BJ46 Super GLow- Pre Heating Timer issue

[akifjanjua]

Hi All,

I am in the process of restoring my BJ44.. i got the whole 24v wiring stuff from a JDM BJ46.

TOday we fired the engine for the first time and we got the first fault

As soon as the ignition was turned ON.. the starter engaged!!!! Yes it was shocking .. traced it down to the pre heating timer of the super glow system.. the timer box was quite hot.. unplugged and starter behaved normally.

The white/black stripe current sesing wire is not yet connected.. one of the guys at the shop was telling me to ground it! the diagrams show it connected to the busbar. Can this un connected connection cause this malfunction? Is the timer shot ?

The timer has a 9-pin connector with part no 28521-57010.

Any help guys.. im kinda stuck... dont want to go the wilson switch way.. spent alot on picking up the relays and sensors etc.. want to get the super glow thing to work

 

[lostmarbles]

...As soon as the ignition was turned ON.. the starter engaged!!!! Yes it was shocking .. traced it down to the pre heating timer of the super glow system.. the timer box was quite hot.. unplugged and starter behaved normally.

The white/black stripe current sesing wire is not yet connected.. one of the guys at the shop was telling me to ground it! the diagrams show it connected to the busbar. Can this un connected connection cause this malfunction? Is the timer shot ?

The timer has a 9-pin connector with part no 28521-57010.

Any help guys.. im kinda stuck... dont want to go the wilson switch way.. spent alot on picking up the relays and sensors etc.. want to get the super glow thing to work

WB wires normally are grounds. (All the superglow diagrams I've seen seem to show it used for grounding/earthing.)

Please post pics of your wiring diagrams that show WB wires connected to the busbar?

Where timer wires go "to the busbar", they generally go to either end of a special "sensing resistor" that sits in the main feed to the busbar. And my diagram gives these colour codes as B and BR. ("black" and black/red stripe.)

The timer is connected to the starter relay so incorrect wiring (or perhaps a faulty timer) could cause what you've got.

 

[akifjanjua]

Thanks lostmarbles.. u knw i dont have a clear wiring diagram for this JDM

However this does match with a Later BJ42.. found a diagram on mud but that was unreadable.. I was just looking at one of the diagrams posted by you in a thread that has thsi 8-pin timer without the sensing resistor.. shows WB to ground.. will do that and see if it makes a difference... the wiring is pretty much untempered so i suspect its an internal short that is making the timer go hot and starter crank on ignition

 

[akifjanjua]

Okay.. check all wiring.. it was Okay

Opened up the timer box.. an FET transistor mounted on a heat sink appeared overheated.. changed the FET.. now the glow light isnt coming up

Can anyone through some light on the role of current sensor.. if the current sensor is unplugged will the glow light not come up?? or its only related to glow time

Im working on making a microcontroller based timer device making it a bit easy... lets see how well we do

 

[lostmarbles]

Okay.. check all wiring.. it was Okay

Opened up the timer box.. an FET transistor mounted on a heat sink appeared overheated.. changed the FET.. now the glow light isnt coming up

Can anyone through some light on the role of current sensor.. if the current sensor is unplugged will the glow light not come up?? or its only related to glow time

Im working on making a microcontroller based timer device making it a bit easy... lets see how well we do

I think you are breaking new ground with this work Akifjanjua.

I doubt anyone here is in much of a position to be able to help. Certainly I'm not.

I would like to find out "the intricacies of superglow workings" .. such as the exact role of the current sensor.

I suspect some superglow timers monitor the overall plug current (via that sensing resistor) so they know when the plugs should be glowing brightly (because each plug will draw less current as it gets hotter). But I'm only guessing.

 

[BreckenridgeCruiser]

This may help you understand what is happening.

The current sensor is really sensing resistance in the plugs.

The superglow will send 24v to a 14.5v plug for a few seconds if the resistance is not too high (from an already hot plug). the second time you glow a superglow truck, the light barely comes on before the sensor detects that the plug is already warm and only needs the 12v smoothing glow.

If you have disconnected the sensor, the resistance is infinite and therefore the 24v glow never happens, therefore no light...

 

[bj40green]

This may help you understand what is happening.

The current sensor is really sensing resistance in the plugs.

The superglow will send 24v to a 14.5v plug for a few seconds if the resistance is not too high (from an already hot plug). the second time you glow a superglow truck, the light barely comes on before the sensor detects that the plug is already warm and only needs the 12v smoothing glow.

If you have disconnected the sensor, the resistance is infinite and therefore the 24v glow never happens, therefore no light...

Now this is what I call: Light in the darkness!
Thanks for the explanation.

Rudi

 

[akifjanjua]

Good explanation.. look what i found.. the 9-pin timer box's pinout.. it matches my trace work too.. and its from LJ78's FSM

I did attach the current sensor connector.. but the complete wiring up of busbar remains... need the resistor post to complete

 

[bj40green]

Hi Akif,

I'm very interested in that diagram, especially the explanation text, but it's difficult to read.
Can you, will you or are you able to make one in a Higher Resolution? Or maybe in pdf format? and post it up here (or send to my PM)?

Thanks,

Rudi

 

[akifjanjua]

Rudi, thats the image i got... Copy it to your PC and Zoom in to make it better readable.. worked for me

 

[bj40green]

Rudi, thats the image i got... Copy it to your PC and Zoom in to make it better readable.. worked for me

Akif, that's what I did but then it get's fuzzy / unreadable.
I've sent you an e-mail.

Thanks,

Rudi

 

[BreckenridgeCruiser]

Ak,

Post up a picture of your bus bar and wiring setup so I can compare my working one. I will try to get a picture of mine later today to post up for you....

 

[akifjanjua]

Okay guys.. im badly stuck with the glow system.. everything else is working

Here is a pic of the glow resistor properly wired.. also the current sensor properly connected.

still no glow light not even a blink.. the diagnostic chart says that if the bulb is okay and there is power to the timer and no glow lights means the timer is shot

Any other possibility... what am i missing? For the time being im thinking of adding a wilson switch till i make a microcontroller based timer

 

[bj40green]

I see the busbar but I don't see the cable to the busbar to power the glowplugs, unless it's hooked up somewhere else.

Rudi

 

[akifjanjua]

there are 2 wires that power the busbar.. both are connected to the Resistor or the 5th plug on the intake.. the lower one gives 24v directly to the strip leading to the busbar.. the top ones actuated by the after glow relay gives 24v to the resistor terminal that drops the voltage to 14nish for the after glow... the strip leading to the busbar has the current sensor terminals soldered.. its just a 1.5 ohm resistor that helps the timer know how much current is flowing

but all seems to be Okayy and the timer doesnt work

 

[akifjanjua]

Okay its working I have a fully working superglow system

the mistake was very small.. There is a white/black ground wire hanging in the loom shown in pic.. Although this wire showed continuity to ground but when i grounded it.. It started working

one good thing... Getting superglow to work has made me an expert in these systems many thanks to the great Mud community

 

[bj40green]

Okay its working I have a fully working superglow system

the mistake was very small.. There is a white/black ground wire hanging in the loom shown in pic.. Although this wire showed continuity to ground but when i grounded it.. It started working

one good thing... Getting superglow to work has made me an expert in these systems many thanks to the great Mud community

Yahooooooo! Finally. Good job akif!

Rudi

 

[lostmarbles]

Well done Akif.

We certainly need your knowledge and expertise here!