P&W ENGINE SERVICES, INC. IntelliStart+ DPU-I LOG OF REVISIONS

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2 P&W ENGINE SERVICES, INC. IntelliStart+ Rev Status of Sheets REVISION HISTORY Rev Q P P P P P P P P P P P P P P P Sheet i ii iii iv Rev P P P P P P P P P P P P P P P P Sheet Rev P P P P P Q Q P P P P P P P P Q Sheet Rev P P P P P P P P P P P Q P P P P Sheet Rev P P P P P P P P P P P P P P Sheet LOG OF REVISIONS REV. NO ECO # DESCRIPTION PAGES REVISED NOTE: A Initial Release B 116 Revise parts kit and OAT Installation Instructions. Correct typographical errors. Refer to ECO C & D 114 Revise Wiring Schematic and Part Kit layout. Refer to ECO E 140 Change Revision level. Cover Page F 155 Revise parts list. Refer to ECO G 148 Correct Trend Lamp Figure. 45 H 249 Revised Download Port Wiring and environmental reference documents. I 176 Revise FTSV figure nomenclature. Correct Temperature Probe P/N. Refer to ECO Refer to ECO J 213 Revise FTSV Parts Kit. Refer to ECO K 561 Revise to Current Format. Refer to ECO L 667 Correct address and typographical errors Refer to ECO M 739 Reformatted pages and added TH-67. All N 777 Revised the following: TH-67 Pitot Kit. OAT Probe Installation Instructions. Altitude (Static) Calibration Instructions. FTSV Parts Kit and figure. O 822 Removed reference stating that the fuse is generally installed near the processor and added Installation Cautions. P 958 Updated company name, logos and address. Corrected spelling and grammar. Added wire numbers to text and schematics. Corrected part numbers in tables and text. 6, 7, 18, 19, 26, and 49 Cover, i, and 40 Q 1136 Update Initial Power Up Test and Optional Lamp Wiring Cover, i, 34, 35, 44, 56 If the IntelliStart+ Installation Manuals are revised, all operators will be provided with a copy of the applicable revision. If you have a subscription with TurbineTracker, you will be informed via of new revisions to this manual. In addition to this, Pratt & Whitney Engine Services maintains the latest versions of all manuals in the Support Section of TurbineTracker. If you are not a subscriber to TurbineTracker, you may call Pratt & Whitney Engine Services Customer Support at for the latest revision. All - i -

3 P&W ENGINE SERVICES, INC. IntelliStart+ TABLE OF CONTENTS 1 THE P&W ENGINE SERVICES INTELLISTART+ SYSTEM Data Acquisition Engine Start Fuel Trim INSTALLATION Parts List IntelliStart+ by Parts Kits: Components by Kit How to Use This Installation Manual System Overview Mechanical Installation Instructions System Processor Cockpit INTEL START Lamp and Communication Port Torque Transducer Outside Air Temperature Probe Pitot / Static Pressure Transducers (Optional) Pitot / Static Pressure Transducers Engine Fuel Trim Solenoid Valve (FTSV) Electrical Installation Instructions J1 Harness J2 Harness J3 Harness Pitot and Static Transducers (Optional) Outside Air Temperature (OAT) Engine Torque Engine Fuel Trim Solenoid Valve Cockpit INTEL START Switch / Lamp Connector Wiring OPTIONAL AIRCRAFT INDICATOR LAMP (Annunciator Panel) Communication Port Connector Wiring Engine TOT (T4.5) Engine N1 (Ng) Speed Sensor Engine N2 (Np) Speed Sensor Aircraft Nr (Rotor) Speed Sensor Engine Start Signal Aircraft Power Connections Bus Power Breaker Connection Fault Lamp Fused Power Connection Fault Lamp Fused Power Connection Battery Power Connection Final Wiring Instructions Initial Processor Test SYSTEM CONFIGURATION AND CALIBRATION Definitions Processor Configuration Pre-Calibration Sensor Test Calibration Using Test Equipment Calibration Using Aircraft Cockpit Instruments AIRCRAFT TESTING Aircraft Ground Test Aircraft Flight Test Test Data Retrieval and Review Continued Airworthiness Instructions WIRING DIAGRAM ii -

