Wiring Diagram for CESSNA 180

type circuit breaker is used. Leave in "ON" or closed position at all times. DON'T install battery cables in reverse polarity. Connect positive lead to positive post and negative lead to negative post. DON'T operate Alternator at any time with Alternator "OUTPUT" lead disconnected. DON'T ground field terminal at any time Alternator is operating. 1 each 1 each Section ! ALTERNATOR INSTALLATION BASIC INSTALLATION KIT #SE Single Engine Aircraft PARTS LIST Quan tity 1 each 1 each 1 each 2 each 1 each 1 each 1 each 1 each Part Number 015-01237 625-61609 635-62448 015-01240 A-1670 245-23709 A-178 165-15041 A-178-2 435-42408 A-178-4 395-37992 A-178C 415-40054 Ref. No. A-152A A-1530 OVR-12B OVR-12A-6 AR65-113 NOTE: To make Alternator inoperative when checking for radio noise, only the field circuit should be opened. On aircraft that do not have an individual switch for the Alternator field circuit (gen. switch), it will be necessary to disconnect the field lead at the Alternator and then run engine. (See SECTION III) See Section IV Optional Equipment and Spares List Description Alternator Assembly Voltage Regulator Overvoltage Relay Mounting Kit Spike Guard Capacitor Clamps Lead Kit Hardware Kit Placard Installation Instructions KIT #SE Report 65-113 PART I: 1. ALTERNATOR INSTALLATION Instructions for Installation Single Engine Aircraft INSTALLATION OF ALTERNATOR AND REGULATOR Disconnect battery, identify, mark, and disconnect original wires from Generator and Regulator. Remove Generator and Voltage Regulator. 2. 3. Install Alternator, Part Number 015-01237, using existing generator mounting brackets. Install mounting bar with hardware supplied in kit, Part Number 015-01240 KIT SE Report 65-113 PART II: INSTALLATION OF OVERVOLTAGE RELAY 1. 2. 3. 4. Install Overvoltage Relay, Part Number 635-62446 or 635-62448, in an area behind instru ment panel which will provide clearance from other electrical component connections and clear of moving parts. Mount to convenient structure using No. 8 screws and nuts. Install a 5 amp trip free circuit breaker such as MS24510-5 or equivalent. Connect the wire marked "Pos" from the relay to the 5 amp circuit breaker. Connect the wire marked "Gnd" from the relay to a good airframe ground. 5. KIT #SE 4. 5. 6. 7. 8. 9. Use AN970-5 washers to adjust spacing between generator bracket and har bracket. If front hole in bar is utilized, install short ANSHSA with two washers to prevent interference with ANBH15A bolt Adjust for proper pulley alignment and install approved drive belt and adjust belt tension in accordance with standard procedures. Safety wire bolts together as required and safety ANBH15A bolt around support bar. Install Voltage Regulator, Part Number 625-61600, where original regulator was mounted. Check that the free end of the bonding strap is well grounded to the airframe. Using hardware, clamps and leads, mount spike guard capacitor, Part Number 245-23709, to regulater as shown on diagram If original circuit breaker is rated less than 60 amp, remove and replace with Part Number 295-29694, 60 amp circuit breaker. Reconnect wires. Connect the large wire removed from the generator output terminal, to the output terminal of the alternator, AC-43.13-1A, Chapter 11 covers in detail, wire size require ments to accommodate the 50 amp alternator output. Connect the small wire removed from the generator field terminal to the field terminal of the alternator. Install a bonding strap or a wire, as large, or larger than, the original generator output wire, from the ground terminal of the alternator to the engine mount or engine case. Be sure you have a good ground between the alternator and the airframe. 10. Install an 18 ga. wire from the ground terminal of the alternator to the ground terminal of the voltage regulator. 11. Install an 18 ga. wire from the alternator rag or (aux) terminal to the reg. terminal of the voltage regulator. 12. Connect the original field wire from the cabin generator field switch to the field terminal of the voltage regulator. Note that this wire was originally attached to the field terminal of the old regulator. 13. Splice the remaining two heavy wires which were connected to bat. and gen/armature terminals of the original voltage regulator together using butt or ring type amp terminals of proper size. At the field switch in the aircraft, disconnect the wire going to the Alternator field terminal and splice one of the two wires marked "Field" to the disconnected wire. Connect the remaining "Field" wire to the terminal of the field switch vacated in Step 5. 