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Pulley Selection Guide

Alternator Pulley Selection Guide

The standard diameter pulley for Balmar alternators is 2.7″. While all Balmar high-output marine alternators are rated for much higher speeds, the ideal sustained operating range is 4000-4500 RPM.

Divide your crankshaft pulley diameter by the alternator pulley diameter to get the speed ratio. Multiply this by the engine’s cruising RPM to get the alternator RPM.

For Example:

  • Engine crankshaft pulley diameter: 5.0″
  • Alternator pulley diameter: 2.7″
  • Engine cruising RPM: 2400

5.0″ รท 2.7″ = 1.85 (Speed Ratio)
1.85 x 2400 RPM = 4440 RPM (Alternator)
Perfect!

If your engine is typically run at low speeds, or if it has a small crankshaft pulley, select a smaller alternator pulley.

CAUTION: Use of an undersized pulley may cause the alternator to exceed its RPM rating when the engine is run at wide-open throttle (WOT). Use the formula above to determine the alternator RPM at max engine speed.

Note: Certain marine engine applications have specific pulley requirements, and other pulleys are available. We have attempted to make the selection as easy as possible for you, and the selections provided will fit most engine applications. However, if you have questions, please contact us.

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Marine Engine Applications

Marine Engine Alternator Applications

Use the table below to lookup your engine manufacturer, and select the proper alternator mounting style.

ALTERNATOR APPLICATION GUIDE

Engine Type

Balmar Alternator Series

Bukh

Motorola Style (Note 1)

Caterpillar

Off Engine Only, Most Isolated Ground (Note 1)

Chrysler

Hitachi Style or Motorola Style (Note 1)

Crusader

Motorola Style(Notes 1, 2)

Cummins

Mounts vary by engine model

Detroit Diesel

Delco Style (Note 1)

Flagship

Motorola Style (Note 1)

GMC

Motorola Style (Note 1)

Greymarine

Motorola Style (Note 1)

Hawk Marine

Motorola Style (Note 1)

Hino

Motorola Style (Note 1)

Indmar

Motorola Style (Note 1)

Isuzu

Motorola Style, some Hitachi Style (Note 1)

John Deere

Motorola Style or J-180 Style (Note 1)

Lehman (Ford)

Hitachi Style or Motorola Style (Notes 1, 3)

Lehman (Sabre)

Hitachi Style, requires tension arm mod.

Lugger

Varies by model (Notes 1, 4)

MAN

No standard (Note 1)

Mercedes

Hitachi Style (With Spacers) (Note 1)

Mercruiser

Varies by model Hitachi Style or Delco Style (Note 1)

Mitsubishi

Hitachi Style (With Spacers) (Note 1)

MTU

No standard (Note 1)

Nanni

Hitachi Style

OMC

Motorola Style (Note 1)

Pathfinder

Delco Style (Notes 1, 5)

Perkins 4107,4108

Delco Style (Note 1)

Perkins (other)

Motorola Style (Notes 1, 5)

Perkins-Volvo M

Hitachi Style (Isolated Ground)

Pleasurecraft

Motorola Style

Universal (Atomic)

Delco Style (Note 1)

Universal 30, 50

Motorola Style (Note 1)

Vetus Denouden

Hitachi Style (Note 1)

Volvo 2001, 2003

Delco Style (Note 1)

Westerbeke

Varies Hitachi Style or Delco Style

Yanmar

Hitachi Style

Yanmar 6LP

Delco Style

  1. Mounting configuration may vary by model and year. Follow directions for determining proper replacement alternator by visual inspection described on following page. Cat 3208 may use 8-Series alternator.
  2. Some Crusader models may require alternator with an offset tensioning arm.
  3. Dual belt models will require special Lehman pulley with 3/8″ spacing between belts.
  4. May require Lugger mounting kit.
  5. Use original alternator pulley.
  6. Use 9mm x 4″ pulley if belt is driven directly off flywheel.
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Alternator Selection

How Do I Choose The Proper Alternator For My Vessel?
Once battery capacity and battery type have been determined, the size of the alternator can be calculated. If the batteries used are standard or deep cycle flooded, the alternator output should be sized at 25 percent of the combined capacity of all house batteries. If your house battery capacity is 400 amp hours, for example, the alternator’s rated output should be 100 amps. If AGM or gel technology is used, the alternator output may need to be increased to 35-50% of the combined battery capacity, as those battery technologies will demand greater output.

Will A High Output Alternator Work With My Engine?
Depending on your application, the size of the engine and drive belt may limit ability to support a high-output alternator. In most cases, an engine with a 3/8″ wide drive belt will support an alternator rated at 70 to 80 amps. A greater load may result in belt dusting and premature belt failure. A single 1/2″ belt will typically support a 100-amp to 110-amp alternator. It may be necessary to consider converting to a dual pulley system if a 120-amp or larger alternator is used. Some engine applications use serpentine (flat) belts to drive the alternator and auxilliary loads. In most cases, a 5-groove or 6-groove serpentine belt will be compatible with alternators rated to 150 amps.

What About Mountings?
Nearly all marine engine manufacturers rely on one of four specific alternator mounting styles:

  • 3.15″ I.D. Dual Foot (Hitachi style) – Mounting arm at engine pivot point features two mounting feet, one in front, one in rear. Distance between mounting feet is 3.15″. (See Image 3 at left)

  • 4″ I.D. Dual Foot (J-180 style) – Mounting arm at engine pivot point features two mounting feet, one in front, one in rear. Distance between mounting feet is 4″. (See Image 4 at left)

Our Alternator Application Guide provides a general guideline for various engine applications, matching engine manufacturer and model to the corresponding alternator series and model. Unfortunately, actual mounting styles can vary based on model year, marinizer, and other factors. We strongly recommend comparing your existing alternator to the different mounting configurations shown at left to ensure a proper fit and an easier installation.

How Does My Alternator Size Up?
Making sure your new alternator fits into the same location as your old alternator can make all the difference in avoiding installation irritations. Balmar alternators are broken down into three categories: small case, large case, and extra-large case.

Small case 6-, 7- and 8-Series alternators are usually appropriate to be used in place of standard alternators on most marine gasoline and diesel engines. Some larger engines may support large or extra-large case 94-, 95-, 97- or 98-Series alternators in the factory position, or may be mounted on a custom bracket.

Keep in mind each alternator series is unique in its dimensions. It is always wise to compare the dimensions of your existing alternator to the replacement alternator to ensure a proper fit.