Balmar · Alternator

Balmar alternators & regulators

Balmar’s small-case alternators are the usual upgrade from a stock alternator on sailing-yacht and trawler diesels. The 6-Series comes in three mounts — 60 (3.15 in dual foot, the Hitachi style of Yanmar and Westerbeke), 621 (1 or 2 in single foot, Motorola or Delco style, e.g. Volvo Penta) and 604 (4 in J-180) — with 100 or 120 A at 12 V (70 and 150 A in the data sheet) or 70 A at 24 V; the XT-Series puts 170 or 250 A, or 90 A at 24 V, into a similar case and replaced the AT-165 and AT-200. Both carry a Smart Ready internal regulator as a get-home backup but are built for an external multi-stage regulator: ARS-5 (6-Series up to 120 A), MC-618 (successor to the MC-614), MC-624 for 24 V, MC-612-DUAL for two alternators on one engine. When buying parts, the end of the number gives the pulley (SV, DV, K6, J10) and older units carry -SR-IG names; above 100 A Balmar wants a dual-vee or serpentine drive, which on most older diesels means the AltMount kit made for that engine.

Manuals & documents

The links go straight to Balmar. We host no manuals or drawings — the manufacturer’s copy is the current one.

Wear parts & part numbers

PartOEM numberAlso fitsNote
Alternator60-100-DV1,2,3,4replaces 60-100-SR-IG—60-Series, 100 A at 12 V: 3.15 in dual-foot (Hitachi-style) saddle mount, dual deep-vee pulley, isolated ground, 4.0 hp belt load; Balmar names Yanmar, Westerbeke, Lehman and Perkins-Sabre as typical engines. Same alternator with other pulleys: 60-100-SV, 60-100-K6, 60-100-J10.
Alternator621-100-DV5,6,4replaces 621-100-SR-IG—621-Series, 100 A at 12 V, single-foot (spindle) mount: 1 in foot for Motorola-style mounts, with the supplied bushed spacer for 2 in Delco-style mounts. Balmar names Volvo Penta (petrol and diesel), Westerbeke, Perkins and GM-based engines. Also 621-100-SV, -K6, -J10.
Alternator60-120-DV7,4,8replaces 60-120-SR-IG—120 A at 12 V, 4.8 hp: needs a dual-vee or serpentine drive; on an engine with a single vee belt Balmar points to an AltMount kit. Single-foot version 621-120-DV, 4 in J-180 version 604-120-DV.
Alternator60-24-70-DV9,4,10,11,12,13replaces 60-24-70-SR-IG—24 V, 70 A, 5.6 hp, 3.15 in dual foot. Balmar requires a Max Charge regulator (MC-624) for 24 V and at least dual 1/2 in belts on every 24 V alternator. Also 621-24-70-DV and 604-24-70-DV.
AlternatorXT-DF-170-K614,15replaces AT-DF-165-K6replaces AT-DF-165-12-IG—XT-170, 12 V, 3.15 in dual foot, K6 serpentine pulley, case ground (isolated ground: XT-DF-170-K6-IG); 5.2 hp. Replaces the AT-165 dual-foot units; Balmar names Yanmar, Westerbeke, Lehman and Perkins-Sabre as typical engines.
AlternatorXT-SF-170-K616,15replaces AT-SF-165-K6replaces AT-SF-165-12-IG—XT-170 with the 1–2 in single foot (Motorola or Delco style), K6 pulley, case ground (isolated ground: XT-SF-170-K6-IG). Replaces the AT-165 single-foot units.
AlternatorXT-DF-250-J1017,18,15replaces AT-DF-200-J10replaces AT-DF-200-12-IG—XT-250, 12 V, 3.15 in dual foot, J10 serpentine pulley, case ground; 6.0 hp (2023 data sheet: 6.6 hp). Replaces the AT-200.
AlternatorXT-CR-170-K619,18,15replaces XT-DF-170-K6-3YM—XT-170 configured for Yanmar common-rail engines introduced after 2013, K6 pulley, case ground; 250 A version XT-CR-250-K6.
Alternator & regulator kit60-YP-MC-100-DV20,21,22,23replaces 60-YP-MC-100-SR-KIT—60-100-DV with a Max Charge regulator, alternator and battery temperature sensors and mounting hardware. Balmar’s kit page still names the MC-614, which the MC-618 has replaced; the 120 A kit is 60-YP-MC-120-DV.
Voltage regulatorMC-618-H24,23,10,25replaces MC-614-H—Max Charge multi-stage regulator, 12 V, with 54 in harness, fused sense pigtail and magnetic programming tool; without harness: MC-618 (was MC-614). 15 A field, 9 battery programs incl. LiFePO4, links to the SG200 battery monitor.
Voltage regulatorARS-5-H26,27,10—ARS-5 multi-stage regulator, 12 V, with 54 in harness (ARS-5 without). 9 A field, 5 battery programs; Balmar lists it for 6-Series alternators up to 120 A and single-alternator, single-engine boats only — not for the XT.
Voltage regulatorMC-624-H28,29,10,4—Max Charge regulator for 24 V with harness (MC-624 without); 10 A field, a 15 A version exists. Needed with every 24 V Balmar alternator.
Voltage regulatorMC-612-DUAL-H30,10,11—One regulator for two alternators on one engine, 12 V, with twin 54 in harnesses (MC-612-DUAL without); senses either both alternators and one battery bank or one alternator and two banks.
