' 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 12-volt parts included with the
alternator models: Model 7060 Offshore
Parts Kit are:
Model 7060 Alternator Model: 60-70-SR-IG
12-Volt Offshore Parts Kit 1. Regulator
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
4. Regulator Washer
5. Rectifier Assembly
621-150-SR-IG 6. Rectifier Gasket
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
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.
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
3. Solder wires in
place with high-
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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