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' 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
                                                                                                                                                                               1
                                                                     intended for use with the following 12-volt            parts included with the
                                                                     alternator models:                                     Model 7060 Offshore
                                                                                                                            Parts Kit are:
                                                                                                                                                                       2
    Model 7060 Alternator                                                Model: 60-70-SR-IG
                                                                                60-100-SR-IG
   12-Volt Offshore Parts Kit                                                                                               1. Regulator
                                                                                                                                                         3
                                                                                                                                                                   4               6
                                                                                60-120-SR-IG
    Installation Instructions                                                   60-150-SR-IG                                2. Brush Holder Assembly
  Professional Installation Is Required                                                                                                                        5
                                                                         Model: 621-70-SR-IG                                3. Rear Bearing


         START HERE                                                             621-100-SR-IG
                                                                                621-120-SR-IG
                                                                                                                            4. Regulator Washer
                                                                                                                            5. Rectifier Assembly
                                                                                621-150-SR-IG                               6. Rectifier Gasket
                                                                                                                                                                           7
                                                                         Model: 604-120-SR-IG                               7. Front Bearing
                                                                                604-150-SR-IG                               8. Instruction Sheet (Not Shown)




3. Tools Required                                                    4. Remove Pulley                                       5. Remove Rear Cover
The following tools will be required to install                      The 6-Series alternator's 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 alternator's positive or negative
                                                                     pulley shaft. A 15/16" 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. Non-Marring 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 re-assembled.                               before fully removing cover.
10. E-5 Torx Socket/Driver




6. De-Solder Stator & D+ Wires                                       7. De-Solder Ground Wires                              8. D+ Circuit Resistor
The 3 wires supplying the                                            The alternator's ground is connected to the recti-     Some 6-Series alternators include a 100 ohm
D+ terminal on the rear                                              fier, regulator and brushholder assemblies via a       resistor that's mounted between the regulator
cover of the alternator must                                         three-wire connector that attaches to the alterna-     ground terminal and the alternator's D+ termi-
be de-soldered prior to                                              tor's ground terminal stud. One of the three wire      nal. The resistor must be re-installed on the
removal. A high-tempera-                                             leads is soldered to the brushholder assembly.         same connection points when replacement
ture iron like that shown                                            The remaining wires are connected to the rectifi-      parts are installed.
below must be used, as                                               er and regulator with ring terminals. To remove
high-temperature solder is used.                                     the brushholder wire:
                                          High-Temp 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 terminals.



9. Remove Screws                                                     10. Separate Front & Rear Cases                        11. Removing Front Bearing
Four E-5 Torx head screws secure the rectifier,                      Once the rear assemblies have been removed,            We strongly recommend the use of a press to
brushholder 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 does
regulator and                                                                apart, using care to ensure the cases are            not crack.
rectifier                                                                    spread evenly around their perimeters.           2. If a press is not available, use a dead
assemblies                                                                   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 that
alternator                                                           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 faceplate.



12. 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 posi-
required 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 bearing
brushholder                                                                                                                 in place.
assembly,         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 the
alternator case.                                                                                                            rotor shaft.
15. Re-Assemble Case                                  16. Isolating Fiber Washer                             17. Install Brushholder
To re-assemble 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 bolt
       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
                                                                                                                  sleeves.




18. Brushholder Ground                                19. Install Rectifier Gasket                           20. Pre-Drill Rectifier
Prior to installing the brushholder, the ground       To install the replacement rectifier gasket:           Prior to installing the rectifier assembly:
wire connection should be soldered to the               1. Place gasket on bare metal portion of the            1. Insert a step drill into the bolt hole near-
assembly:                                                    rear case, as shown below.                              es the rectifier's ground post. See photo.
  1. Insert ground wire (without ring terminal)         2. Align bolt holes with pre-drilled 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 high-temperature solder, fuse the
     wire to the ground tab.




21. Install Rectifier                                  22. Install Regulator                                 23. Install Regulator (continued)
To 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 100-ohm (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 bolt
      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                                         below.Insert 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                                         re-installing rear
      remaining Torx bolt.                                 enough for minor                                          cover.
                                                           adjustment).



24. Attach Stator / D+ Wires
The rectifier assembly has three terminals
required to provide connection to the alterna-
tor's 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
         place.
    3. Solder wires in
         place with high-
         temperature sol-
         der.



25. Install D+ Circuit/Rear Cover
 To re-install the D+ terminal:
 1. Slip 100 ohm resistor ring terminal onto
    the D+ terminal stud.
 2. Insert the D+terminal stud through the D+
    terminal hole in rear case cover.
 3. Re-install 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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