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Sounds like maybe the PO wired the alternators and batteries in parallel to make it 12V rather than in series. You need to get some paper and trace out every wire that connects to the batteries, alternators and terminal boards (bus) and draw a picture of what is currently connecting to what...

COTS = Common Off The Shelf (meaning not custom designed like a HMMVW). They are just plain jane gm trucks with a modified starting system. My understanding is that the HMMVW is all 24V. Because voltage is EMF (Elctro Motive Force). It is what pushes electrons through things creating...

Discussing something and actually doing something are two different things. Discussing how to do something and the issues involved can lead to a deeper understanding of how the stock systems work and why they are designed the way they are.

These trucks are COTS vehicles. Everything is 12V except the starting system. You have changed the glow plug part of the charging system to 12V. You would have to replace the passenger 12V alternator with a 24V alternator. It would ground to the engine block just like the drivers side does...

It only flickers at idle right after startup? No flickering any other time? May need to rebuild that passenger alternator. Search for warthogs posts about the rebuild kits.

Short circuit current. Fuses are supposed to open to protect wires and components. Fusible links will also open to protect wires and components. You could have open fuses, electrically check them and make they are making good contact in the holder. The fusible links may look good but may be...

When doing electrical work on a vehicle always remove the ground terminal from the battery (or in our cases from all of the batteries). Might want to check ALL of your grounds, especially the one under the dash on the drivers side (above the parking break). When grounds are broken, damaged or...

Doesn't the valve on the IP modulate the vacuum the transmission sees to control shift points?

The dogbone cable between the batteries could be bad.

Fast or slow fuse? A slow fuse can be smaller than a fast fuse. I would think 80A or greater. A fusible link might be cheaper and easier.

I for one am grateful that this site was created just for my benefit and that all the members are here to fix my truck when its broken or find me a part when I need it. Give back? What!! Give back to this site or its members? Are you kidding! I do not have the time or money to give back to...

A short piece of #8 SXL along with #12 fusible link should be fine. The actual amp draw depends on the actual resistance of your glow plugs. You could measure them all with an ohm meter then calculate the current draw. Or go here for an approximation...

Draining a battery too far can ruin it. The front battery may be damaged. I have had a battery fail in such a way that I could not jump start the vehicle with the bad battery connected, I put in a new battery and the vehicle started right up.

Fuel output at the fuel pump? Coincidental failure? Connect a new fuel line to the input side of the fuel pump and put the other end in a fuel can of clean diesel and try priming again. Clogged fuel sock at the tank?

IR2 heating. Resistance in a circuit causes heat as current flows. If the contacts at the 30A fuse are dirty/corroded then there is high resistance at that point. Also loose connections cause high resistance. Resistance equals heat, dirty/loose/corroded contact points are now acting like...

Welcome to the site. Check this link for more information. People here talk about breaking the tip off (if you cannot get it out) and removing the injector to go fishing for the missing piece. There are also tools that can be made/bought to help remove swollen plugs. Steel Soldiers::Military...

Wouldn't most city street lights wash out the light from the blackout lights? In others would anyone even know they were on unless it is really dark and the service lights are off?

What is 'it' that started to smoke?

LMC Trucks is in Lenexa. 15450 W. 108th Street Lenexa, KS 66219 . I believe they have new tailgates. Catalog Search

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.