Sunday, October20, 2019

' Balmar Offshore Parts Kit Manual'


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                              19009 61 Ave. NE #4
                              Arlington, WA 98223
                              360-435-6100 PHONE
                              360-435-3210 FAX

                               GENERAL INSTRUCTIONS
It is recommended that this kit be installed by a qualified marine/automotive alternator expert.
While the parts may appear the same as standard automotive, and are exchangeable in size,
the characteristics are special to our high output marine designs.

Should you have to attempt the repair yourself, follow the steps below.

1. Remove alternator and place on bench/work area.

2. Remove pulley using 15/16 inch socket, preferably attached to an impact wrench. If no
impact wrench is available, use a 15/16 inch socket, hold socket with vice grip, and insert
5/16 Allen wrench through the hole in the socket and into the rotor. Nut is torqued on firmly,
so sufficient force must be applied.

3. Remove the four cap socket bolts using 5/32 inch Allen wrench.

4. Carefully split the case apart, leaving the stator with the rear housing.

5. To remove the bearing, first remove the rotor from the bearing, then unscrew the three
retaining screws and plate.

6. Tap out the bearing and press in the new one. Replace the retainer plate and replace rotor

7. 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 place.
       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 bearing.

8. Diodes normally do not need replacement but, when required, should be pressed into

9. Reassemble alternator.

The above process has been presented in simplified form and assumes a fair degree of
electro-mechanical skills plus access to the basic tools required.                       8/98

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