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Change the glow plug temperature sensor and see if that corrects the problem. Your GP card thinks the engine is warm enough to start without heating the glow plugs but in fact it is not. Sounds as if you have a defective test lead or did not have a good connection when you tried to force the...

New cards are available Here http://www.glowplugcards.com/ And Here http://www.hillbillywizard.com/cucv-and-k30-parts/cucv-glow-plug-card-new/ You may want to inspect and test each glow plug as well to ensure that all of them are working correctly.

The glow plug relay is located in the engine compartment on the fire wall,drivers side, near the brake system master cylinder.

Some trucks have a "dead zone" where the engine temperature sensor is not providing a resistance value to the glow plug card to turn the glow plugs on. If the resistance from the temperature sensor is low the controller will not send the ground to close the relay. If the resistance from the...

Try manually closing the GP relay for 5-10 seconds the next time the engine is warm and will not start. See if it starts after you turn the glow plugs on for a short period of time. To do this, turn the key to the Run position, take a clip lead and attach it to the terminal on the GP relay with...

Updated photos.

My M1009 set up.

If your card made by BMI is not working, send it back and I will see that it gets repaired.

It is the small green component that is soldered to the board next to the large black 3 terminal transistor and the index slot on the connector edge of the card. The transistor has the stainless steel screw holding it to the board.

http://www.eastwood.com/burgundy-interior-paint-aerosol-12-oz-net.html I have used this on numerous trucks. Works and looks great.

Here is what happened to my GP relay. http://www.steelsoldiers.com/showthread.php?97492-Glow-Plug-Relay-Repair&highlight=

http://www.steelsoldiers.com/showthread.php?72880-Battery-Wiring-Maintenance&highlight= Some other things to check are mentioned in this thread. I suspect you have a bad battery, connection, wire or other issue with the front battery. The GP relay chattering means that it is not getting a...

I installed a small "ice cube" style relay that switches the volt meter connection from the orange wire that monitors the GP voltage to the 12 volt side of the electrical system.

I agree with Tim, it appears that you have a relay that fails under load. This thread shows what can happen inside the GP relay. After the relay was replaced, I added a 2nd voltmeter to monitor the voltage to the glow plugs with a second voltmeter. Post#29 shows pictures of the additional...

6.8 volts is low. It should be much closer to 12 volts. What is the voltage on the other big terminal (on the relay) in the RUN position?

Went to start the M1009 today, no start completely dead. Found the front battery was dead. Connected jumper cables and noticed the GEN1 light was on with no key in the ignition. Got it started and the both voltmeters were low. I have volt meters on the 12 and 24 volt side of the electrical...

Tim, Now we will have to make the "GPD-4" card with the GP system diagnostics and a remote start option! I like your ideas and innovations.

Here is some info on the PA window tinting laws: http://www.tinting-laws.com/pennsylvania/ http://www.cartintlaw.com/pennsylvania/ Putting a camo paint scheme on the rear and back window of a M1009 should be legal in PA. A couple of years ago I tried to camo the rear side windows of my M1009...

Cleaned them with this http://www.eastwood.com/vinyl-prep-aerosol-14-09-net.html And then painted them with this http://www.eastwood.com/burgundy-interior-paint-aerosol-12-oz-net.html

M1010 Clean Up Removed most every thing from the M1010 cab and painted same. Looks much better now.