Got an '84 crew cab conversion with an '89 engine. The tensioner locked up yesterday & was replaced. It ruined the bearing in the alternator. Replaced it today. Driving it just after the new alt was installed it started smoking, electrical, not the good kind. A minute later it died. Got power everywhere else, just no start.
More info, the column is out of an'86 with a new ignition switch. The harness is ugly from the p.o. Got all kinds of electrical issues, the power sources to the fuse panel are dying, I've jumped a couple to keep accessories working, but it always ran.

 

You have a fuse link problem

 

Check the fusable links between the battery and the hood hinge.

 

With all that electrical nightmare I'd check to make sure you have a Ignition 12V to you shutdown Solenoid. My guess is you have no power there, so motor is essentially shut off.

 

here is a link from the sticky on how to redo the fuse links. https://www.dieseltruckresource.com/...09#post1407509

Hopefully there was a fuse link in there and it wasnt direct power, i didnt think fuse links smoke so that might not be good.

 

Where is the shutdown solenoid located? Is it on the injection pump?

 

Thanks for the replies. I assume I simply follow the posative leads from the battery back to the firewall plug & check for power there in order to determine which links to replace? Also, pardon my ignorance I'm new to the Cummins world, but where exactly is the shutdown solenoid? I assume it's on the injector pump? Finally, I'm looking for a good electrician in Minneapolis if you can recommend one. Thanks again for the help.

 

The shutdown solenoid is at the rear of the pump over top of the injector lines.

 

Sound's like you need a complete wiring harness to replace what you have and clean everything up .

 

Two entirely different scenarios here.

If it turns over and no start then it could be the FSS or fuel switch. Right where Onemoparnut described with two wires going to it.

If it doesn't even turn over and the switch is new then start checking the fusible links etc as described above.

The '89 engine really needs only minimal wiring to start and run.

Good luck.

 

The truck will not crank at all. Going to start bypassing bad fusible links. I like the idea of replacing the entire harness, but where would I source one from? Not sure I trust one from a junk yard. Has anyone gone with a Painless harness with any luck? Also considering replacing all the gages with aftermarket to make the last option easier.

 

If you need to start the truck to move it then you can use a paper clip to jump the two wire connector that's just a few inches down from the positive post to engage the starter. Check to see if there is power at the fss (fuel shutoff solenoid) first.

Can you take a picture of your harness around the fuse links?
where was the smoke coming from when it burned up?
What other electric items do not work in the truck?
What is your auto electrical capability? There are several schematics floating around here to diagnose the electrical systems so you run new wires and add fuse blocks and relays to fix up the weak areas.

 

That right there will help us narrow it down. Unless the harness is just totally cobbled up.

 

Don't go with a "Painless" wiring harness...the are anything but. Keep your eyes on E-bay, and put want ads on the cummins forums looking for a complete wiring harness from a 89...engine and under dash.

If you can't find one quickly, in a couple months I might part with the 89 system on my crewcab...going to all 93 with the 4x4 conversion. PM me if your interested.

 

The starter circuit also has to pass through either a neutral interlock or a clutch interlock switch as well as a starter inhibit switch if there is an alarm installed.
tug on the fuse links and see if any of them stretch.
Jim