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INSTALLATION OF
JASCO 6565-1 12 VOLT 50 AMP ALTERNATOR SYSTEM |
- REASON FOR MODIFICATION
- The 50 amp. generator and voltage regulator are heavy, costly to overhaul, hard to
obtain parts for and rather unreliable. For those reasons a modern, lightweight alternator
system, together with solid state voltage regulator and over voltage control has been
provided by means of this modification.
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- DESCRIPTION OF CHANGE
- The generator and voltage regulator are substituted by JASCO components. The locations
of the new components are identical to the original units. Cooling is provided for by a
2" diameter blast tube. The original generator field switch is utilized to control
the alternator; however, a 3 amp circuit breaker is added to this field circuit to added
over voltage protection.
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- INSTALLATION INSTRUCTIONS
GENERAL:
- Accomplish all work and installation in accordance with appropriate sections of AC
43.13.
- Refer to Helio civilian aircraft maintenance manual as well as DWG SK 780316 to modify
alternator electrical installation.
- Route new wires neatly, providing adequate support and length for engine movement.
EXTENT OF DISMANTLING:
- Remove top engine cowling.
- Disconnect aircraft battery.
- Remove the Generator and Voltage Regulator.
- Remove and discard wire #19, connecting generator A+ to voltage regulator G terminal.
FABRICATION OF PARTS:
- Fabricate voltage regulator sub panel SP.1 as per drawing on page 7.
- Make up wiring harness WH.1 jumper wire JW.1 and ground wire GD.1 as per drawing on page
11. When alternator kit 6565-T is used, delete 90 degree connector MS 3108E20-20S and
install terminals to mate with terminal board ESC-2. All wiring is 18 gauge except S50A-6
which is 6 gauge.
- Fabricate blast tube adapter assembly as per drawing of page 8.
INSTALLATION:
- Secure JASCO Alternator to engine drive pad by means of original nut and washers. Air
intake to be positioned horizontally pointing left.
- Position SP.1. 2.5 inches above engine mount cross tube and drill flanges to
match existing bolt holes in fire wall.
- Position noise filter RFI70 six inches above engine mount and two inches inboard of SP.1
and bolt to fire wall.
- Cut hole in rear left engine baffle in location indicated by DWG 780321 and secure
adapter 685 in position. (Note: Position may be varied slightly to avoid gromotes, rivets,
and other protrusions on baffle surfaces).
- Bolt voltage regulator, over voltage control and terminal block to positions indicated.
USE:
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AN52010R7 |
Bolt |
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AN365-1032 |
Nut |
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AN960-10 |
Washer |
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AN960-10L |
Washer |
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AN363-440 |
Nut |
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AN515-4R6 |
Screw |
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AN960-4 |
Washer |
- Install 2" diameter blast tube securing ends with clamps part No. QS-200-M28.
- Bolt sub panel SP.1 complete with voltage regulator, over voltage control and junction
block to fire wall. Use two AN4-4 bolts and AN960-416 washers.
- Install diode Cessna part No. 0770728-1 to master solenoid as per SK780316.
- When terminal board connector is used in lieu of 90 degree plug, make up wiring harness
in accordance with installation instructions. Connect wires as follows: A to white.
B to red. C to green. D to black.
- Route and connect all electrical connections as per DWG's SK 780316 and KS 780321.
- Cover terminals ends at noise filter RFI 70 and solenoids with terminal covers
MS-25171-25.
- Install resistor #1513 between points #2 and #4 of the terminal board. Install lamp
holder above the altimeter on the shock mounted panel. Connect a 20gauge wire from
terminal point #4 to the light and 20 gauge wire from the instrument circuit breaker to
the other light post. Install the #328 bulb.
- Install 3 amp circuit breaker 7274-2-3 in alternator field circuit as per SK 780316.
Position next to field switch on instrument panel if space permits. Or in the most logical
position for panel in question.
- Label 3 amp circuit breaker "Alternator Field".
- Double check all electrical connections against DWG.
- Re-connect battery, replace top cowling and carry out electrical test.
- Amend weight and balance data sheet and equipment list. Weight change - 11 lbs. at
54" aft of datum.
- Make up and affix to instrument panel a placard with the following wording: "Do not
turn off alternator in flight except for emergency purposes".
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