![background image](http://html1.mh-extra.com/html/balmar/96-series/96-series_installation-and-operation-manual_3607547002.webp)
2
www.balmar.net / Customer Service: +1 (360) 435-6100 x1 / Technical Support: +1 (360) 435-6100 x3
Tech Service is available Monday - Friday (8:30am - 7:30pm EST)
The following instructions are intended for use by experienced marine electrical
installers. If you are not experienced at installing electrical system components,
we recommend the use of
a qualified marine electrical technician.
The
96-Series alternators cannot be driven (receive field voltage) from a regulator
that supplies 48V field voltage. The MC-620 cannot be powered from 48V battery.
Irreparable damage will occur immediately if 48V power is applied improperly. Sustained
48V power connected to the regulator’s power input can result in fire.
NOTE:
The engine manufacturer’s instructions for alternator installation
take precedence over these basic instructions.
NOTE:
This manual follows best practices and standards of The American Boat and Yacht Council
(ABYC). If installation is being used in another jurisdiction or application, please consult with the
appropriate governing body or standards organization for any appropriate guidelines or regulations.
ALTERNATOR INSTALLATION CONSIDERATIONS
It is out of the scope of this manual to provide step-by-step alternator mounting instructions, as every installation and
engine configuration is different. Below you will find information that can help ensure a complete, safe installation. If
you are unsure about any aspect of the installation, please consult with a qualified installation professional.
1.
Ensure the battery switch is in the OFF position. Prior to installation, ensure that the Balmar alternator mounting
configuration is compatible with the mounting hardware installed on the engine. Ensure that the replacement al-
ternator is adequately sized to meet the demands of your battery banks. As a rule of thumb, the alternator should
be rated at 25-40% of your house battery capacity, depending on the battery chemistry.
2. Ensure that the belt or belts driving the alternator are capable of handling the alternator’s horsepower load.
3. Only use the MC-620 regulator with 96-Series alternators, and visa-versa.
4. 96-Series alternators are NOT isolated ground (they are case ground), but provide an auxiliary ground stud on the
rear cover of the alternators for convenience and best performance.
5. Cables should be sized for <3% voltage drop over the length of the cable.
6.
Secure heavy battery cables to the engine within 12 inches from the alternator. The cables MUST be attached to
the engine first, before transitioning to the vessel or a surface that is not part of the engine. Failure to do this may
work harden the alternator posts/connections, resulting in damage.
7.
Check all electrical connections for continuity and ensure no cable or wire can touch the belt or other moving parts
of the engine.
8. After installation of the alternator, check for pulley alignment. Misaligned pulleys are one of the largest causes of
alternator overheating and failure.
9. 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.
Use extreme caution when handling the alternator or other engine components during or after use. Should your alter-
nator become so hot that it emits a burning smell, or if there is indication of discoloration at the pulley or pulley shaft,
shut off the alternator immediately and (once it becomes safe to inspect the alternator) check the tension of the drive
belt. Under- and over-tensioned belts are the leading cause of overheating and alternator damage. See the Trouble-
shooting section, later in the manual, for alternator inspection guidelines.