4 P&W ENGINE SERVICES, INC. IntelliStart+ 6 HARNESS CONNECTOR SIGNAL PINOUTS Power / Sensor Cable J1, 15 Pin S Keyed Connector Sensor Cable J2, 15 Pin SA Keyed Connector Cockpit TREND/Sensor Cable, J3, 37 Pin S Keyed Conector SYSTEM OPERATION OVERVIEW IntelliStart+ Functional Description Engine Run Logging Cycle Logging Event Monitoring and Time History Buffer Fuel Trim System Initialization and Lamp State Description System Modes Run Mode Description: States and INTEL START Lamp Display Configuration Mode: INTEL START Lamp Display Manual Self Test (Loopback Test) Logic Diagram of System States MAINTENANCE REQUIREMENTS SERVICE Customer Support Disclaimer SPECIFICATIONS System Specifications Specifications for Supplied Sensors Interface Requirements for Aircraft Sensors iii -

5 P&W ENGINE SERVICES, INC. IntelliStart+ LIST OF FIGURES FIGURE 1: SYSTEM CONNECTION... 2 FIGURE 2: PROCESSOR MOUNTING DETAIL FIGURE 3: BRACKET INSTALLATION DETAIL FIGURE 4: SUGGESTED PROCESSOR LOCATION, PROFILE VIEW FIGURE 5: SUGGESTED PROCESSOR LOCATION, PLAN VIEW FIGURE 6: COCKPIT FAULT LAMP AND COMMUNICATION PORT FIGURE 7: SUPPLIED STANDARD TORQUE TRANSDUCER INSTALLATION FIGURE 8: HIGH PRECISION TORQUE TRANSDUCER INSTALLATION FIGURE 9: OAT PROBE AND DOUBLER PROFILE DETAIL FIGURE 10: SUGGESTED OAT LONGITUDINAL LOCATION, PROFILE VIEW FIGURE 11: PITOT / STATIC TRANSDUCER CONNECTIONS FIGURE 12: SUGGESTED PITOT AND STATIC TRANSDUCER LOCATIONS, PROFILE VIEW FIGURE 13: PITOT / STATIC TRANSDUCER CONNECTIONS TH FIGURE 14: SUGGESTED PITOT AND STATIC TRANSDUCER LOCATIONS, PROFILE VIEW TH FIGURE 15: FUEL TRIM SOLENOID VALVE MOUNTING DETAIL FIGURE 16: SUGGESTED FTSV MOUNTING LOCATION, PROFILE AND SECTION FIGURE 17: FUEL TRIM SOLENOID VALVE (FTSV) CONNECTION BLOCK DIAGRAM C10 / C18 / C FIGURE 18: FUEL TRIM SOLENOID VALVE (FTSV) CONNECTION BLOCK DIAGRAM C28 / C FIGURE 19: SINGLE OR DUAL WIRE SPLICE FIGURE 20: SHIELD CONNECTION (OUTER HEAT SHRINK TUBING NOT SHOWN) FIGURE 21: PITOT / STATIC FINAL WIRING FIGURE 22: OAT PROBE FINAL WIRING FIGURE 23: TORQUE FINAL WIRING FIGURE 24: FTSV CONNECTOR WIRING FIGURE 25: INTEL START (TREND) SWITCH AND FAULT LAMP CONNECTOR WIRING FIGURE 26: COMMUNICATION PORT CONNECTOR FIGURE 27: TOT (T4.5) WIRING FIGURE 28: AIRCRAFT BUS POWER BREAKER WIRING FIGURE 29: AIRCRAFT LAMP FUSE WIRING FIGURE 30: TH-67 LAMP FUSE WIRING FIGURE 31: AIRCRAFT BATTERY POWER WIRING FIGURE 32: INTELLISTART+ WIRING SCHEMATIC LIST OF TABLES TABLE 1: ELECTROMAGNETIC COMPATIBILITY TEST TABLE TABLE 2: GROUND TEST DATA TABLE TABLE 3: FLIGHT TEST DATA TABLE iv -

