sign of all bad GPs.

Have you left your key on?

What GPs do you have in it?

Are you still supplying the GP relay with 24v through the stock resistors?

 

[MakersTeleMark]

Sounds like your card is fried. Try grounding the blue wire to the card and see if it cycles your glowplugs.

 

[dobo17]

thanks for the quick replies, i really appreciate the help, so i took out my GP card and it didnt appear fried, so i bought some new AC60g's and installed them yesterday, however when i was changing my glowplugs, i noticed that the glow plug wires were green on every one except for the front left cylinder, which had a larger gauge black wire and a poorly crimped female connector, then i noticed that the green wire was on the temperature sensor next to that glow plug, so it looks like somewhere down the line someone mixed up those 2 wires, i hope that im right in switching them back so the first GP has the green wire.
So i had to jump the truck to start it, and when it started, the resistor bank behind the intake started smoking almost instantly, so i think i will bypass the resistor bank today and try that out,
any opinions on switching the wires or bypassing the resistor bank?

 

[Warthog]

There are two green wires. a fusible link for the glowplug and a darker green for the temp sensor. Where did the black wire connect to? Was it spliced into something else? Can you post a picture?

The resistor pack will smoke if the GP system hasn't worked in awhile. All the dirt and leaf buildup. Bypassing it is a good idea.