6. 7. Install placard, Part Number 415-40054, on instrument panel in view of pilot near alternator field switch. 8. Use ring and butt type terminals and splices such as amp 32951 and 321026 for all connections. 9. Insure all wires are properly secured and work is done in compliance with A.C.43.13-1A PART III: 1. 2. PREPARATION OF FORM FAA 337 Install Alternator in accordance with Supplemental Type Certificate No. SA334SW. Weight Change: (Compute weight and balance as necessary). Check size of wire from Alternator output terminal to Alternator circuit breaker and from Alternator circuit breaker to buss and size of Alternator circuit breaker with A.C. 43.13-1A. (Note: Continue this statement as applicable. If wire and circuit breaker sizes are satisfactory, so state. If not satisfactory, state wire and/or circuit breaker size installed to conform with A.C. 43.13-1A.) Modify aircraft equipment list by removal of generator listed and adding alternator installation. WEIGHT: Alternator installation-11 lbs ARM: Refer to Aircraft Equipment List SPIKE GUARD REG. REGULATOR A EXISTING WIRES SEE NOTE A B ADD, 18 ga. WIRES ADD, GROUND BONDING SEE NOTE A AIRCRAFT FIREWALL FIELD TERM B A GROUND TERM OVERVOLTAGE RELAY FIELD SPLICE ORIG. FIELD SWITCH FIELD AIRCRAFT GROUND PART II STEF SAND 5 AMP C.B. (COMMON ON TWIN ENGINE> (MS 24510-5 OR EQUIVALENT) TO A/C BATTERY 60A CB. A BUS SPLICE PART I STEPS ALTERNATOR OUTPUT TERM. TERM TO WARN LIGHT (IF USED) AM LA CHAPTER 11 SECTIONS AND BUILD BE CONDULTCO FOR MINIMUM FOR no AP OUTPUT TYPICAL WIRING DIAGRAM ALTERNATOR SYSTEM, SINGLE AND TWIN ENGINE INSTALLATION See SECTION IV for Optional Equipment Section II BASIC INSTALLATION KIT #TE ALTERNATOR INSTALLATION Twin Engine Aircraft PARTS LIST tity Quan Part Number Reference 2 each 2 each 2 each 015-01237 2 each 015-01240 635-62448 625-61609 2 each 2 each 4 each 2 each 395-37992 435-42408 165-15041 245-23709 1 each 1 each 415-40055 Description Clamps Spike Guard Capacitor Mounting Kit Overvoltage Relay Voltage Regulator Alternator Assembly Placard Hardware Kit Lead Kit Installation Instructions Report 65 113 KIT=TE Report 65-113 PART I: 1. 2. ALTERNATOR INSTALLATION Instructions for Installation KIT #TE Report 65-113 Twin Engine Aircraft INSTALLATION OF ALTERNATOR AND REGULATOR Install Alternators and Regulators on each engine in accordance with instructions for Single Engine. Remove paralleling relays and secure wires. The Alternator system does not require paralleling relays. SECTION III RADIO NOISE SUPPRESSION TECHNIQUES The Alternator system has built-in radio noise suppression, and virtually eliminates all noise and interference, on most installations. If additional suppression is required, a qualified Radio Maintenance Technician should be consulted for recommendations. SECTION IV OPTIONAL EQUIPMENT AND SPARES LIST OPTIONAL EQUIPMENT PART II: INSTALLATION OF OVERVOLTAGE RELAY Req. 1. Install overvoltage relays for each engine in accordance with instructions for single engine. Per Engine Part Number Reference No. Description 2. Install placard, Part Number 415-40055, on instrument panel in view of pilot near alternator field switch. 1 295-29694 A-154 PART III: PREPARATION OF FORM FAA337 Install Alternator in accordance with Supplemental Type Certificate No. SA334SW. Weight Change: (Compute weight and balance as necessary.) Check size of wire from right and left Alternator output terminals to right and left Alternator circuit breakers and from right and left Alternator circuit breakers to buss and size of right and left Alternator circuit breakers with A.C. 43.13-1A. (NOTE: Continue this statement as applicable. If wire and circuit breaker sizes are satisfactory, so state. If not satisfactory, state wire and/or circuit breaker size installed to conform with A.C. 43.13-1A.) WEIGHT: Dual Alternator Installation weight - 22 lbs ARM: Refer to Aircraft Equipment List 295-29699 A-200 465-45923 A-168 Circuit Breaker, 60 amp (KLIXONCLMG0) Circuit Breaker, 5 amp (MS24510-5 or equivalent) Ammeter, 60 amp (SW359M) 015-01246 A-152-3 Fan, Cooling, for opposite rotation engine 015-01245 A-179-1 Arm, Belt Adjust, PA-22 *Reference Fan/Alternator rotation from rear of Alternator. (Fan should pump air from inside Alternator.) -10- -11- Spares List Section V Req. Per Engine/Aircraft Part Number (Old P/N) 015-01237 A-152A 245-23693 A-177-1 655-64139 A-152A-1 115-09964 A-152-2 015-01247 A-152-4 015-01245 A-152-3 015-01240 A-1670 