Annoying Generator Light

[Flipseat]

I searched the forums, and found some very good info.. but not everything I'm looking for.

I drove home the other night in my 61 westy after work (headlights on) and pulled up to my garage. I shut the bus off to use the keys for the garage, went to start the bus, and not enough juice to turn it over. It was the first day out of the year and the bus has been sitting since the beginning of December with an occasional running. The wife and I later had to push it in the garage up a small incline

Anyways... today I took the battery out and gave it a charge. Its at least 3 years old. The water level is *just* under the top of the plates, but I haven't topped it off yet. I put it on the charger at work (50amp!) because thats all I have that charges 6V right now. I took it back home and put it in the bus. I then checked the generator brushes (3 year old gen) and they were tall and fine with good tension on them. I polarized the generator and when I did that it spun over fast and freely. I then hooked everything back up and put my meter on the battery. It read 6.4V.

I then started the bus and the gen light was glowing at idle, even bright at times. I revved it and upon high revs (probably 3000 rpm) voltage at the battery would read up to 7.2V at the highest. At idle it was at 6.3-6.4 volts. When I turn on my headlights it reads 6.1V at idle and no matter how high I rev it the voltage won't go above 6.45V and the generator light glows all the time.

This glowing light annoys the hell out of me. I didn't take apart the regulator because I didn't bring any torx bits home from work, but I believe the generator is charging, just not enough, or maybe the battery is on its way out. This glowing light started last fall.

Any ideas? My old boss is now an Interstate dealer and I think I'm going to buy a 6V Optima battery from him. Its 85 bucks. Could the regulator be at fault here? Any ideas? The entire wiring harness is 2 years old, grounds are all good and clean, soldered headlight switch, but I have yet to solder the fuse box.

Thanks for any input.
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[Nitty]

In order of increasing cost: Connections, Regulator, Battery, Generator.

[Andrew]

Were those voltage numbers checked at the generator or at the regulator?
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-Andrew

[Flipseat]

[Nitty]

At fast idle you should get 7.4 to 8.1v. When you turn on the lights the voltage should drop temporarily, but then come back up if the charging circuit is working properly.

If the voltages are more than above, problem is probably with the regulator. If less than above (like it seems in your case) problem probably lies in the generator.

If you replace the generator, you should probably also replace the regulator.

[Eric&Barb]

[Flipseat]

Alright... I topped off the battery with distilled water so that the plates are just covered. I also did the test on here http://www.geocities.com/aussiebug1970/generator.html for the unregulated generator output, and I am getting 20V. I pulled out my 1955 bus workshop manual, but the only section missing is the generator section I'll have to consult the Bentley at work tomorrow. I also pulled the cover off of the regulator to check the points, and nothing is sticking, so thats good. I'm leaning towards a bum regulator, but I don't have a spare like I thought I did and no parts stores have them, so I'll have to order one or see if a friend has one for me.
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[arthurnugen]

Flipseat,

I recently had the same problem and a new regulator fixed it. It was one of the few easy repairs I've done to my bus! Good luck.

[dstefun]

The light comes on when the voltages on both sides of it are different. One side of the light goes to the battery via the ignition switch, the other goes to regulator terminal 61. Your voltages at the battery of 7.2 above idle (and at the gen unregulated at 20V) are OK so that leaves the regulator or dirty connections along the way. More than likely a slightly flaky regulator. One thing to try would be to clean the gen with sandpaper where the regulator mounts and be sure you're getting a good ground there. Good luck!
-Dave

[Clara]

If you read your owners manual, it suggests that with a 6V system, the red light dimly glowing at idle is normal. I have also seen 6V buses with the light glowing with the headlights on, that ran fine, and continued to start up. Basically, don't freak out.

However, not all have had this syndrome. Perhaps going through the system, cleaning up connections, and using dielectric grease will help.

edit: Also, if your headlight switch gets warm or hot, it has corrosion inside. Which means it should be taken apart and cleaned up in there. After cleaning up/ dielectrical greasing connections to the headlights on my 53, they became much brighter. Light still glows at idle though.
I think there are scans of owners manual on this site.
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[Flipseat]

[Eric&Barb]