6 P&W ENGINE SERVICES, INC. IntelliStart+ 1 THE P&W ENGINE SERVICES INTELLISTART+ SYSTEM Aircraft and engine maintenance procedures are key to flight safety and lower operating costs. Pratt & Whitney Engine Services, Inc., in conjunction with the DP series fuel control manufacturer, has developed the IntelliStart+ system to perform four primary functions: Fuel Modulation: The fuel trim solenoid valve (FTSV) can perform real-time temperature monitoring and automatic fuel modulation during engine start to provide an optimal temperature sequence, eliminating hot starts. Exceedance Event Recording: The IntelliStart+ processor can monitor critical engine parameters and record instances where they have exceeded preset values (exceedances). Engine Trend Monitoring: The IntelliStart+ can gather and store engine data samples for trend analysis. Cockpit Indication: The IntelliStart+ provides system self-test indication. It can also be configured to warn the pilot of an exceedance event which occurred on a prior engine run. An exceedance warning is displayed prior to engine start. The IntelliStart+ system enables the operator to control, quantify, and manage engine maintenance operations and reduce direct operating costs Data Acquisition In its data acquisition role, the IntelliStart+ is a passive receiver of information. It can be configured to record data either manually or automatically. button. Manual Operation: The pilot can quickly record a dataset from all sensors by pressing a cockpit-mounted trend Automatic Operation: The system may be configured to automatically record exceedance events and sensor readings during a period immediately before or after an exceedance (Time History). It may also be configured to record data samples when stable aircraft conditions are achieved. These conditions are configurable, and the data gathered may be used for engine trend analysis. Retrieving Data: Collected data is accessed through a serial communication port for each engine. Communication with the IntelliStart+ is achieved through P&W Engine Services Monitor Link Program (MLP) which can be used both to retrieve data and send system configuration files to the processor. The MLP can also be used to assist maintenance personnel in performing system diagnostics and calibrations by setting the processor mode for a real-time live sensor display. System Configuration: The IntelliStart+ system is shipped with a predefined set of software sensor configurations, exceedance event specifications, cycle specifications, and engine start/stop definitions. System configurations can be altered by the user to suit special requirements

7 P&W ENGINE SERVICES, INC. IntelliStart Engine Start Fuel Trim In its fuel modulation role, IntelliStart+ assists the pilot during engine starts by examining sensor input and trimming fuel flow when a sensor reading falls outside pre-set boundaries. Fuel trim control only occurs when the aircraft is on the ground. Once in the air the IntelliStart+ is locked out of the fuel control system. Self-Test and Sensor Failure: IntelliStart+ performs a number of self-tests during operation to ensure that the sensor data being used for fuel modulation is valid. It will disable the fuel trim function in case of major system failure. In cases of minor failure, however, it may still assist the starting process. The processor primarily utilizes Turbine Outlet Temperature (T4.5) data for fuel trim purposes, but can also utilize Gas Generator Speed (N1) sensor input for degraded start protection in the case of a T4.5 sensor failure. Since it can use either sensor input for performing fuel modulation, only a combination of both and T4.5 and N1 signal failures (or a processor fault) will cause the system to fully disable the fuel trim function on startup. System Functional Diagram: A block diagram of the system is shown in Figure 1. The Fuel Trim Solenoid Valve assembly (FTSV) is plumbed into the Main Fuel Control outlet. When fuel modulation is required the FTSV takes fuel from the nozzle flow and returns it to the fuel pump inlet. In use, the processor limits the engine start temperatures by providing pulse-width-modulation control of the FTSV. Fuel Trim Solenoid takes fuel directly from nozzle flow FTSV TO ENGINE FUEL NOZZLE MAIN FUEL CONTROL ENGINE FUEL PUMP AIRCRAFT BOOST PUMP(S) FUEL Figure 1: System Connection - 2 -

