glow plug wire question

[ericwade381]

Wanted to see if I could get some advice on this..the po put some heavy copper wire in near my large fusible line on the glow plug wiring harness. Aby way the plastic fusable link is burnt and smokes some when I warm the glow plugs up. Now the thing the green wire on the fender solenoid that runs down near that passenger side headlight it eventually turns black with orange stripes that wire is getting seriously hot smokes and turns red. Should I trace this down to make sure it's not grounded or is this a glow plug issue? What does this wire do? It did it before when I would only charge the batteries ?

 

[FoolhardyIDI]

Picture of the situation are worth a thousand words.

 

[ericwade381]

Will do sorry forgot to post

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Green wire off solenoid that's the worst issue

 

[ericwade381]

Burned wire

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[ericwade381]

http://www.oilburners.net/forums/sh...w-plug-harness-smoking&highlight=wire+smoking

 

[FoolhardyIDI]

My old harness started to smoke and melt so this is what I did to correct the problem.

 

[FoolhardyIDI]

Is the burnt wire the one that goes on the top small post of the solenoid?

 

[ericwade381]

It's actually on the bottom of it if I can remember right it is one of the green wires I think there are two tied together

 

[ericwade381]

Has a rubber boot plug on one end that goes to the solenoid

 

[icanfixall]

My old harness started to smoke and melt so this is what I did to correct the problem.

This is the classic wires too damn small for the glow plug solenoid. Many years ago some bean counter engineer figured out it was cheaper to run 2 small gauge wires instead of one heavy gauge wire to handle the load. You see this all the time on the steel towers carrying power from hydro to sub stations of our home or business electrical. Now this may look good on paper till you reduce the capasity thru this main engine wire harness plug. Any corrosion or dirt in that plug. Even a loose fitting male to female plug will create plenty o heat. then the plug smokes. Some car fires have burned down our truck because of this. My fix was bypass the plug with some heavy speaker wire found at any radio install shop. I used some 6 gauge wire that had the huge amount of wire strands in it. I purchased new lugs that can carry the load too. Crimped and soldered them. Now I have a direct feed fron the fender solenoid to the plug controller. Fast heat ups and no more fire risk. Just cut loose the 2 wires that normally fed the controller. No real need to take them out of the harness either. Should you ever need to remove the engine again just install a disconnect or remove the new wire you have installed.

 

[ericwade381]

Thanks for the info! So is the real culprit the two yellow wires that foolhardy had taken a picture of that causes the smoking? Should I replace the wire on my solenoid with a bigger gauge wire or is the problem in the wiring harness it's self?

 

[OLDBULL8]

Is the burnt wire the one that goes on the top small post of the solenoid?

No the battery power wire goes on one of the large posts. If you put the battery power wire on a small post, you could have destroyed the controller or relay.

 

[ericwade381]

Foolhardy what kind of connectors are they that you used

 

[FoolhardyIDI]

I used a male and female connector of what is in the picture. I have had zero problems with it hooked up this way.

 

[ericwade381]

I replaced all of my burned wires today which one from the junkyard and use these electrical connectors pretty heavy duty everything seems to be working good now keeping my fingers crossed!

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