Question on wiring an Alternator - Defender Source
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  #1  
Old November 12th, 2015, 07:33 AM
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Question on wiring an Alternator

I purchased a new alternator and from what I can tell it is the same alternator that was removed, but I am having some issues.

I installed the wiring but when I start the engine, what I believe is the - wire gets super hot immediately and will smoke a little. I also saw a little smoke in the cabin around the volt meter. I have three wires, +, - and a D+ wire going into the alternator.

I did take a picture of the old alternator before I removed it. The new alternator has no markings for + or -, only markings for D+. I assumed based on my picture of the old one and based on the new one that the + post is larger in diameter than the - post coming out of the alternator.

Here is the info on the alternator (for a 3.5):

Alternator - A127/65Ref: STC234Application: Defender 2.5NA, Turbo Diesel and
200 TDI - S/s from RTC5845 - Also Defender V8 S/s
from PRC2668
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  #2  
Old November 12th, 2015, 08:17 AM
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There should only be three wires. One is a tach signal wire, if you dont have a tach this simply dead ends behind your dash- that goes to the post labeled 10. One is the wire to the charge light on the dash. The third is the large charge wire/heavy brown. There is no ground although some will run a ground to the outer housing. In theory the alternator should be grounded fine through its mounts to the engine.

The heavy gauge brown wire is not a ground it is the positive and runs around to the positive terminal on the starter which then links to the battery. Brown is typically un-switched power on land rovers. Black is ground.
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Old November 12th, 2015, 08:30 AM
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I have red, yellow and white wires and no tach has ever been hooked up. My new alternator does not have any markings, except for D+. What would case one of the wires to get hot?

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Old November 12th, 2015, 08:36 AM
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Here are the pictures of the old one before I removed
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Old November 12th, 2015, 08:39 AM
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If your original alternator was a 45 amp and your new one is considerably higher output the harness gauge may not be sufficient to handle. A heavy gauge wire from the charge post on the alternator to the starter positive will provide the additional capacity.
Small gauge white should be tach signal.

Looking @ your pictures. Which wire is getting hot ? Based on your picture the red is the charge wire and goes to the positive on the starter. Yellow should be to the charge lamp on the binnacle.
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Old November 12th, 2015, 08:47 AM
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Thank you!

I have no idea what amp the old alternator was.

So you are recommending the red wire (+) go to a hire gauge? Any recommendation on the wire gauge I should use?

Also can I just leave the white wire disconnected?

So what does the yellow wire do, it is hooked up to the D+ post?

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Old November 12th, 2015, 08:57 AM
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rather than change your red I would suggest running an additional heavy wire to handle the load. Rather than run one heavy gauge wire the oem harness used two wires clamped in the same connectors @ ea end to keep the harness flexible.

Your wiring doesnt appear to be original. Just went and looked @ my sons 83 and all the wires in the OE wiring harness to the alternator are brown.
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Old November 12th, 2015, 07:10 PM
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I disconnected what I think is the tach wire. When running the engine that wire is a hot wire when I check it and the post on the alternator is also hot, probably why it was getting warm when it was connected. I think there are 2 positive post on the back the of the alternator. So if my volt meter on the dash is up around 14 does that mean my battery is charging or is there another way to check to see if my battery is actually charging? Thanks for responding electrical is not my strong point.
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Old November 13th, 2015, 07:40 AM
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The blue circles in the picture is the terminal that I have not hooked anything to. What is a single phase terminal used for? Should I have a wired hooked up to it?
So far I just have the + and D+ hooked up.


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Old November 13th, 2015, 09:00 AM
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The single phase terminal is for a tachometer.
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Old November 15th, 2015, 06:43 AM
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Thank you, I am up and running, the alternator is charging the battery.
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