JD 2630 Alternator Issue

Mustangs

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John Deere 2630 with Motorola Alternator

I had the alternator rebuilt, reconnected it as shown in the picture. The alternator worked fine for approximately 3 hours of use and then the light came on. The gentleman who rebuilt the alternator expressed his doubt of the need for the smaller orange wire near the large red one. The slide connector is to the alternator light. I assume the black is a ground. I was brush hogging and detected an electrical smell. The alternator light came on & after a while went off, then came back on.

Does the alternator need four wires running to it? If not, which one can be disconnected? They all look factory due to no splices, repairs or other signs of someone changing them. They were reconnected as originally when I bought the tractor.
 
If it worked for 3 hours, I would assume it was wired correctly.

A couple of possibilities, a bad regulator that caused it to overcharge and overheat to the point it damaged the alternator or burned the fuse link (if equipped). Check the big connection on the alternator, the BAT wire, it should have battery voltage at all times.

Or if the battery was not charged after the alternator was repaired, and the alternator had to try to bring up a dead or defective battery, it could have damaged the alternator or burned the fuse link.

Check the BAT terminal for voltage not running, check the condition of the battery and be sure it is charged, try it again. Have a volt meter ready, across the battery should be about 14-15 volts running and revved up.

If down around 12v, it is not charging. If over 15v it is over charging.
 

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