Installation manual

GEM INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.4
INSIGHT
INSTRUMENT CORP. 9 BOX 122, FORT ERIE, ONTARIO, L2A 5M6
Upgrading from GEM 610 or GEMINI 1200
Upgrading from models 610 or 1200 is similar to upgrading from 602 or 603 with a few
differences.
Previous 610 installations will already have all holes drilled for panel mounting a G1, G2 or
G3. G4 models require a 3.125 inch hole.
Previous installations of 610 and 1200 models may already have an Insight OAT probe and
wiring that can be retained and connected to a G-series GEM. See wiring drawing 610C-
315.
Upgrading to G4 Single
The single engine G4 display (3.125 inch) is plug compatible with the G3 display (2.25
inch). Refer to 610C-315 and 1200-018 wiring diagrams.
Upgrading to G4 Twin
The twin engine G4 display is plug compatible with the EGT/CHT/TIT wiring harnesses
of legacy GEMINI 1200 installations. The G4 twin display has an additional interface
connector (P2) to provide connections to additional sensors such as fuel flow and
tachometer, etc. Refer to G4-315 and 1200-018 wiring diagrams.
Upgrading GEM installations in twin-engine aircraft
Twin engine aircraft may be equipped with two single-engine GEM displays or a twin
engine GEM display. Check the ground wire configuration if upgrading from older
GEMs. Wire the thermocouple harnesses according to wiring diagram #1200-018.
Install the supplementary feature wiring according to wiring diagram 610C-315for 25-
pin D-sub connectors and diagram G4-315 for 37-pin D-sub connectors.
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 for mounting and plumbing of the Oil Pressure Sensor, the plumbing for the
Fuel Flow sensor, and the plumbing for the Manifold Pressure port.