Someone with a manual on the 2000 needs to tell you if it is the right color code. Something is wrong because it should not be blowing the fues regardless. The system works, has been tried and installed many times. Mine is hooked up that way for a very long time, my son has the same setup on a Caravan.

 

I talked to my brother in law earlier and he said it was the right wire, unless he looked up the wrong year or something like that. Can you hook the wire to something else that only activates when the key is on, what about straight to the battery or something else live all the time, Anything I need the truck on the road

 

Better go over the wiring again. The system works but you have a mistake in it. I'm not there so I can't figure it for you. Do this. Disconnect the alternator field wires. Hook one terminal to ground, the other to the hot battery terminal. Just for a second, it should start charging full capacity. Don't leave it on that way, it will be too much voltage. That will check the alternator, that it is working well.

I have been trying to figure what you are into and the fuse you blew is probably 10 amp. If so you have the wrong wire, this is a heavy wire. You would be on the wrong side of the relay, the input side instead of the output. To test, put a test light on it and turn on the key. The light should come on for a few seconds then go out. Bump the starter and it will come on for a long time and go out. The only fuse in this line is a 30 amp fuse, real heavy. It is a number 10 wire, make sure you have that wire. It looks like there is a small wire the same color.

Next hook up a wire from the ASD relay wire without the regulator hooked up. Ground the other alternator wire. That should do the same thing, over charge. Then you know that the power supply from the ASD wire is good and there are no problems there.

That hot wire should be hooked to the terminal of the regulator that is the low point on the triangle shaped connector. This is where most mess up. You may have hooked it to the wrong one and shorted the regulator. Make sure it is like the picture.

Even if hooked up wrong, it will trash the regulator but will not blow the 30 amp fuse.

 

If the fuse you are blowing is on the side of the dash, you are hooking the wrong wire.

 

I have given up for tonight, the fuse I have been blowing is the 30 amp Engine control in the fuse box under the hood. I hooked the hot wire from the green-orange stripe to the alt. and then to the top part of the triangle on the regualtor as shown in the pic. The green-orange stripe wire is on the left most plug on the pcm, it goes into a harness that goes across the firewall and then along side the engine to the power center. In the morning I am going to the other side of Meadeville Pa to a guy that can put a regulator in my existing Alt. for pretty reasonable. Does anybody know if a PCM from a 95 will work in a 2000. I'll just keep working at it till I get it. Thanks

 

Actually you have a short somewhere or it would work right. Sounds like you have the right ASD wire.

 

I guess I'll just start tracing the wire. Thanks

 

Just an idea.
If you hook the positive wire to the wrong terminal on the voltage regulator it will last about a hundredth of a second before it fries. Not sure if it would cause a fuse to blow after it's fried but it definitely will never work again.

 

You probably already have this straight, but just for the record in case you misunderstood.... The alternator has three terminals on it. It has the large terminal that is hot and through the main fuse, over 100 amps. You do not touch that one. There are two small terminals, generally with a plug in the back of the alternator. The only wires that go to those terminals are the two from the new regulator, the original wires have to be removed and taped off. The two terminals are interchangable, does not matter which is which. Neither of these can touch ground when hooked to the regulator. You should be also adding a ground wire from the frame of the alternator to the case of the regulator, generally under one of the mounting screws.

Once set up it is really simple and is very dependable. Mine is more stable than it ever was with the PCM controlling it.

How it works.... If 12+ is hooked to one terminal and 12- is hooked to the other terminal on the alternator, it will charge at max voltage and amperage. With the regulator system, 12+ is hooked to one terminal and the regulator modulates the negative to regulate the voltage output.

 

I must have been grounding the system somewhere it should not have been, I had a regulator put inside the back of my Alt. and hooked the power wire up using the ASD wire from the PCM and everything was fine. I must have just messed something up last night. Thanks for all the help guys, if it ever happens again I'll know what to do.