cucv no power to starter relay

[aspen2hhi]

HI Yesterday I was cutting dass in my m1009 for radio install all the sudden starter started cranking and wires started smoking pulled the battery cables removed starter relay put cables back on no smoke did the doghead relay mod truck fired up everything worked except voltage gauge. all good. today went to install radio the metal case slid through and sparks from the top of relay went to start truck starter wont turn. I tried jumping the rad and purple wire with screw driver nothing got out electrical tester no light on either red or purple. is there a fuse or fuseable before the starter relay
help please

 

[SouthernSteel]

http://www.steelsoldiers.com/showthread.php?t=75505&highlight=wiring+diagram take look at these wiring diagrams these should help ya get started tryin to trouble shoot the starter circuits(Bottom left corner of the pics is the one your after] Good luck warthog and doghead will probably help ya if u ask :]

 

[doghead]

Look at the link posted above, in the second picture(starter circuit), above the word Suppressor, there is a red "thermo wire". Thats the fusible link that supplies the starter relay power. You probably blew that. It is under the hood, on the passenger side connected to the buss bar.

wrong schematic, there SS

 

[doghead]

This one,

 

[mistaken1]

The number one rule when installing electrical gizmos (or doing any electrical work) is to remove the negative wires from both batteries. That prevents the electrical fireworks from appearing right before things stop working.

 

[aspen2hhi]

thanks doghead it is defiantly fried it also had some 3rd party name on it where can I get a replacement is it a napa part

 

[doghead]

Yes,NAPA.

the tm says the fusible link should be 4 gauges higher than the lead it is connected to. The schematic shows the wire it feeds is 16ga, so it looks like you need a 20 gauge fusible link.

like this, http://shop.advanceautoparts.com/webapp/wcs/stores/servlet/product_Fusible-Link-Wire-Carded-Chrysler-20-Gauge-Dorman---Conduct-Tite_22141098-P_N3062A_A%7CGRP2020A___

 

[aspen2hhi]

thanks Doghead I will get one tommarow

 

[Warthog]

To clear up a question from Doghead, on the Starter Relay hot feed wire, the wire to the relay is 3 RED-2Y and the fusible link protecting it is 1 RED-2Z

Using the cheatsheet from the first couple of pages of the Troubleshooting section of the TM 9-2320-289-20 or TM 9-2320-289-34 technical manuals,
the sizes and types of the wires are:

3 RED-2Y (SXL) is a 12 gauge Heavy-walled, high abrasion, cross-link polyethylene

1 RED-2Z (Thermo HW) is a 16 gauge fusible link, heavy-walled, silicone over cross-link polyethylene


So you will need a a 16 gauge fusible link wire.

And for future reference, the wire size of a fusible link is molded into the black plastic barrel connector. In this case you should see a "16" on the flat surface.

Hope this clears up some confusion

 

[doghead]

Thank you Warthog, for the correction. I was looking at the fusible link and thinking that was the wire number, then adding 4 to that gauge number, and came up with 20ga(incorrect).

I should have followed the wires complete path, and I would have seen the correct number for the wire. Then I would have realized the fusible link info was right there and did not need to add 4 gauge sizes to it(oops).

I appreciate your prompt reply.

Sorry for the confusion.

 

[aspen2hhi]

HI Guys
so I changed the fuseable link and started to hook up the batterys and it started smoking is it possible i screwed up the starter relay

 

[Recovry4x4]

Is your radio tray still laying on top of the start relay under the dash? Wasn't that the source of the recent issue?

 

[aspen2hhi]

nothing is touching the relay buy this all started after my radio tray did touch the relay and there were sparks

 

[mistaken1]

12V (or more) of DC acts like a welder. Did you check the circuits you repaired to make sure they are not grounded (or open) somewhere else along the path?

IOW you could have melted some metal onto a terminal that is now more or less fused into a dead short.

 

[aspen2hhi]

so I replaced the link and when i hooked up the battery it started to smoke I have looked for areas where the wires look messed up and cant find anything wrong anyone have a clue where to start

 

[doghead]

Have you looked at your relay? is anything touching it?

You could disconnect the wire at the relay, then connect your batteries and see if you still have a short.

 

[aspen2hhi]

just got done doing that still shorting

 

[doghead]

Better look over that wire, from the buss bar all the way to the relay.

 

[mistaken1]

so I replaced the link and when i hooked up the battery it started to smoke I have looked for areas where the wires look messed up and cant find anything wrong anyone have a clue where to start

What is 'it' that started to smoke?

 

[Warthog]

Try disconnecting the "new" relay and see if you still have smoke when hooking up the batteries.