Alternator Installation Issues
1. While each alternator series may have some varied installation issues, the following guidelines should be considered when installing any Balmar alternator:
2. Ensure, prior to installation, that the Balmar replacement alternator features a compatible mounting configuration to the alternator being replaced. See information above.
3. Ensure that the replacement alternator is adequately sized to meet the demands of your battery banks. As a rule of thumb, the alternator should be rated at 25% of your house battery capacity.
4. Ensure that the belt or belts driving the alternator are capable of handling the alternator’s horsepower load. As a rule, a single 3/8" belt is capable of supporting up to 80 amps@12 volts, and a single 1/2" belt can support 100-amp@12-volts. Dual belts will typically support alternator outputs of up to 300+ amps/12 volts. Driving an alternator on an undersized belt will substantially increase the risk of belt slippage and premature belt failure. All 24-volt Balmar alternators require a minimum of dual 1/2” belts for optimal performance. Balmar offers a wide selection of AltMount serpentine pulley kits for marine diesel engines. Visit the Balmar website for more information and application charts.
5. Balmar alternators are designed to be used in conjunction with external P-type regulators. We recommend the Balmar multi-stage regulator for maximum charging performance. Certain Balmar alternators, designated as SR or Smart Ready®, feature a single-stage internal regulator. Those alternators can be controlled by either the internal, or an external voltage regulator. Please note that the internal regulator must be disabled when an external regulator is being used.
6. All Balmar alternators, unless otherwise noted, are equipped with isolated grounding terminals. Isolated ground alternator installations MUST include a dedicated cable connecting the alternator ground terminal to system ground. The ground cable must be equal in size to the alternator’s positive output cable, and must meet the cable gauge requirements outlined in the cable size chart shown on Page 3.
7. Belt tension is a critical aspect of alternator performance. Monitor belt tension after every charge cycle for the first several weeks of engine operation. We recommend a belt tensioning gauge for accurate deflection measurement. Make belt tension monitoring and adjustment a part of regular maintenance
6-Series and AT-Series alternators feature dual internal cooling fans, and are designed to provide maximum cooling protection when rotated in a clockwise rotation (looking at the front of the alternator when mounted on engine). Using 6-Series or AT-Series alternators in reverse (counter-clockwise) rotation applications may affect alternator cooling and performance. Large case 94, 95, 97, 97EHD and 98-Series alternators feature bi-directional fans, which are equally effective in normal or reverse rotation applications. 97-Series Alternators
Extra large case 97-Series Alternators provide outputs of 160 amps at 12 volts, or 140 amps at 24 volts. 4" ID J-180 saddle mount. Alternators feature isolated ground terminals, external regulation and 16-pole stator output. Models with a BL indicates brushless rotor/ stator combination that reduces alternator noise, and eliminates key wear points.
1. Positive Output Terminal - Must be connected via properly-sized cable to the battery or batteries being charged. Cable size is determined by alternator output and length of cable run. See Page 3.
2. Negative Terminal (Ground) - Must be connected to system ground via properly sized cable. Cable size is determined by alternator output and length of cable run. See Page 3.
3. Stator Output - Can be used as a signal for an electric tachometer. In 12-volt systems, stator terminal will connect to WHITE wire. In 24-volt systems, the Stator Wire will connect to the ORANGE wire in the regulator wiring harness.
4. External Field Terminal - Connects to external voltage regulator via wiring harness.
An unsupported cable may damage the positive or negative terminals, resulting in damage to alternator, regulator and wiring. Ensure that cables are adequately supported to supply strain relief.