GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 CHECK WIRING HARNESS BEFORE INSTALLATION INSTALLATION MANUAL FOR INSIGHT GEM 610C-001 G4-001 AND G4-002 DOCUMENT No. 070906 READ THESE INSTRUCTIONS COMPLETELY BEFORE PROCEEDING WITH INSTALLATION Insight Instrument Corporation • Box 122 Fort Erie, ON L2A 5M6 Tel: 905-871-0733 • Fax: 905-871-5460 • Web: www.insightavionics.com Copyright 2009 Instrument Corp. INSIGHT INSTRUMENT CORP.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 If You Read Nothing Else Read This page! Follow these recommendations to minimize installation related problems. USE CAUTION when crimping the terminals onto the end of the GEM harness. Test each crimp by tugging on it sharply. It is almost impossible to pull off a properly crimped terminal. KEEP the GEM harness at least 1 inch away from the ignition harness, P-leads, and alternator wiring.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 GEM Fuel Totalizer Cautionary Notice (Cont'd) When the aircraft is filled prior to takeoff, the number is the total available on board. If partially filled to a known configuration (ex. tips empty) then the total is easy to calculate. However if tanks are partially filled on top of a poorly known original value - errors will abound. Unaccounted fuel loss from leakage, fuel vent overflow or theft will of course produce erroneous results.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Table of Contents IF YOU READ NOTHING ELSE READ THIS PAGE! ............................................................... 2 GEM INSTALL LOCATION CAUTIONARY NOTICE .................................................................. 2 GEM FUEL TOTALIZER CAUTIONARY NOTICE ...................................................................... 2 WARRANTY POLICY ..................................................................................................
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Table of Contents CHT PROBE WIRING ............................................................................................................... 15 ROUTING THE WIRING HARNESS..............................................................…......................... 15 CONNECTING AND ROUTING THE OAT HARNESSES ......................................................... 16 CHECKING THE INSTALLATION ............................................................
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 INTRODUCTION This Installation Manual will acquaint you with the installation requirements, operational functions and some of the powerful features of the Insight G-series Graphic Engine Monitors. Please read it carefully and completely before starting. Insight Instrument Corp.’s Graphic Engine Monitors provides simultaneous analog and digital display of engine temperatures for nearly all makes and models of piston-powered aircraft.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Installation Planning Plan the location of the GEM display such that it is not positioned near any source of high electrical current and is easily visible by the pilot. The GEM's wiring harnesses should be positioned away from sources of high energy, such as ignition harnesses, P-leads, alternator wiring and high frequency radio wiring and antennas. Some thought about the steps needed may save hours of installation time and trouble-shooting.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 The G1, G2 and G3 models have a top control knob or push-button that requires a clearance hole in the instrument panel, check GEM display drawing 610C-001 and outline drawing #930309 for hole sizes and locations. The G1 GEM is a functional direct replacement for a 602 or 603. Note that the G1 must be configured at the Insight factory. Specify four or six cylinder, turbo-charged or non-turbo, and carburetor or fuel-injected at time of ordering.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Tools and Materials Required (NOT included in GEM kit - Installer supplied) · Proper wire stripping tools. · Proper crimping tools, Insight recommends; M22520/2-01Crimping tool and M22520/2-08 Positioner or equivalent. · Insertion/extraction tool for Amp pin #205089-1. · Trip-free, re-settable Circuit-breaker (1 AMP). · Hardware and plumbing for mounting and connection of the Oil Pressure Sensor, and the Manifold Pressure connection.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Installing the Exhaust Gas Temperature Probes The Exhaust Gas Temperature (EGT) probe is designed fit into a hole in each exhaust stack and be secured with an integral stainless steel clamp. It is important that each probe is mounted a uniform distance from the exhaust stack flange. For normally aspirated engines, a nominal distance of 2 to 3 inches from the flange is recommended.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 CHT Probe Characteristics The Spring Probe (2852) has a probe bushing with a screwdriver slot to facilitate tightening into place. A drop of anti-seizing lubricant on the threads before installation will ease installation, and subsequent removal. When installing Spring Probes be sure you have correctly identified the standard thermo-well. Some aircraft have fuel primer ports with the same thread size.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Installing the Turbine Inlet Temperature Probes There are three types of Turbine Inlet Temperature (TIT) probes which can be used with the GEM G- series system.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Installing the Vibration Sensor The GEM is supplementary for Vibration Measurement. Insight provides a shielded cable pre-terminated with a mating 7-pin circular plastic connector (CPC) for connection to an Insight Vibration Sensor (Insight P/N 1000004V). Refer to Drawing 610C-315 or G4-315 for electrical connections. Wire as shown for option "A".
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Wiring Considerations The GEM is supplied with a factory-assembled EGT/CHT (TIT) wiring harness configured for the specified number of cylinders and required length (for each engine). The harness edge connector contains a polarization pin which mates with a slot in the display’s printed circuit board. This prevents improper engagement of the connector.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 EGT Probe Wiring The temperature probes must be wired with the correct polarity. The EGT probes connect to the harness wires with the yellow jacket. The probe leads and harness wires are color coded (red and yellow) to facilitate correct polarity. Each wire is marked with the cylinder number. Slide the wire marker down the wire so it remains with the installation for trouble-shooting. Strip the wires according to Drawing No.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Connecting and Routing the OAT Harnesses Refer to Drawings 1200-016 and 610C-315 for wiring information. Route the OAT harnesses (factory-terminated with probe connectors) to the probes, and secure. Attach the harness connectors to the probes making certain that the connectors engage properly and that the male pins on the probes are undamaged Checking the Installation Verify the power and ground connections before applying aircraft power.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 FLIGHT TESTING THE GEM It is essential that the G-series GEM installation be flight tested. The GEM must be observed in all phases of flight for consistency in performance. If a problem is noted during the flight test, discontinue the flight test and trouble-shoot the system. Should you have any questions or problems during installation or trouble-shooting of the GEM don’t hesitate to contact Insight Product Support.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Troubleshooting The following is a compilation of the common symptoms and causes of problems which may be experienced with the GEM Systems. Close examination of these symptoms should assist in identifying the cause of the problem. Symptom: The G-series Display does not illuminate. Cause: No ground return at Pin 15, of the edge connector from airframe ground Cause: Voltage is missing at Pin S, of the edge connector from the circuit breaker or bus.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Symptom: No CHT in one or more columns. Cause: Faulty probe. Turn top knob on GEM to the probe analysis page to check probe Integrity. For 8 foot harness on probe analysis page resistance should be 8 - 3 EGT / 1 - 6 CHT. For 24 foot harness on probe analysis page resistance should be 26 - 10 EGT / 4 - 18 CHT. Symptom: Display goes out during engine start. Cause: Voltage transient or over voltage condition.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Symptom: EGT indication is not uniform. Cause: The EGT indication for a fuel-injected engine will typically vary a bar or two from perfectly uniform when leaned for cruise. Clean the fuel injection nozzles. Non-uniformity is normal in carbureted engines. All cylinders are measured by the same circuitry. It is almost impossible to not have identical response on all channels of the GEM series.
GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 Drawings Drawing No.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.3 If you have difficulty installing or using a G3 or G4 system, please read the G series documentation. Every G series system is shipped with complete instructions for installation and use on a CD. You may also find the same information on our website www.insightavionics.com under G3 Documentation. The answers to many technical questions can be found in these documents.
