' Balmar Offshore Parts Kit Manual'

ST 19009 61 Ave NE 4 Arlington WA 98223 3604356100 PHONE 3604353210 FAX ALTERNATOR OFFSHORE PARTS KIT GENERAL INSTRUCTIONSIt is recommended that this kit be installed by a qualified alternator expertWhile the parts may appear the same as standard automotive and are exchangeable in sizethe are special to our high output marine designsShould you have to attempt the repair yourself follow the steps below1 Remove alternator and place on benchwork area2 Remove pulley using 1516 inch socket preferably attached to an impact wrench If noimpact wrench is available use a 1516 inch socket hold socket with vice grip and insert516 Allen wrench through the hole in the socket and into the rotor Nut is torqued on firmlyso sufficient force must be applied3 Remove the four cap socket bolts using 532 inch Allen wrench4 Carefully split the case apart leaving the stator with the rear housing5 To remove the bearing first remove the rotor from the bearing then unscrew the threeretaining screws and plate6 Tap out the bearing and press in the new one Replace the retainer plate and replace rotorshaft7 The brush springs are probably hanging out now so do one of the following a Put the spring back in place insert the brush and slip a toothpick or small wire through the rear of the case to hold the brush while you slide the rotor in placeor b Install the new brush holder and pull the pin after the rotor is in place Care must be taken to prevent any foreign material from entering the rear bearing8 Diodes normally do not need replacement but when required should be pressed intoplace9 Reassemble alternatorThe above process has been presented in simplified form and assumes a fair degree skills plus access to the basic tools 898