Temperature sensorMC-TS-A31,32,11—Alternator temperature sensor, 54 in lead (80 in: MC-TS-A80). Balmar’s product page calls alternator temperature sensing required for every externally regulated installation. The ring lug goes on the stud at about 10 o’clock on the 6-Series rear case — do not bend it.
Temperature sensorMC-TS-B33,34,35—Battery temperature sensor, 20 ft lead (30 ft: MC-TS-B30); lets the regulator compensate voltage and stop charging when the battery overheats.
Wiring harness101036,37,38—Regulator harness for 12 V 6-, AT- and 9-Series alternators, grey field/stator plug, 54 in; 120 in version 1020. Balmar uses 14 AWG wire; beyond 10 ft rewire in 12 AWG.
Wiring harness101239,40—Regulator harness for 24 V 6-Series alternators, grey field/stator plug, 54 in; 120 in version 1022.
Rebuild kit706041,42—Offshore/rebuild kit for 12 V 60-, 621- and 604-Series alternators (70–150 A, including the older -SR-IG units): Smart Ready regulator, brush holder, front and rear bearing, rectifier with gasket. Balmar calls for professional fitting — the joints use high-temperature solder.
Rebuild kit7060-2443—The same rebuild kit for 24 V 60-Series alternators: bearings, brushes, rectifier and Smart Ready regulator.
Rebuild kit70-XT-17044,45—XT-170 (12 V): bearings, regulator with integral brushes, rectifier, bearing retainer plate. For the XT-250: 70-XT-250.
Rebuild kit70-AT-16546,47—AT-165 (12 V): bearings, brushes, rectifier. For the AT-200: 70-AT-200.
Alternator pulley61-007048—K6 serpentine, 2.45 in, 17 mm bore — the standard K6 pulley on the 6-Series.
Alternator pulley61-002049,50,51—Dual 2.7 in × 1/2 in deep vee, 17 mm bore (single groove: 61-0010). Balmar’s deep-vee pulleys also take 3/8 and 7/16 in belts.
Alternator pulley48-AM-10652,53,54—AltMount J10 serpentine, 2.4 in, 17 mm bore, for AT-Series alternators; with spacer 48-AM-107 it fits the 6-Series (together the same as 48-AM-38). For the stock Hitachi alternator on a Yanmar: 48-AM-97.
Serpentine pulley conversion kit48-YSP-3JH-A55,56,57replaces 48-YSP-3JH-Breplaces 48-YSP-4JH-Creplaces 48-YSP-4JH-A—AltMount J10 kit for Yanmar 3JH4-E, 3JH5, 4JH4-E and 4JH5: three pulleys (crank overlay, water pump, alternator), two 44.5 in J10 belts (one spare; single belt 48-B-445) and hardware. With an AT-200 a longer belt may be needed.
Serpentine pulley conversion kit48-YSP-4JH-E58,56,59—AltMount J10 kit for Yanmar 4JH2-TE, -HTE, -DTE and -UTE; 47 in belts (single belt 48-B-47).
Serpentine pulley conversion kit48-YSP-3GM-A60,56—AltMount J10 kit for the Yanmar 3GM30, 39 in belts. 3GM30-F and 2GM20-F take 48-YSP-3GM-B, 2GM20 and the older 3GM take 48-YSP-3GM-C.
Serpentine pulley conversion kit48-VSP-MD-A61,62,56—AltMount J10 kit for the Volvo Penta MD2030 and Perkins Perama M20, M25, M30; 33 in belts. MD2040: 48-VSP-MD-B.
Serpentine pulley conversion kit48-VSP-D2-A63,56—AltMount J10 kit for the Volvo Penta D2-55 A to F; 44 in belts.
Serpentine pulley conversion kit48-WSP-44A64,56replaces 48-WSP-44B—AltMount J10 kit for Westerbeke 44A, 44B and 44C; 40 in belts.
Installation kit6-002065,66,67,15—Alternator installation hardware for Yanmar engines (not the CX and LP series); included in every dual-foot Yanmar XT kit. Yanmar 6CX: 6-0030; LP, 6LP: 6-0040.
Belt tensioner / adjustment armUBB68,69,70,71,38—Belt Buddy: universal adjustment arm UAA (10.3 in long, 4.5 in of travel) with the screw mechanism BB. With a 1/2 in offset arm: UBB2. The mechanism alone for an existing arm is BBU — it costs some travel.
Alternator surge protectorAPM-1272,73,74,75,76—Alternator Protection Module, 12 V, wired between B+ and B− at the back of the alternator: absorbs spikes from battery-switch or lithium-BMS disconnects (clamps up to 60 V, reacts to sustained overvoltage from about 20 V). Green LED = protecting, red LED or beeping = replace. 24 V: APM-24, 48 V: APM-48 — the wrong voltage gives no protection.
Tachometer signal adapter15-TSS77,78,38—Tachometer signal stabilizer for AT- and XT-Series alternators (16 stator poles instead of the usual 12) when the tachometer cannot be recalibrated; adjusted with a potentiometer against a hand-held tachometer.
Upgrade kit30-SR12-0279,80,81,82,83—Smart Ready retrofit for the Valeo 120 A/12 V alternator on recent Yanmar engines: swaps its internal regulator so it accepts a Balmar external regulator and keeps a get-home internal mode; with regulator: ARS-5-VL-01 or MC-618-VL-01. Balmar’s serial list includes 3JH5E from E12749, 4JH5E from E14236, 3YM30E from E20848, 2YM15 from E05891 and 3YM20 from E11910.

