Generator Light

Hi all, latest conundrums on my Karmann Ghia.

So the generator light popped on last weekend - I checked the fan belt straight away and it was intact (plus it was only replaced about six months ago) so I went ahead and got new generator brushes and a new regulator. Fitted them last night and checked all the connections were good & clean. The battery is relatively new - last month - so know thats in good shape.

Drove the KG this morning to work and the generator light was still on. In addition to that, I can tell there is really low power running through her - lights barely on, wipers barely going, gear change (auto stick shift transmission) super sticky. She's not happy!

So where should I head to next? Thoughts & inspiration much needed!

Cheers,
Joanna

Are you still getting the generator light coming on?

Make sure all your connecting wires and ground straps are tight and in good shape. I would also make sure your regulator is the correct one for your generator. I had a mismatched pair on mine and experienced the same problems.

If you or dave can limp it out tomorrow night we could take a look at it.

If the generator light is not on, check the bulb. The generator needs the draw from the bulb to start the charging process. A blown bulb will keep the generator from starting the charging and you will be running off just the battery.

I had a similar situation once. Wire on the backside of the DF stud broke loose. Since you replaced the brushes, sounds like you had a good look inside there, but still may want to check it out. Here is a thread from the samba that describes the problem and fix.
http://www.thesamba.com/vw/forum/viewtopic.php?t=245285

DiggerD wrote:If the generator light is not on, check the bulb. The generator needs the draw from the bulb to start the charging process. A blown bulb will keep the generator from starting the charging and you will be running off just the battery.

I think this only holds true for alternators, generators can charge without the light.

Did you polarize the new gen? Also, check and recheck all the connections, make sure they are in good condition. Check to see if you have voltage coming off of the generator and then check at the VR. To check for a short, place one lead of a meter on a bare metal surface of the car and the other on an outside ground (something grounded other than the car). To check for a broken wire, ohm out each wire. With all those checks, you should have some answers. Good luck.

Generator may of lost it's polarization. Check your main grounds to the engine as well, trans strap and ground connection. Make sure those are secure and clean!

Remove belt.
Remove regulator from generator(Wiring)
Ground DF terminal.
Use another 12v supply, battery or jump box.
Place red+ to D+ and the blk- to the DF
The generator should turn like a motor.
Do not run it long, 15 - 20 sec or so.
Connect the 12v source to the terminals several times, waiting about 1 min between each run. This allows the windings to cool a bit.

The more this is done the stronger the field and the higher the AC voltage going to the regulator. Higher AC to regulator helps regulator produce a stronger 12v output when needed.

Remove the ground on DF and install the belt. Now run the engine up to about 2000rpms and read the AC voltage on terminals D+ and DF. It should be high, around 35-40 volts AC. If it is lower no problem but it should be at least 18v AC. AC not DC at this point. The regulator converts the AC voltage to DC.

Reinstall all the wiring and regulator if it was removed.

See how it is now.

Recently my car needed to be jumped off and I'm guessing a surge went in and zapped the generator. I had to re-polarize my Generator to get it to charge.

Thanks all, will go through these suggestions tonight when I get in from work. Will let you know how I go!

Latest news ... it took two jump starts to even get her going and into gear this evening in the car park at work. Finally moving, we came out of the car park and then the engine died (before we even got to the first set of traffic lights - all a bit tragic). Just got her back home on the back of a tow truck. Conceding defeat for tonight.

perhaps you got a bad generator. When i had the alt go out on my bug, i replaced it, and it went bad with in a week. exchanged it out, and has issues with the brushes sticking for over 6 months (had to rev it hard, for the light to go off) before it went out again. then replaced it again, a few months ago, and the brushes are sticking again. still works, but have to rev it hard, to get the light off, lol. just a thought

Getting the generator replaced - Billie's sorting it out for me, hopefully pick her up Monday night. Fingers x'ed that sorts it!

Generator replaced - thanks Billie, great job! Now onto the ignition ... anyone know where to get a replacement neutral safety switch from??