8 P&W ENGINE SERVICES, INC. IntelliStart+ 2 INSTALLATION 2.1. Parts List The parts listed below consist of the complete installation kits applied for under the supplemental type certificate. Assembly kit numbers are listed in section 2.2 and individual components are detailed by kit numbers in section IntelliStart+ by Parts Kits: IntelliStart+ for C10/C18 P/N DPU-K Processor Assembly 1 DPU-K Engine Harness Kit 1 DPU-K Engine Fuel Trim Solenoid Valve 1 DPU-K Engine Torque Kit 1 DPU-K Aircraft OAT Kit 1 DPU-K Aircraft Pitot Pressure Kit (Optional) 1 DPU-K Aircraft Static Pressure Kit (Optional) 1 DPU-K Cockpit Fault Lamp Assembly Kit 1 DPU-K Additional Installation Materials Kit 1 DPU-K Documentation Kit 1 DPU-K IntelliStart+ for C20 P/N DPU-K Processor Assembly 1 DPU-K Engine Harness Kit 1 DPU-K Engine Fuel Trim Solenoid Valve 1 DPU-K Engine Torque Kit 1 DPU-K Aircraft OAT Kit 1 DPU-K Aircraft Pitot Pressure Kit (Optional) 1 DPU-K Aircraft Static Pressure Kit (Optional) 1 DPU-K Cockpit Fault Lamp Assembly Kit 1 DPU-K Additional Installation Materials Kit 1 DPU-K Documentation Kit 1 DPU-K IntelliStart+ for C28 P/N DPU-K Processor Assembly 1 DPU-K Engine Harness Kit 1 DPU-K Engine Fuel Trim Solenoid Valve 1 DPU-K Engine Torque Kit 1 DPU-K Aircraft OAT Kit 1 DPU-K Aircraft Pitot Pressure Kit (Optional) 1 DPU-K Aircraft Static Pressure Kit (Optional) 1 DPU-K Cockpit Fault Lamp Assembly Kit 1 DPU-K Additional Installation Materials Kit 1 DPU-K Documentation Kit 1 DPU-K

9 P&W ENGINE SERVICES, INC. IntelliStart+ IntelliStart+ for C30 P/N DPU-K Processor Assembly 1 DPU-K Engine Harness Kit 1 DPU-K Engine Fuel Trim Solenoid Valve 1 DPU-K Engine Torque Kit 1 DPU-K Aircraft OAT Kit 1 DPU-K Aircraft Pitot Pressure Kit (Optional) 1 DPU-K Aircraft Static Pressure Kit (Optional) 1 DPU-K Cockpit Fault Lamp Assembly Kit 1 DPU-K Additional Installation Materials Kit 1 DPU-K Documentation Kit 1 DPU-K IntelliStart+ for C30 w/ High Freq. N1 P/N DPU-K Processor Assembly 1 DPU-K Engine Harness Kit 1 DPU-K Engine Fuel Trim Solenoid Valve 1 DPU-K Engine Torque Kit 1 DPU-K Aircraft OAT Kit 1 DPU-K Aircraft Pitot Pressure Kit (Optional) 1 DPU-K Aircraft Static Pressure Kit (Optional) 1 DPU-K Cockpit Fault Lamp Assembly Kit 1 DPU-K Additional Installation Materials Kit 1 DPU-K Documentation Kit 1 DPU-K IntelliStart+ for TH-67 P/N DPU-K Processor Assembly 1 DPU-K Engine Harness Kit 1 DPU-K Engine Fuel Trim Solenoid Valve 1 DPU-K Engine Torque Kit 1 DPU-K Aircraft OAT Kit 1 DPU-K Aircraft Pitot Pressure Kit (Optional) 1 DPU-K Aircraft Static Pressure Kit (Optional) 1 DPU-K Cockpit Fault Lamp Assembly Kit 1 DPU-K Additional Installation Materials Kit 1 DPU-K Documentation Kit 1 DPU-K