Numbers checked against the sources below on 23 October 2026. Always confirm against your serial number and exact type before ordering.

Service intervals

TaskInterval
Belt tension checkAfter every charge cycle for the first several weeks of engine running, then as part of regular maintenance; replace a worn or damaged belt with the best quality available11
Belt tension checkAltMount serpentine drive: re-tension after the first few runs, then as part of routine engine maintenance; check pulley alignment and the crank and water-pump pulley bolts if the belt dusts84
Electrical connectionsNo fixed interval — Balmar’s first step whenever charging falls off: take apart and clean every charging connection, positive and negative, check the regulator harness for continuity and replace any damaged or corroded ATC fuse (10 A and 1 A)11,25

From Balmar’s alternator manual SUP-0207, the MC-618 manual and the AltMount instructions. Balmar gives no hours or years for brushes, bearings, rectifier or regulator: they come as rebuild and offshore kits (7060, 70-XT-170 …) for a professional to fit. The only recurring job in the books is belt tension.

Specifications

Models6-Series (small case): 60 = 3.15 in dual foot, 621 = 1 or 2 in single foot, 604 = 4 in dual foot; 12 V with 100 or 120 A (data sheet also 70 and 150 A; 150 A on the 604 today), 24 V with 70 A4,22,85,11
ModelsXT-Series (small case, braided stator, 16 poles): XT-170 and XT-250 at 12 V, XT-24-90 at 24 V; mounts SF (1–2 in single foot), DF (3.15 in dual foot), CR (dual foot for Yanmar common-rail engines after 2013), DF4 (4 in), VT (GM Vortec). Replaced the AT-Series 165 and 200 A15,18,19,14
TypeExternally regulated P-type (positive field) alternators with a built-in Smart Ready single-stage regulator as backup (14.1 V, or 28.2 V on the 24 V 6-Series); 6-Series isolated ground with D+ lamp output, XT case ground (XT-170 isolated ground on request); 50 A diodes, 3+3 (6-Series) or 6+6 (XT)22,15,11
MountingBalmar’s own engine pointers: 3.15 in dual foot (Hitachi style) for Yanmar, Westerbeke, Lehman, Perkins-Sabre; 1 in single foot (Motorola style) for Westerbeke, Lehman, Hino; 2 in single foot (Delco style) for Volvo Penta petrol and diesel, Perkins, Mercruiser and GM-based engines; 4 in dual foot (J-180) for Caterpillar, Cummins, John Deere. 60/604 feet: 10 mm bore (8 mm bushings available); 621: 1/2 in bore on the 1 in foot, 3/8 in with the supplied spacer51,1,5,8,86
Pulleys & beltsSuffix = pulley: SV 1/2 in single deep vee, DV 1/2 in dual deep vee (both 2.7 in, also take 3/8 and 7/16 in belts), K6 and J10 serpentine. Belts: 3/8 in to about 70–80 A, 1/2 in to 100 A; above 100 A at 12 V and on every 24 V Balmar dual belts or a multi-groove belt22,11,51
Engine fitAltMount kits, Yanmar: 2GM20 and 3GM 48-YSP-3GM-C; 2GM20-F, 3GM30-F 48-YSP-3GM-B; 3GM30 48-YSP-3GM-A; 2YM15, 3YM20 48-YSP-3YM-A; 3YM30 48-YSP-3YM-B; 3HM35 48-YSP-3HM-A (-F: 3HM-B); 3JH2 48-YSP-3JH-C; 3JH3 48-YSP-3JH-E; 3JH4-E, 3JH5, 4JH4-E, 4JH5(-E) 48-YSP-3JH-A; 4JH(E) 48-YSP-4JH-F; 4JH2 48-YSP-4JH-E; 4JH3 48-YSP-4JH-D; 4JH4-TE/HTE/DTE 48-YSP-4JH-B; 4LH-A 48-YSP-4LH-A; 6LY 48-YSP-6LY-A56
Engine fitAltMount kits, Volvo Penta and Perkins: 2001/2002/2003(T) 48-VSP-2001 (three pulleys) or 48-VSP-2001R (two); MD2030 and Perkins Perama M20/M25/M30 48-VSP-MD-A; MD2040 48-VSP-MD-B; D2-55 A–F 48-VSP-D2-A; Prima, TMD22 48-VSP-PR-A; Perkins 4107/4108 48-PSP-410-A; Perkins 6.354 48-PSP-6354; Prima M50/M60/M80 48-PSP-PR-A56
Engine fitAltMount kits, Westerbeke and Universal: Westerbeke 12C/12D, 20B, 30B 48-WSP-12C; 13A, 21, 27 48-WSP-21; 18, 21A, 27A, 35B, 38B, 42B 48-WSP-18; 30C, 33 48-WSP-33; 40 48-WSP-40; 44A/B/C 48-WSP-44A; 46 48-WSP-46; 71, 82 48-WSP-71. Universal M25/M25XP 48-USP-M25; M35 48-USP-M-B; M25XPB, M35B, M40B 48-USP-M35B; M50/M50A/M50B, 5444 48-USP-M50; 5432 48-USP-543256
