Manual glow plug switch.

notenuftime

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So I want to wire in a manual glow plug switch. From what I gather all I have to do is disconnect the white wire on the GP controller, connect my two leads off my switch one ground one to where the white wire connected. Then disconnect the blue wire and done?
 

Farmer Rock

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If you want your wait to start to work when the GPs are activated, then when you cut the blue wire, lengthen the longer side of that wire (not the side the enters the controller) then use a terminal ring and connect that wire on the same terminal as the GP harness. Other wise, it pretty simple and well worth it. Use a "quality" switch, and i use that term lightly. Also install an inline fuse. 20 amp will be fine, since the switch probably won't be rated for much more than that.



Rock
 

nelstomlinson

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If you want your wait to start to work when the GPs are activated, then when you cut the blue wire, lengthen the longer side of that wire (not the side the enters the controller) then use a terminal ring and connect that wire on the same terminal as the GP harness. Other wise, it pretty simple and well worth it. Use a "quality" switch, and i use that term lightly. Also install an inline fuse. 20 amp will be fine, since the switch probably won't be rated for much more than that.

Rock
Rock, in your second diagram, could things be simplified a little more by connecting the terminal with the red wires directly to the terminal with the yellow wires (connecting the top two terminals together), and cutting off the red wires entirely? That way the controller is entirely out of the picture except as a mount for the relay.

Or is leaving the red wires in place going to allow the controller to function normally as long as you hold down the switch in dash?
 

Farmer Rock

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What gauge wire should I use?
you can use 14ga. There isn't many amps running through those wires.
Rock, in your second diagram, could things be simplified a little more by connecting the terminal with the red wires directly to the terminal with the yellow wires (connecting the top two terminals together), and cutting off the red wires entirely? That way the controller is entirely out of the picture except as a mount for the relay.

Or is leaving the red wires in place going to allow the controller to function normally as long as you hold down the switch in dash?
Rock, in your second diagram, could things be simplified a little more by connecting the terminal with the red wires directly to the terminal with the yellow wires (connecting the top two terminals together), and cutting off the red wires entirely? That way the controller is entirely out of the picture except as a mount for the relay.

Or is leaving the red wires in place going to allow the controller to function normally as long as you hold down the switch in dash?
I don't see why not, but I don't think it's worth doing that while using the factory style relay/controller.This diagram is meant to work with the factory setup. If that is what you are looking to do, you will be better off with a fender mount setup, You could just use the factory style relay and buzzbar and just mount them on the fenderwell. I might be doing this soon to my f250,


Rock
 

rhkcommander

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I gutted all the wiring to and from the controller myself...

With that relay you have two big posts and two little posts. One big post is connected to the battery positives, the other goes to the glowplugs. One little post is a ground, like an upside down T, and the other is the signal/switch post with an S.

I made a little relay jumper from big battery + post to the little switch post. Then all you do is run a wire from the little ground to the dash and, get a nice momentary button, attach to it and then run a wire from it to any ground.

Then you only have 1 wire in the cab, and its a ground wire so if it shorts it'll kill your plugs maybe but won't arc/spark and start a fire like a positive could. Its also very easy to wire up that way.

16 gauge should be good either way, 14 if you want. Either way it needs to be stranded, solid wire will break over time due to bending and vibration. and if you go running a positive wire the signal post doesn't draw anywhere near 20 amps, I'd recommend something like 5 amps. If you do get a short you want the fuse to blow before you catch on fire, oversized fuses are harder to blow.


You can splice into the old wait to start light if you want that, all I did instead was put a LED next to my switch, use a wire from the switch for the negative, and added a resistor to the positive before tapping into a positive somewhere. It is ground actuated. I think I have pictures here somewhere of my control panel I made with momentary starter and glowplugs, and toggle reverse lights and fog light switches. I used a flashing LED for the reverse lights so I wouldn't forget leaving them on.
 