10 P&W ENGINE SERVICES, INC. IntelliStart Components by Kit PROCESSOR ASSEMBLY KIT Processor DPU-A Qty 1 Mounting Bracket DPU-D Qty 1 Shock Mounts, Lord Qty 4 Washer, Processor Mount Qty 4 Nut, Locking, Processor Mount MS Qty 4 Screw, Mount MS Qty 4 Nut, Locking, Mount MS21044N10 Qty 4 Alternative P/N AN A Washer, Mount AN960-10L Qty 4 Strap, Ground DPU-C Qty 1 ENGINE HARNESS KIT Cable Assembly, J1 DPU-C Qty 1 Cable Assembly, J2 DPU-C Qty 1 Cable Assembly, J3 (Comm) DPU-C Qty 1 ENGINE HARNESS KIT Cable Assembly, J1 DPU-C Qty 1 Cable Assembly, J2 DPU-C Qty 1 Cable Assembly, J3 (Comm) DPU-C Qty 1 ENGINE HARNESS KIT Cable Assembly, J1 DPU-C Qty 1 Cable Assembly, J2 DPU-C Qty 1 Cable Assembly, J3 (Comm) DPU-C Qty 1 ENGINE HARNESS KIT Cable Assembly, J1 DPU-C Qty 1 Cable Assembly, J2 DPU-C Qty 1 Cable Assembly, J3 (Comm) DPU-C Qty 1 ENGINE HARNESS KIT Cable Assembly, J1 DPU-C Qty 1 Cable Assembly, J2 DPU-C Qty 1 Cable Assembly, J3 (Comm) DPU-C Qty 1 DPU-K DPU-K DPU-K DPU-K DPU-K DPU-K

11 P&W ENGINE SERVICES, INC. IntelliStart+ ENGINE FUEL TRIM SOLENOID VALVE KIT FTSV DPU-D Qty 1 Adapter, Straight to 37 o Flare Qty 1 Fitting, T, Swivel Qty 1 Fitting, T, Swivel Qty 1 Adapter, Reducer, 37 o Flare Qty 1 Hose, Pressure, Fuel, Inlet AE6209E Qty 1 Alternative P/N AE6682E Hose, Pressure, Fuel, Outlet AE E0306 Qty 1 Alternative P/N AE E0306 Connector, FTSV MS3108E10SL-3S Qty 1 Plate, Mounting DPU-D Qty 2 Screw MS24693-S273 Qty 2 Screw MS Qty 4 Screw MS Qty 4 Washer, Flat, #10 AN Qty 8 Nut, Elastic Stop AN A Qty 8 Shield, Heat DPU-D Qty 1 Nut, Qty 1 ENGINE FUEL TRIM SOLENOID VALVE KIT FTSV DPU-D Qty 1 Adapter, Straight to 37 o Flare Qty 1 Fitting, T, Swivel Qty 1 Alternative P/N Fitting, T, Swivel Qty 1 Adapter, Reducer, 37 o Flare Qty 1 Hose, Pressure, Fuel, Inlet AE6680E Qty 1 Alternative P/N AE6210E Hose, Pressure, Fuel, Outlet AE E0306 Qty 1 Alternative P/N Connector, FTSV MS3108E10SL-3S Qty 1 Plate, Mounting DPU-D Qty 2 Screw MS24693-S273 Qty 2 Screw MS Qty 4 Screw MS Qty 4 Washer, Flat, #10 AN Qty 8 Nut, Elastic Stop AN A Qty 8 Shield, Heat DPU-D Qty 1 Nut, Qty 1 DPU-K DPU-K ENGINE TORQUE KIT Transducer, PSIG Qty 1 Adapter, Pipe to 37 o Flare Qty 1 Fitting, T, Swivel Qty 1 Hose, Pressure, Qty 1 Clamp MS21919WCJ16 Qty 1 DPU-K

