Balmar 60 Series, Installation And Operation Manual

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If voltage is not present on the RED, the BROWN and the Positive Battery Sense Wire, the regulator will not
work. If voltage is as expected at the RED the BROWN and Positive Battery Sense wire, and there is zero, or an
unexpected voltage reading at the BLUE wire, contact our technical support staff at +1(360) 435-6100, or e-mail
us at balmar@balmar.net.
If all voltages at the regulator meet expectations, yet the alternator is
not producing charging current, test the
alternator. The following tests are recommended for determining alternator functionality.
Alternator Testing
TEST #1 - The following test is used to isolate the alternator and determine if the failure is a result of the
alternator. Once
again, testing at either the alternator or regulator is only effective if the wiring, fusing and
batteries have been determined to be in correct working order. The alternator and regulator can be tested for
function by determining if a magnetic field exists at the alternator’s pulley shaft or rear bearing. To test:
1.
With the ignition in the OFF position, place the tip of a non-magnetic steel screwdriver near the nut on
the pulley shaft or near the rear bearing of the alternator. There should be no evidence of a magnetic
field pulling the screwdriver toward the alternator. (A slight amount of magnetism may be present, due to
residual voltage in the alternator).
2.
Engage the ignition, without starting the engine, to activate the voltage regulator. If an oil pressure switch
is used, a jumper between the RED and BROWN wires in the Ford-
style plug will activate the regulator.
3.
After allowing time for the regulator’s start-up delay, place the head
of a steel screwdriver near the nut on the pulley shaft or near the
rear bearing of the alternator. There should be substantial magnetic
pull. If a magnetic field is present, the voltage regulator, alternator
brushes and rotor are likely to be working properly.
If there is little or no magnetic pull at the pulley shaft or at the rear bearing,
initiate the following test:
With the key off and the engine off, remove the large harness plug from the
regulator.
1.
Insert the end of a short length of electrical wire to the RED
connector slot of the regulator harness and the other end of the wire
to the BLUE connector slot. This bypasses the regulator and tests the alternator and the harness.
2.
Using your steel screwdriver, inspect for a magnetic field as described above.
3.
With your voltmeter, check for voltage on the blue wire at the alternator. If voltage does not exist, the
harness may be at fault. If voltage does exist at the harness, but no magnetism is present, the alternator is
likely to be malfunctioning.
4. If a magnetic field is present. Both harness and alternator brushes and rotor appear to be working
properly. If no magnetic field is present, proceed with the next test.
Testing the actual output of the alternator is known as “Full Field Testing”. This can be accomplished by jumping a
positive 12VDC current to the field terminal at the rear of the alternator. This test eliminates both the regulator and
the harness, making it easier to isolate your investigation to the alternator.
CAUTION: Ensure that all voltage sensitive equipment is turned off prior to starting the engine. Voltage is
unregulated during this test and could damage sensitive electronics. DO NOT let the engine run any longer than
necessary to detect charging. If the system is not charging, remove the alternator and have it inspected by a
qualified alternator shop, or call Balmar for warranty evaluation. To test the alternator:
1.
Clip a jumper wire to the positive post of the alternator, or on the battery side of the isolator (if an isolator is
in use). Use a SHIELDED alligator clip for post attachment. Unintentional contact between the alligator clip
and the alternator case could result in damage to your electrical system.
2. Disconnect the field wire from the rear of the alternator and attach the other end of the jumper wire to the
alternator’s Field terminal (F). CAUTION: Do not allow the wire to contact the case while it is attached to
the positive post. The case may be grounded and severe damage could occur.
2.
The regulator is now bypassed. When the ignition is engaged and the motor is started, the voltage should
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