Installation manual

GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.4
INSIGHT
INSTRUMENT CORP. 8 BOX 122, FORT ERIE, ONTARIO, L2A 5M6
Upgrade Installations
GEM upgrade kits are designed to utilize existing Insight Instrument Corp. EGT/CHT/TIT/OAT
wiring and probes that are already installed in the aircraft. Prior to ordering an upgrade kit,
inspect the aircrafts existing GEM wiring and probes for condition, suitability, and length for
use with the new GEM. If an existing harness is not suitable for upgrade use, new
replacement harnesses are available from Insight.
Legacy GEMs were typically installed as supplemental (non-primary) EGT/CHT/TIT
instruments. New G-series GEMs may be used as primary EGT/CHT/TIT instruments. Check
the GEM STC for eligibility.
Check the existing GEM instrument-panel location for compliance with the new GEM's
location requirements. Primary instruments require clear and easy visibility for the pilot which
may not have been required for existing non-primary instrument installations.
Upgrading from legacy GEM models
Upgrading from GEM 602 or 603
Many aircraft have been equipped with GEM 602 or GEM 603 systems. Model 602
systems supported four or six cylinder engines, and 603 systems supported four or six
cylinder engines with turbo-chargers. Any 602 or 603 equipped aircraft can be easily
upgraded to a G-series GEM system.
New G-series GEMs are plug-compatible with legacy wiring and EGT/CHT/TIT probes from
a GEM 602 or 603 system with one difference, the instrument ground wire (black) may
have been attached to the engine case and should be moved to an airframe or avionics
ground. See wiring drawing 1200-018. The new GEM housings are shorter than old GEM
housings, check that the harness length is sufficient to reach the new GEM housing.
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. Specify four or six
cylinder, and turbo-charged or non-turbo at time of ordering. The G1 GEM is not field-
configurable and must be returned to Insight if a configuration change is needed.
The G2, G3 and G4 models have an additional interface connector (P2) to provide
connections to supplemental features such as fuel flow sensors, tachometer ,etc. Upgrade
kits contain much of the wiring and sensors to accomplish installation, contact Insight for
details. See the following sections of this manual for installation details of the new sensors
and wiring.
The G4 models are available in single engine and twin configurations. The G4 displays fit
into a standard 3.125 inch panel hole. See drawing #930309.