015-01245 A-179-1 625-61609 A 1530 625-61610 A-153-3 1 245-23810 A-178A 1 245-23709 A-178 165-15041 A-178-2 435-42371 A 178-1 435-42372 395-37992 A-178-3 A-178C 635-62448 415-40054 415-40055 OVR-128 OVR-12A-6 OVR-12A-7 Reference No. Description ALTERNATOR ASSEMBLY Capacitor Resistor Brush Assembly FAN, COOLING, STANDARD ROTATION FAN, COOLING, for opposite rotation engine MOUNT BAR ASSEMBLY W/HARDWARE Arm, Belt Adjust, PA-22 VOLTAGE REGULATOR ASSEMBLY Strap, Grounding SPIKE GUARD ASSEMBLY Capacitor Clamp Lead Assembly 3.5" Lead Assembly 5.5" Hardware Kit OVERVOLTAGE RELAY Placard, Single Engine Placard, Twin Engine REFERENCE FAN/ALTERNATOR ROTATION FROM FROM REAR OF ALTERNATOR. FAN SHOULD PUMP AIR FROM INSIDE ALTERNATOR REMANUFACTURED EXCHANGE PART NO. REF. NO. DESCRIPTION 015-01248 A-152-A ALTERNATOR ASSEMBLY -12- SUPPLEMENTAL INFORMATION. 1. Bonanza Aircraft S/N's 04866 through 06162 2. Contra Rotating Engines and Fan Ratation 3. Piper PA 24-250 Belt Recommendations 4. Lycoming Wide Deck Engines 5. Downer (Republic) RC-3 Seabee, Franklin 6A8-215 1. Compliance with the following excerpt from (BEECHCRAFT SERVICE NEWS), Vol. XIII, No. 2, Feb. 1960 is recommended when an INTER AV Alternator kit is retrofitted to Bonanza Aircraft. "SHOCK MOUNTED GENERATOR BRACKETS-A new shock mounted generator bracket which will reduce vibration, the major cause of premature generator and generator bracket failures, has been developed for the Con- tinental O-470 and 10-470 series engines. The shock mounted generator bracket is available for installation on the Bonanza series of airplanes, ser- ials D-4866 through D-6161. Installation of this new bracket will be made at the factory on all Model 33 aircraft and on Bonanzas, serials D-6162 and after This improved bracket assembly was developed by Continental Motors and is available in Continental kit EQ-5841. The kit consists of four rubber shock mounts, a new generator brace, a new mounting bracket, attach- parts, and installation instructions. Further information concerning Kit EC- 5841 or the kit itself may be obtained by contacting the Continental Motors Corporation of Muskegon, Michigan or any authorized Continental Distribu- NOTE: tor. It is our understanding that the kit mentioned in the above exerpt is no longer available as a kit, but individual parts are currently available from Teledyne Continental Motors through their customer service department in Mobile, Alabama (See Generator and Brackets, Models 10-470 C through S in Continental Motors Book.) 2 Installation of Alternators on aircraft equipped with Counter Rotating Engines: An opposite rotation fan, Part Number 015-01246, is available from the factory on an exchange basis at no charge. Remove the Part Number 015-01247 fan from the Alternator to be installed on the opposite rotation engine and replace with Part Number 015-01246 fam 3. Piper PA-24-250 Belt Recommendations - Gates Belt P/N's 575TG (31"). 8353 (31-1/8") or 8242 (32-1/8"), STC SA3345W is approved for installation on these aircraft listed on Page 2 using the "narrow deck" Lycoming engines. Later versions of some aircraft will have the "wide deck" Lycoming engine installed. Check with your local GADO for assistance with field approval to install this alternator system on wide deck Lycoming engines. +13- SECTIONM INTER AV INC. ALTERNATOR INSTALLATION Dummer (Republic) RC SHADEE Franklin 68-215 T This is an illustration of one method of mounting the Alternator. methods may be employed at the discretion of the installing agency, provided that installation conforms with instrui troms dutlincil in Report 65-111 (single vaginë). In order to properly align fir alternal will be necessary to modify the existing front generator steel mounting bracket by drilling any 5/16" hole 1/2 ahead of the slot. Cut the slotted and off and reinstall the bracket on the engine, using the same cap screw. Assemble the alternator feet on the alternator mounting bar and install the feet on the front side of the original generator brackets, using the original bolts, as shown on the sketch. ALTERNATOR MOUNT FEET- The generator belt tension adjustment bar in turned upward and attachec to the threaded hole in the alternator, nearest the ingine case. It may be necessary to add washers to the lower end of the bar in order to align the bar with the alternator. In the event your belt adjustment bar is the long type, drill new hole in har që për sketch and cut off excess material. Use Franklin P/N 14883 or Goodyear 51.380 Belt. REMOVE BAR MODIFICATION