Output6-Series at 13.5 V, cold / hot, alternator rpm 2,000 – 3,000 – 6,000 (about engine 1,000 – 1,500 – 3,000 at Balmar’s 2:1 example ratio): 100 A 83/70 – 106/93 – 108/93 A; 120 A 80/60 – 121/105 – 125/109 A; 150 A 80/65 – 132/111 – 159/129 A; 70 A 24 V (at 27 V) 36/25 – 68/50 – 76/55 A22,87
OutputXT-Series at 13.5 V, cold / hot, alternator rpm 2,000 – 3,000 – 6,000: XT-170 128/118 – 174/144 – 198/166 A; XT-250 203/142 – 256/190 – 290/221 A; XT 24-90 66/46 – 94/70 – 112/85 A. Balmar: up to 128 A (XT-170) and 186 A (XT-250) at idle87,15
Belt load (power take-off)6-Series: 70 A 2.8 hp, 100 A 4.0 hp, 120 A 4.8 hp, 150 A 5.2 hp, 70 A 24 V 5.6 hp. XT: 170 A 5.2 hp; 250 A 6.0 hp (2023 data sheet: 6.6 hp); 90 A 24 V 5.2 hp (data sheet: 4.8 hp)22,4,18,15
Alternator speed6-Series: cut-in 1,320 rpm; maximum 12,000 rpm (the spec table of the same data sheet says 15,000). XT: cut-in 1,150 rpm (170 A) or 1,350 rpm (90 and 250 A); maximum 18,000 rpm22,4,15
Dimensions6-Series: case Ø 136 mm, height 190 mm, case length 129 mm, overall length 168 mm (SV), 185 mm (DV), 175 mm (K6), 181 mm (J10); 167 mm between mounting bolt and tension-arm bolt; 12 stator poles22,86
DimensionsXT-170: case Ø 134 mm, height 188 mm, overall length 203 mm (DV) or 193 mm (K6). XT-250: case Ø 142 mm, height 198 mm, overall length 181 mm (DV). Both 16 stator poles15,86
Direction of rotation6-Series and XT: clockwise seen from the pulley end (internal fans); running them the other way round costs cooling and output11
Operating temperatureAlternator normally 82 °C, maximum 108 °C (6-Series and XT); case can pass 93 °C under long heavy load. Regulators throttle the field from the MC-TS-A reading (MC-618 default alarm 225 °F, about 107 °C); MC-614 regulator itself up to 90 °C22,15,11,25,35
Belt tensionV-belts: 1/4–3/8 in (6–10 mm) deflection under thumb pressure at mid-span, better with a tension gauge. J10 serpentine (AltMount): 1/32 in per inch of span under 25 lb11,84
Tightening torquesPulley nut: Balmar’s FAQ gives 45–50 ft·lb (61–68 Nm) on the 6-Series and 70 ft·lb (95 Nm) on the AT-Series; the AltMount instructions say 70–80 ft·lb. Fit with an impact wrench (15/16 in or 24 mm socket); the shaft cannot be held38,84,41
Power cable sizeSize the output cable from alternator amps and round-trip length to the battery for 3 % voltage drop (chart on page 3 of the manual); the ground cable of an isolated-ground alternator must be the same size11
Breaker / fuseOutput fuse or breaker at about 140 % of the alternator rating, below the cable’s capacity. Regulator harness: 10 A ATC fuse in the red power wire, 1 A in the sense wire11,25
ControlMC-618 (12 V): 15 A field, 9 battery programs incl. LiFePO4. MC-624 (24 V): 10 A field, 15 A version available. MC-612-DUAL: two alternators on one engine. ARS-5 (12 V): 9 A field, 5 programs, only for 6-Series up to 120 A and one alternator. Twin engines feeding one bank: Centerfielder II (CFII-12/24) with Max Charge regulators10,11
Data connectionsMC-618: SmartLink network to the SG200 battery monitor through the SG2-0404 adapter on an SG2-0403 (5 m) or SG2-0400 (10 m) cable; setup from the SG200 display, full programming from the Balmar app with the SG2-0300 Bluetooth gateway25,88,89,90
SuccessorAT-165 → XT-170 and AT-200 → XT-250 (Balmar: more output, 5–10 °C cooler); MC-614 → MC-618 (same price and functions plus the SG200 link); 6-Series names ending -SR-IG → today’s -SV, -DV, -K6, -J1015,14,17,23,91,1
Warranty2 years from purchase, only for products bought from authorised Balmar dealers and fitted by a qualified installer; parts made more than 10 years ago are not covered even if bought recently11,92