Farmer Rock

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A 20 amp fuse will blow when a dead short is at play, and so will a 30. That is what they are for. If you have a 20 amp switch, the fuse should be 15 amp. you should have around a 5 amp safety so the fuse blows.



Rock
 

rhkcommander

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A 20 amp fuse will blow when a dead short is at play, and so will a 30. That is what they are for. If you have a 20 amp switch, the fuse should be 15 amp. you should have around a 5 amp safety so the fuse blows.



Rock

True, a hard short should blow a fuse. If the short isn't "dead enough" and draws 29.99 amps the fuse won't blow but something could light off from the arcing/heat generated - my wild butt guess is 12v x 30a = 360w of energy in one tiny area can be bad. Rare I know, especially if everything is sized appropriately. Thats most of the point of having fuses to begin with. But I've heard a fair few stories of IDIs let alone other vehicles catching on fire, some of which were likely electrical fires. Some were exhaust fires from brush etc, but still. I've never seen a used idi with a clean engine bay, they look like the Exxon Valdez, and I assume the hood liner is flammable but again that's just an assumption.

Fuse sizing depends on wire size too. I prefer to size my fuses based on the load additionally with the extra safety you mentioned, a relay draws minimal power from the signal post is all I'm getting at. I'm on my phone or I would upload the 12v wire gauge guide, it should show maximum amperage for wire gauge, at different lengths, with different efficiency losses. The longer the wire, the less load it can handle. If I get some spare time I'll try to test how much power it takes to actuate the relay, but I'm sure its very little since that's the point of relays.
 

Farmer Rock

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@rhkcommander . I agree with that. I also use appropriate sized wire for each job. Around 30amp, then I use 10ga, if 20 I use 14ga, and if 10 or under I use 16ga. Quality of wire is big difference as well. I try to by rolls of wire from Lowe's or home depot, instead of the parts store, since there wire seems to always be 2ga smaller than it should be, or is advertised as.




Rock
 

ISPKI

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Make sure to use a good heavy duty momentary switch, not those cheapo plastic ones on amazon. Had one of those stick on me a few months after install, had to rip the wires out of it to shut off the GPs. Ended up replacing it with a heavy duty weather proof industrial push button. Been going good for about 4 years now.
 

rhkcommander

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I used Bulgin Anti Vandal push button switches, they are spendy but very reliable and durable.

You can get them momentary, latching with or without LED rings. Ip 66 or 68 rating and tough.
 

RuzzL

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If the controller is fried, the relay is probably not great either.
I ousted my melted controller and just wired a simple relay with the existing harness. I put my momentary switch between the 'wait to start' light and ground, since it's already in the dash (blue wire), to make the low amp side of the glow plug relay. Indicator lights up and crusty glow plugs work great.
 
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masonb101

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So I want to wire in a manual glow plug switch. From what I gather all I have to do is disconnect the white wire on the GP controller, connect my two leads off my switch one ground one to where the white wire connected. Then disconnect the blue wire and done?

hey man if you dm me your phone number I will send you a video of how I did my and how to set it up proper
 

ttman4

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If you want your wait to start to work when the GPs are activated, then when you cut the blue wire, lengthen the longer side of that wire (not the side the enters the controller) then use a terminal ring and connect that wire on the same terminal as the GP harness. Other wise, it pretty simple and well worth it. Use a "quality" switch, and i use that term lightly. Also install an inline fuse. 20 amp will be fine, since the switch probably won't be rated for much more than that.



Rock
(View Attachment above is @Farmer Rock posted pic of GP Manual set-up)

#1......I got glow plug set-up questions:

Several yr ago I was at Ford House, asked how to set up manual GPlugs. Mechanic said "Cut black ground wire coming out of bottom of controller, run thru push button switch inside of cab, then run to good ground."
I did & done this since mid '90s. What is wrong with this way vs above pic set-up?

Question #2:
How can I test to see if GP Controller is good or not?
Question #3:
How to test GP Relay is good or not?

I got couple complete GP Controllers that I think may not be good, how to test/check them?
 

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