Saturday, July21, 2018

' Balmar 7060 Offshore Kit Rebuild Instructions'

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1 Kit Compatibility 2 Offshore Parts Included
The Model 7060 Alternator Offshore Parts Kit is The offshore replacement
intended for use with the following 12volt parts included with the
alternator models Model 7060 Offshore
Parts Kit are
Model 7060 Alternator Model 6070SRIG
12Volt Offshore Parts Kit 1 Regulator
4 6
Installation Instructions 60150SRIG 2 Brush Holder Assembly
Professional Installation Is Required
Model 62170SRIG 3 Rear Bearing
4 Regulator Washer
5 Rectifier Assembly
621150SRIG 6 Rectifier Gasket
Model 604120SRIG 7 Front Bearing
604150SRIG 8 Instruction Sheet Not Shown
3 Tools Required 4 Remove Pulley 5 Remove Rear Cover
The following tools will be required to install The 6Series alternators pulley is held in place by The black plastic case at
the rear of the alterna
the parts included in the Offshore Kit a nut and lockwasher A hexagonal indent is pro tor provides access to the
rectifier assembly
vided in the end of the pulley shaft should it be brushholder assembly and Smart Ready inter
1 Adjustable Wrench necessary to remove the nut with hand tools nal regulator To remove the
rear cover
2 Flat Head Screwdriver It is preferable to use an electrical or pneumatic 1 Remove any wires or
cables connected
3 Wire Cutter impact wrench to remove the pulley nut from the to the alternators
positive or negative
pulley shaft A 1516 or 24mm impact wrench output terminals
4 Needlenose Plier
socket is required To remove the pulley 2 Remove nut and washers from D stud
5 Allen Wrench Set
1 Loosen and remove pulley nut 3 Carefully pry the plastic retainer tabs
6 Rachet Deep Well Socket Set
2 Remove lock washer away from the alternator case to allow
7 NonMarring Mallet 3 Remove pulley the rear case cover to
be released from
8 Heavy Duty Gear Puller During disassembly keep parts separated and in the alternator case
Be sure that the D
9 High Temperature Soldering Iron order to ensure they are properly replaced when terminal assembly is
free from the cover
the alternator is reassembled before fully removing cover
10 E5 Torx DeSolder Stator D Wires 7 DeSolder Ground Wires 8 D Circuit Resistor
The 3 wires supplying the The alternators ground is connected to the recti Some 6Series alternators
include a 100 ohm
D terminal on the rear fier regulator and brushholder assemblies via a resistor thats mounted
between the of the alternator must threewire connector that attaches to the alterna ground terminal and
the alternators D termi
be desoldered prior to tors ground terminal stud One of the three wire nal The resistor must be
reinstalled on the
removal A hightempera leads is soldered to the brushholder assembly same connection points when
iron like that shown The remaining wires are connected to the rectifi parts are must be used as
er and regulator with ring terminals To solder is used the brushholder
HighTemp Soldering Iron
1 Heat wire terminal at rectifier 1 Heat wire terminal at brushholder until sol
until solder becomes fluid der becomes fluid
2 Use small flat screwdriver to 2 Use small flat screw
carefully pry terminal open driver to carefully pry
3 Remove D wire and stator terminal open
wire from terminal jaws and 3 Remove B wire and
remove excess solder remove excess solder
4 Repeat at remaining Remove Screws 10 Separate Front Rear Cases 11
Removing Front Bearing
Four E5 Torx head screws secure the rectifier Once the rear assemblies have been removed We strongly recommend the use
of a press and internal regulator assemblies the alternator case can be opened To split the remove the front bearing
from the faceplate
to the rear alternator case Remove the Torx case 1 Place the faceplate face
up on a flat work
screws indicated in the illustration below 1 Remove the stator wire isolating retainer ing surface Provide
support under the
When the four screws are from the wires and save faceplate surrounding
the underside of
removed the 2 Carefully pry the front and rear cases the bearing to ensure
the faceplate and apart using care to ensure the cases are not
spread evenly around their perimeters 2 If a press is not available use a
The humps where the the four case bolt blow hammer and
can be holes extend through the front and rear deep well socket to
removed cases provide optimal pry points tap the bearing out
from the Note The stator and front bearing will typically of the faceplate Use
back of the remain in the faceplate when the case is opened care to ensure
The rear bearing may remain on the rotor shaft or the bearing is tapped
case in the brushholder assembly The following steps evenly to avoid dam
describe bearing removal age to the Removing Rear Bearing 13 Installing
Front Bearing 14 Installing Rear Bearing
