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Generator pulley gets really hot
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Kiptere
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PostPosted: Wed Jul 16, 2014 1:02 pm    Post subject: Generator pulley gets really hot Reply with quote

So hot I can't touch it. I've recut the threads on it twice. Can my bug catch on fire because of this? It's too hot in Texas right now to replace the whole generator.
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talljordan
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PostPosted: Wed Jul 16, 2014 1:05 pm    Post subject: Reply with quote

Post a photo, are the cooling vents orientated correctly?
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PostPosted: Wed Jul 16, 2014 1:18 pm    Post subject: Reply with quote

Is the belt slipping? Is it tight enough? Supposed to be around 1/2" deflection possible at the centre of the span.
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TheAmazingDave
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PostPosted: Wed Jul 16, 2014 2:12 pm    Post subject: Reply with quote

I'm interested in reading your responses. I have the same issue. Belt set for correct tension, generator is mounted properly for cooling air, and I even bought replacement brush covers to help direct airflow through the generator properly.

To be fair though, everything in my engine bay gets hot to the touch after a good drive.
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jwold
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PostPosted: Wed Jul 16, 2014 3:12 pm    Post subject: Reply with quote

I just replaced my pulley as I was going through belts and couldn't figure out why they were hot and disintegrating so quickly (1 per month or so).

Turns out the front half of the pulley had worn a groove in the back half of the pully at the shaft so the two pulley halves were spinning independent of each other and wearing out the belts.
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Kiptere
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PostPosted: Wed Jul 16, 2014 4:37 pm    Post subject: Reply with quote

I've got 5 shims in there and the belt still seems a little tight. The back half of the pulley is stock, the front half chrome. This may raise some red flags but it previously worked fine. No heat. I should probably remove the belt and see how freely it turns but I have red loctite on the nut now and that will be a problem. I'll post a pic.
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Kiptere
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PostPosted: Wed Jul 16, 2014 4:46 pm    Post subject: Reply with quote

Image may have been reduced in size. Click image to view fullscreen.

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jwold
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PostPosted: Wed Jul 16, 2014 5:23 pm    Post subject: Reply with quote

I can't quite tell from that angle, but it looks like the belt is riding pretty deep in the channel.
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Kiptere
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PostPosted: Wed Jul 16, 2014 6:19 pm    Post subject: Reply with quote

Would that cause the heat? I noticed the five shims I added had almost no effect of the loosening of the belt.
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Tim Donahoe
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PostPosted: Wed Jul 16, 2014 8:04 pm    Post subject: Reply with quote

Yeah, that belt looks like it's far too deep.

Is it the correct belt?

I only have two shims left in my pulley. The belt's original from the PO when I bought the car in Oct. of 2012.

Tim
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johnnypan
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PostPosted: Wed Jul 16, 2014 8:58 pm    Post subject: Reply with quote

Straight edge the face of the crank pulley and gen pulley,a belt will run hot of the pulleys aren't on the same plane..
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Kiptere
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PostPosted: Thu Jul 17, 2014 3:04 pm    Post subject: Reply with quote

OK. I found a belt that doesn't ride so low in the pulley and installed it. The pulley still gets super hot. Back to my original question - can this situation catch my bug on fire?
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smokey503
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PostPosted: Thu Jul 17, 2014 7:28 pm    Post subject: Reply with quote

Most likely seize your engine if the belt snaps and you don't notice the light in time.
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goober
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PostPosted: Thu Jul 17, 2014 8:22 pm    Post subject: Reply with quote

With the belt off, does the generator spin freely?

And, unless it's stamping marking on the pulley, it looks like oil or grease radiating from the center. Grease from the bearing? Oil from behind the crank pulley? Is the belt dry and free of oil?
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Brian
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PostPosted: Thu Jul 17, 2014 8:34 pm    Post subject: Reply with quote

How hot is hot?

the backing plate might be upside down
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jwold
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PostPosted: Fri Jul 18, 2014 12:07 am    Post subject: Reply with quote

I don't think it will catch on fire, but somethings not right. I'd suggest getting the correct pulley and fixing it right. I'd also suggest that you not get a chrome pulley, get something stock.
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Kiptere
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PostPosted: Sat Jul 19, 2014 2:00 pm    Post subject: Reply with quote

Well, I switched back to the stock pulley. Tested it without the belt on (it moved freely). Straight edged it to the crank pulley (it was in alignment). Fixed it so the belt didn't ride so low in the pulley (it lines up with the top of the pulley). It still gets hot as hell. Did a websearch for info on the subject. Found a snipit of info at aircooled.net on the subject but couldn't get into the actual article. All I get is a parts page. if anyone can get into the article, please send me a link. This is the link I found When I google "generator pulley gets really hot vw bug"

VW Alternators, Generators and Related Volkswagen ...
vwparts.aircooled.net › Electrical
52 products - When this happens the generator will get so hot, the soldering will come off the ....

At the website:

http://vwparts.aircooled.net/VW-Alternator-Volkswagen-Generator-s/339.htm

When I click on that website, all I get is a parts page.
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Fab4Fan
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PostPosted: Sat Jul 19, 2014 2:12 pm    Post subject: Reply with quote

It's not an article, it's a description to a regulator
http://vwparts.aircooled.net/Bosch-Voltage-Regulator-12-Volt-Generator-Models-p/30-019.htm

Quote:

New Bosch 12 Volt voltage regulator for VW Beetle, Ghia, and Bus. Generator output is over 14 volts, and regulators charge the battery when it needs it, and more importantly doesn't when it's fully charged! Overcharging will overheat and destroy your battery! When this happens the generator will get so hot, the soldering will come off the armature destroying the generator too!


I guess If this can be the case you should check the charging voltage on the battery.
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jlex
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PostPosted: Sat Jul 19, 2014 4:47 pm    Post subject: Reply with quote

Are you throwing any metal shavings?
Once I had a really hot generator pulley problem. Turns out I pinched the belt between the pulley halves when I installed a new one.
Try reinstalling the correct sized belt by tightening the pulley half while making sure the belt is turning at the same time. As it turns, it will ride up where it's supposed to be instead of getting pinched. Whenever I put a new belt on, I make sure the belt moves with each turn of the wrench as the bolt's being tightened.
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goober
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PostPosted: Sat Jul 19, 2014 4:58 pm    Post subject: Reply with quote

If you have a heavy electrical load on the generator and the belt continually slips, the pulley will probably get hot.

If you turn the generator pulley with a wrench, can you turn over the engine by hand without the pulley slipping to much?
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