DG Flugzeugbau GmbH
Postfach 1480 76604 Bruchsal
Tel. 07251 3020-0
	Installation Instructions EGT 500M
	Issue:	B
Date:	Nov. 1999
Page 1	from 2	
Retrofit of Exhaust Gas Temperature. Indicator (EGT) for DG-500M

1.)	Preparation
–	Both DEI’s (front and rear) have to be modified for the EGT indication.
–	Forward the DEI’s  to DG Flugzeugbau GmbH
–	Check if the retrofit kit is complete
2 x EGT probes with cables and clamps
1 x EGT Amplifier Type 2A for DG500M
1 x Wiring set 
2 x Cable clamps with Teflon sleeves to fix the probes at the exhaust manifold 
2 x Rivet-nuts M5 to fix the amplifier at the firewall 
2 x Allen key bolts M5x12 to fix the amplifier
4 x ty-raps, small
10 x ty-raps, large
Instructions, wiring diagram, 3 photos

2.)   Work at the engine
-	Dismantle the exhaust manifold
-	To locate the EGT probes on the manifold upper side, drill  two Holes of  3,1mm diameter. The positions should be approx. 8 cm from the outlet in the center of the manifold channel. (see photo 1 and 2). The importance not being the exact distance from the outlet, but that both holes have the same distance from it.
-	Insert both probes in the holes and secure with the clamps. Take care that the clamps in the vicinity of weld seams lie flat and even.  If necessary the weld seams should be filed down a little.
-	 Clear borings out of the manifold and reinstall the manifold. At the same time bend the probes carefully as shown in photos 1 and 2.
-	The ends of the probes (where the wire comes out) should be fixed to the manifold with the clamps with Teflon inserts when mounting the manifold to the cylinders.
-	Route both green wires along the engine supports up to the fire wall and fix with ty-raps.

3.)	 EGT amplifier installation
-	The EGT amplifier should be installed on the center portion of the firewall (see photo 3). During installation ensure that all connector plugs can be freely inserted.
-	Mark drill holes for the rivet-nuts and drill diameter 7mm. Care should be taken not to damage the control parts located under the firewall. Rivet the rivet-nuts into the holes and fix the amplifier with Allen key bolts. Secure bolts with Loctite.
-	When fitting the connector plugs of the probes to the amplifier, the front probe should be connected to socket „V“ and the rear probe to „H“.

4.)	Cable routing to front and rear DEI’s  
-	Run both white wires from the EGT amplifier through the wiring orifice at the firewall over the tank forwards to the cockpit. It is very difficult to describe an exact procedure, as individual fuselages vary in accessibility according to the installed equipment. The following description is therefore purely supportive. 
In all cases you need a stiff Polyamide tube of 5 or 6mm diameter for threading the wires. Fix the wires to the tube with tape.

	
DG Flugzeugbau GmbH
Postfach 1480 76604 Bruchsal
Tel. 07251 3020-0
	Installation Instructions EGT 500M
	Issue:	B
Date:	Nov. 1999
Page 2	from 2	
-	Remove the small panel with plugs for radio and charger which is located at the right hand side of the main bulkhead in the rear cockpit. Run wires over the tank up to that position. 
-	Then remove the access cover from the right side console in the rear cockpit. Use the tube to find a location to route the wires between both openings and pull the wires through. Now open the rear instrument-panel and run the wires with the help of the tube to the base of the instrument-panel.
-	This is where the wire set parts. The shorter wires are routed up to the rear DEI and the contact pins have to be inserted into the connector plug (see wiring diagram), therefore dismantle the connector plug. The longer wires must be routed forward below the front seat. Available wiring ducts may be used for the above mentioned. Remove the front instrument-panel cover and route the wires to the front DEI. Dismantle the connector plug and solder the wires to the appropriate connector pins (see wiring diagram):
Solder the blue EGT wire to pin 2.
Note: If an optional outside air thermometer (OAT) gauge was installed, remove the blue wire of cable 90 from pin 2. The OAT gauge is no longer operative.
Solder the black and the red EGT wires to pin 14, don’t remove wire 22 from this pin..

Caution:
Generally speaking, it should always be ensured that no wires interfere with the control system.

5.)	Checking the EGT indications
      After all installation procedures are completed, the DEI can be switched on.
Pressing the change over switch for coolant temperature and battery voltage to the left „E“ should appear in the left display of the instrument, and „-„ in the center and in the right display. Should one or both bars not be visible, then the appropriate probe is not connected or is not working properly.
With engine running, the DEI shows instead of bars the EGT values with graduations of 10°C, for example „58“ means 580°C.
Should one or both values exceed 650 °C, the EGT will be automatically displayed (without operating the selector switch) and the display starts to blink.