If the rear bearing remains on the rotor shaft as The front bearing can be pressed in or tapped in Slip the rear bearing over
the rear end of the
shown in the photo below a puller may be by hand if a press is unavailable See photos rotor shaft The bearing will
slide past the to remove the bearing for replace below Use care to ensure that the bearing is tive and negative
rotor sleeves and will seat just
ment inserted squarely into the faceplate The bearing shy of the rear rotor fan A
deep well socket
If the bearing can be chilled prior to installation to reduce force works well to
remains in the required to seat the bearing when installing drive the
in the
Chilling the rear
bearing and brush bearing prior to
hholder may both installation will
be removed by reduce force
tapping the bear required to prop
ing out from the erly seat the
inside of the rear bearing on case
rotor shaft
15 ReAssemble Case 16 Isolating Fiber Washer 17 Install reassemble the case
The isolating Fiber Washer 4 in parts list must To install the brushholder
1 Insert rotor shaft through the front bear be installed on the alternator before installing the 1 Slide the slotted tabs of the brushholder
ing and press until bearing is seated brushholder or regulator assemblies base around the rear bearing and rear of
2 Slide the rear case onto the rear portion 1 Place the the rotor shaft Temporarily install Torx
of the rotor assembly Ensure that stator fiber washer to ensure alignment
wires extend properly through the case included in 2 Tap the brushholder in place Ensure the
3 Maintain pressure until the bearings and the repair kit brushholder stays
rotor assembly are seated in front and on the bolt straight when tapped
rear cases hole located into position Fiber
4 Insert the four case mount bolts align on the rear washer must stay in
front and rear cases to their proper posi case of the position under bolt hole
tions and tighten the case mount bolts alternator 3 Remove the brush
Ensure that the case bolts are tightened in a See photo retainer ring to seat
uniform manner to ensure proper alignment brushes on rotor
Brushholder Ground 19 Install Rectifier Gasket 20 PreDrill to installing the brushholder the
ground To install the replacement rectifier gasket Prior to installing the rectifier connection should be soldered to the
1 Place gasket on bare metal portion of the 1 Insert a step drill into the bolt hole
rear case as shown below es the rectifiers ground post See photo
1 Insert ground wire without ring terminal 2 Align bolt holes with predrilled holes in 2 Enlarge hole enough to allow the white
into the notch in the negative tab of the the alternator case isolating washer to be inserted in the
brushholder assembly bolt hole
2 Using solder fuse the
wire to the ground tab
21 Install Rectifier 22 Install Regulator 23 Install Regulator install the
replacement rectifier To complete the installation 4 Place ring terminal connections for
1 Connect main ground wire terminal to 1 Place the regulator on the rear case of the ground and 100ohm D resistor
regulator ground stud alternator with the bolt holes aligned with wires and star washer on the underside
2 Insert and tighten Torx bolt at center of the rectifier and the brushholder of the white isolater and push into
the rectifier assembly 2 Insert the tab at the end of the regulator hole marked GND on regulator Star
3 Insert contoured ring terminal in the with the crimp tabs on the rectifier Crimp washer should be at the bottom as
ground wire harness ring terminal is off and solder shown in the wiring diagram
set to allow the ground wire to fit between 3 Insert and tighten belowInsert and tighten Torx bolt
the rectifier plate Torx bolt with 5 Wrap ground
and the brushholder short isolating wires around out
assembly under the washer in mount side of brushhold
white insulating ing hole furthest er to avoid pinch
washer and insert from regulator ing wires when
and tighten the plug leave loose reinstalling rear
remaining Torx bolt enough for minor cover
Attach Stator D Wires
The rectifier assembly has three to provide connection to the stator and D circuit wires After the recti
fier is installed
Model 7060 Offshore Parts Kit
1 Place the three stator wires and the Wiring Diagram
three D wires in their crimp terminals
as shown in the photo
2 Squeeze the
crimp tabs to
hold the stator
and D wires in
3 Solder wires in
place with high
temperature sol
25 Install D CircuitRear Cover
To reinstall the D terminal
1 Slip 100 ohm resistor ring terminal onto
the D terminal stud
2 Insert the Dterminal stud through the D
terminal hole in rear case cover
3 Reinstall flat washers 2 star washer and
retaining nut on outside of rear cover
4 Snap rear case cover onto alternator case
Copyright 2006 Ballard Commercial Industries Inc

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