Balmar alternator repair help please!

[Suijin]

My tachometer has been working intermittently ever since I installed a new Balmar alternator with external regulator a few years ago. Problem was finally traced to the post for the connection between the stator and the regulator. Cracked the case and am a bit mystified by what’s revealed. Pen tip in the picture below is pointing to a ring terminal that is just “laying” against the post plate. Can anyone tell me how this is supposed to be attached/configured? Almost looks like a manufacturing flaw.

Combed the net for any info and found nothing.

[hellosailor]

Certainly looks like some just didn't install the terminal properly, but after this many years, it would be very generous of Balmar to fix it as a manufacturing defect.

More likely, it just needs to be properly screwed down someplace and that will solve the problem?

[EngNate]

does the terminal have two varnished solid wires like the windings? If so it would be one of the stator winding connections. There are three such connections, each going to a pair of the six rectifiers. The tach connection is to (any) one of these

[NYSail]

Did you call balmar and discuss? Dale in the tech department is very helpful and I am sure he can advise you. As mentioned might be just attach. But I am wondering how it has stayed in place all these years if it’s just “laying” there.

Greg

[thereefgeek]

Definitely get ahold of Balmar and ask if this is normal.
Probably should've done that a few years ago when you first noticed the tach issue.
Either way, they can warrantee it out, or at least fix it for you at less than the cost of a new alternator.

[Suijin]

Took this long to figure out because I did not really need the tach. I know the rpm ranges I use by sound.

So went ahead and soldered the connection. May not like vibration; all the other posts have rivet connections. Will fix it properly if the solder ever breaks.

[NYSail]

Does it now work

[Suijin]

Not installed yet lol. Will not have it in until Wednesday. I’m fairly certain it will; appears to be a manufacturing defect that worked (intermittently) and passed testing as it was generally in contact.

[pitlaw]

I am sure you already know this but Pasco Battery off West St in Annapolis is a Balmar authorized rebuilder. They could surely look at it and advise.

[guyrj33]

Solder will break in time.

[GoAway]

If you do call Balmar or take it to Pasco, please let us know what they say. I also have a Balmar alternator and occasionally, my tach stops working briefly. It happens shortly after starting engine and I have always attributed it to somewhat low voltage (although never below 60% SOC) at that time. Perhaps there is another cause.

[EngNate]

It is quite common to temporarily lose the tach signal when a multi-stage regulator switches to float. The voltage setting has just been dropped and the battery is higher than the setting at that point so the alternator goes completely off for a time. Turn some accessory loads on and it will come back more quickly.

[GoAway]

How clever EngNate. I would have never thought of that, but it sure makes sense. Thanks

[Suijin]

Problem solved, so the post was the issue.

A mechanic friend end of mine mentioned that this is a common problem (aside from the specific cause of mine which appeared to be a manufacturing defect) caused by over tightening the nut on the stator contact without putting another wrench on the retaining but. He sees them broken inside with some regularity.

Balmars have a feature to keep the tach working when the charging voltage drops so that should not be an issue other than a momentary lapse.

[LittleWing77]

Thanks very much for the resolution post, Suijin. I was following this, as I'm seeking to broaden my tech knowledge.

Happy New Year!
LittleWing