Good to know

  • Fit the MC-TS-A sensor with any Balmar regulator so it can cut field current before the alternator cooks. On late-model Yanmars (3JH5E, 4JH57) the alternator sits by the heat exchanger behind a belt guard; Balmar’s 2018 bulletin suggests belt load setting b-2 (about 10 % less output), moving the alternator outwards where possible and drilling vent holes in the guard — never removing it.93,31
  • Broken B+ or B− studs are usually the cable’s fault. Balmar’s strain-relief bulletin: clamp heavy cables to the engine or something it carries within 12 in of the alternator, never to the hull or a hatch frame, put only one heavy cable on each stud and add chafe protection.94
  • Volvo Penta engines whose charge-warning lamp or buzzer will not go off after a Balmar is fitted: some Volvos need 2–3 A from the D+ circuit. Balmar’s fix on a 6-Series is a small 12 V relay (coil under 500 mA) switched by D+.38
  • The 6-Series gives 12 tach pulses per alternator turn, AT and XT have 16 stator poles — after swapping to an XT the tachometer reads wrong unless it can be recalibrated; otherwise fit the 15-TSS.11,38,77
  • Buying a used regulator for lithium: MC-614 and MC-612-DUAL units made after September 2017 have the LFP program; older ones must be set up by hand from Balmar’s 2019 bulletin. Regulators from before 19 July 2017 also have their own manuals on the discontinued-products page.95,96
  • Never run the alternator with the battery switch off — it can take out the diodes; a lithium BMS cutting out does the same, which is what the APM is for. And only one regulator at a time: never power the brown excite wires of the internal Smart Ready and an external regulator together, and stop the engine before switching between them.11,75,76

Videos & how-tos

Links to YouTube, nothing embedded. The maker’s own channel comes first; the rest are channels we found clear and correct for this model.

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  94. balmar.net/wp-content/uploads/2019/01/SERVICE-BULLETIN-Strain-Relief-January-2019.pdf
  95. balmar.net/wp-content/uploads/2019/01/SERVICE-BULLETIN-Lithium-Battery-Charge-Programming…
  96. balmar.net/manuals-for-discontinued-products/

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