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TR4/4A TR4A alternator conversion wiring question

Hi Randall - I pulled the brown/green wire and light is still on. Grounded the brown/green wire and light stayed on.

I have never connected it wrong, but I bought this conversion second hand. I guess I need to pull it and go get it tested... Sigh.
 
Nope, if the light is on with the wire disconnected from the alternator, then the problem is outside the alternator.

In fact, I think I see the problem in your photo above. In your new configuration, terminal 1 of the alternator should connect only to one side of the light on the dash. But your photo seems to show connections between all of the control box terminals, so you can't be using them as a tie point. How did you route the wire to the light?
 
Well I pulled it so might as well get it tested anyway!

The PO configured the control box like this;

Tr4aIRScontrolboxasfound.jpg


I am using the brown/green wire as the sense, per Dan's instructions. I haven't traced that brown/green wire through the harness/dash yet.
 
Well, originally I believe the brown/green would have gone to the middle 'F' terminal. However, the light would have been wired with a brown/yellow to the 'D' terminal, which has been linked to A and A1 in your photo.

So if the brown/yellow from the light is still connected to 'D', that would explain why the light comes on as soon as you connect the battery.

I'm a little surprised that Dan suggested using the brown/green wire for terminal 1, but maybe it's just because it already had a suitable connector on it. After all, the electrons don't know what color the insulation is! But somewhere it is going to have to meet the brown/yellow to the dash light.
 
TR3driver said:
After all, the electrons don't know what color the insulation is!

Yeah, they are annoying like that. That makes them as bad as me at following directions. Ha!

TR3driver said:
I'm a little surprised that Dan suggested using the brown/green wire for terminal 1, but maybe it's just because it already had a suitable connector on it.

Dan didn't directly, I picked that up from some articles I found. <span style="font-weight: bold">I don't want to have anyone think any of this is the result of Dan - it's not.</span> Sorry for not being more clear about that.

So Ipulled the alternator as I mentioned and had it tested at PepBoys, it failed. Bummer. But on the way out the guys says "you know, our testing rig is kinda funny. Bring it to Autozone". So I brought it to AutoZone. It passed. Cool.

OK - now back to the charging light issue. Is the best approach at this point to run a new wire from #1 to the charging light?

If I leave the brown/green disconnected at the alternator should I disconnect it at the control box?
 
tdskip said:
OK - now back to the charging light issue. Is the best approach at this point to run a new wire from #1 to the charging light?
Up to you, I guess. But after all that work to make the original control box look realistic, I would want to continue with that approach.

Besides, I think maybe the solution is as simple as pulling the small brown/yellow off of the 'D' terminal and putting it on either 'F' or 'E'. Note in Randy's photo above where he has brown/yellow on 'E'. But it would help if you would tell me how they are connected now.

<div class="ubbcode-block"><div class="ubbcode-header">Quote:]If I leave the brown/green disconnected at the alternator should I disconnect it at the control box?
[/QUOTE]
You lost me here. Disconnecting the brown/green didn't do any good, so why are you considering leaving it that way? But to answer your question, it doesn't matter.
 
Yes, the two small wires Brown/Yellow and Brown/Green should use the F and E terminals as they are jumpered together in the picture. Then the remaining big wires get tied together with the other three terminals. That would be the first place to look, its hard to see how that warning light is getting current unless there is a misconnection at this control box.
 
<div class="ubbcode-block"><div class="ubbcode-header">Quote:]

Up to you, I guess. But after all that work to make the original control box look realistic, I would want to continue with that approach.[/QUOTE]

Yes, I was flailing a bit there. Thanks for keeping me on track.

TR3driver said:
Besides, I think maybe the solution is as simple as pulling the small brown/yellow off of the 'D' terminal and putting it on either 'F' or 'E'.

<span style="font-weight: bold">That was it, I simply had it on the wrong terminal.</span>

I have everything connected properly know and the dash warning light is off now until it is supposed to come on.

Thanks for the coaching and <span style="text-decoration: underline">patience</span>, been fighting with a migraine most of this week and it has made me even more dense than usual (insert joke here: ___________________)
 
Tom - I still treat electrical stuff like voo-doo and its usually the source of my migraines - so no worries there!

Randy
 
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