' 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 12volt parts included with the alternator models Model 7060 Offshore Parts Kit are 2 Model 7060 Alternator Model 6070SRIG 60100SRIG 12Volt Offshore Parts Kit 1 Regulator 3 4 6 60120SRIG Installation Instructions 60150SRIG 2 Brush Holder Assembly Professional Installation Is Required 5 Model 62170SRIG 3 Rear Bearing START HERE 621100SRIG 621120SRIG 4 Regulator Washer 5 Rectifier Assembly 621150SRIG 6 Rectifier Gasket 7 Model 604120SRIG 7 Front Bearing 604150SRIG 8 Instruction Sheet Not Shown3 Tools Required 4 Remove Pulley 5 Remove Rear CoverThe 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 alternathe 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 inter1 Adjustable Wrench necessary to remove the nut with hand tools nal regulator To remove the rear cover2 Flat Head Screwdriver It is preferable to use an electrical or pneumatic 1 Remove any wires or cables connected3 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 terminals4 Needlenose Plier socket is required To remove the pulley 2 Remove nut and washers from D stud5 Allen Wrench Set 1 Loosen and remove pulley nut 3 Carefully pry the plastic retainer tabs6 Rachet Deep Well Socket Set 2 Remove lock washer away from the alternator case to allow7 NonMarring Mallet 3 Remove pulley the rear case cover to be released from8 Heavy Duty Gear Puller During disassembly keep parts separated and in the alternator case Be sure that the D9 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 cover10 E5 Torx SocketDriver6 DeSolder Stator D Wires 7 DeSolder Ground Wires 8 D Circuit ResistorThe 3 wires supplying the The alternators ground is connected to the recti Some 6Series alternators include a 100 ohmD terminal on the rear fier regulator and brushholder assemblies via a resistor thats mounted between the regulatorcover of the alternator must threewire connector that attaches to the alterna ground terminal and the alternators D termibe desoldered prior to tors ground terminal stud One of the three wire nal The resistor must be reinstalled on theremoval 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 installedbelow must be used as er and regulator with ring terminals To solder is used the brushholder wire 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 terminals9 Remove Screws 10 Separate Front Rear Cases 11 Removing Front BearingFour E5 Torx head screws secure the rectifier Once the rear assemblies have been removed We strongly recommend the use of a press tobrushholder and internal regulator assemblies the alternator case can be opened To split the remove the front bearing from the faceplateto the rear alternator case Remove the Torx case 1 Place the faceplate face up on a flat workscrews indicated in the illustration below 1 Remove the stator wire isolating retainer ing surface Provide support under theWhen the four screws are from the wires and save faceplate surrounding the underside ofremoved the 2 Carefully pry the front and rear cases the bearing to ensure the faceplate doesregulator and apart using care to ensure the cases are not crackrectifier spread evenly around their perimeters 2 If a press is not available use a deadassemblies The humps where the the four case bolt blow hammer andcan be holes extend through the front and rear deep well socket toremoved cases provide optimal pry points tap the bearing outfrom the Note The stator and front bearing will typically of the faceplate Useback of the remain in the faceplate when the case is opened care to ensure thatalternator The rear bearing may remain on the rotor shaft or the bearing is tappedcase in the brushholder assembly The following steps evenly to avoid dam describe bearing removal age to the faceplate12 Removing Rear Bearing 13 Installing Front Bearing 14 Installing Rear BearingIf 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 theshown 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 posirequired to remove the bearing for replace below Use care to ensure that the bearing is tive and negative rotor sleeves and will seat justment inserted squarely into the faceplate The bearing shy of the rear rotor fan A deep well socketIf the bearing can be chilled prior to installation to reduce force works well toremains in the required to seat the bearing when installing drive the in placeassembly the Chilling the rearbearing and brush bearing prior tohholder may both installation willbe removed by reduce forcetapping the bear required to proping out from the erly seat theinside of the rear bearing on thealternator case rotor shaft15 ReAssemble Case 16 Isolating Fiber Washer 17 Install BrushholderTo 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 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 brushEnsure that the case bolts are tightened in a See photo retainer ring to seatuniform manner to ensure proper alignment brushes on rotor sleeves18 Brushholder Ground 19 Install Rectifier Gasket 20 PreDrill RectifierPrior to installing the brushholder the ground To install the replacement rectifier gasket Prior to installing the rectifier assemblywire connection should be soldered to the 1 Place gasket on bare metal portion of the 1 Insert a step drill into the bolt hole nearassembly 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 tab21 Install Rectifier 22 Install Regulator 23 Install Regulator continuedTo 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 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 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 adjustment24 Attach Stator D WiresThe rectifier assembly has three to provide connection to the alternators stator and D circuit wires After the rectifier 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 der25 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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