new altenator running hot and electrical lines too

[72bumbee]

just changed the water pump, altenator,fuel pump, all belts and radiator hoses.
started it up and the altenator got very hot and the wire bundle from altenator to the voltage regulator got hot and it looked like smoke was coming from the voltage regulator but not billowing out just a wispy puff or two.
i didnt get a new voltage regulator, as it is a year or two older than the new altenator.
I did no voltage tests, but the gauge inside is holding steady.
Thanks for the help,
Steve

[BRUTUS_T_HOG]

You need to check actual system voltage. The only time wires are going to get hot is if they are too small for the job, or there is a bad connection somewhere.

My bet is a bad ground connection.

Use a voltmeter and check from the alternator B+ post to the battery B+ post with engine running and high beams on, there should be less than 0.5V.

Then check voltage from engine ground to battery neg post, should be less than 0.5V

If you have more than 0.5V on any of these tests you have a bad connection, corroded wires, or too small wires for the task

[72bumbee]

Thanks for the reply BRUTUS_T_HOG!
I got into a big hurry and wanted to go camping this next week and reconnected the ground to the WRONG post.
Its fixed now, and running good! (20 minutes before work)
Is this something I could have used my VOM meter for? I just bought it and have only used it to test continuity on my trailer lights so far!
Thanks again!
Steve

[BRUTUS_T_HOG]

Yes, DVOM would have spotted that in a heart beat using the ground test.

A volt meter reads the difference in voltage from point A to point B. So if you are testing across a wire with load flowing through it and it displayed 2.0V... you are losing 2V through that wire, which means excess resistance and excess heat. As a professional technician I could not survive a day at work without a volt meter