12 P&W ENGINE SERVICES, INC. IntelliStart+ AIRCRAFT OAT PROBE KIT Probe, Temperature TWIN-A Qty 1 Nut, Jam TWIN-D Qty 1 Washer AN L Qty 2 Seal, O Ring AN6227B-10 Qty 1 Bolt, Drilled AN3H-4A Qty 1 Doubler, OAT Probe DPU-D Qty 1 Washer AN Qty 1 Nut, Fiber Lock AN A Qty 1 AIRCRAFT PITOT PRESSURE KIT (OPTIONAL) DPU-K DPU-K Hose, Inlet Pressure Qty 2 Ft. Fitting, Inlet Pressure Hose Qty 2 Adapter, Pipe to 37 o Flare Qty 1 Fitting, T, Swivel Qty 1 Transducer, 0-3 PSID Qty 1 Clamp, Inlet Pressure Transducer MS21919WDG26 Qty 1 Bolt, AN3-5A Qty 1 Nut, Locking, AN A Qty 1 Washer, #10 AN Qty 1 AIRCRAFT PITOT PRESSURE KIT (OPTIONAL) DPU-K Hose, Inlet Pressure Qty 2 Ft. Fitting, Inlet Pressure Hose Qty 1 Fitting, T, Qty 1 Transducer, 0-3 PSID Qty 1 Clamp, Inlet Pressure Transducer MS21919WDG26 Qty 1 Bolt, AN3-5A Qty 1 Nut, Locking, AN A Qty 1 Washer, #10 AN Qty 1 AIRCRAFT STATIC PRESSURE KIT (OPTIONAL) Transducer, 0-15 PSIA Qty 1 Filter, Static Pressure Transducer Qty 1 Coupling, ¼ x ¼ Qty 1 Clamp, Nacelle Static Transducer MS21919WDG16 Qty 1 Bolt, AN3-5A Qty 1 Nut, Locking, AN A Qty 1 Washer, #10 AN Qty 1 DPU-K

13 P&W ENGINE SERVICES, INC. IntelliStart+ COCKPIT FAULT LAMP ASSEMBLY KIT Assy., Cockpit Fault Lamp DPU-A or Qty 1 Alternative P/N DPU-A Lens DPU-D Qty 1 Connector, 6 Pin Female Qty 1 Assy., Communication Port DPU-A or Qty 1 Alternative P/N DPU-A Cover Qty 1 Connector, 6 Pin, Male or Qty 1 Alternative P/N DPU-K ADDITIONAL INSTALLATION MATERIALS KIT DPU-K T4.5 Crimp Lug, Alumel Qty 1 T4.5 Crimp Lug, Chromel Qty 1 Breaker, 2 Amp Qty 1 Fuse, 1 Amp Qty 2 Holder, Fuse DPU-C Qty 2 DOCUMENTATION KIT DPU-K Installation Manual Qty 1 Parts List DPU-L Qty 1 Continued Airworthiness Instructions DPU-T Qty 1 Flight Manual Supplement DPU-T Qty 1 HIGH PRECISION ENGINE TORQUE KIT (OPTIONAL) DPU-K Transducer, High Precision, PSIG Qty 1 Adapter, "O" Ring/ 37 Flare Qty 1 Fitting, "T", Swivel Qty 1 Hose, Pressure, 12" Qty 1 Clamp MS21919WCJ14 Qty 1-8 -

14 P&W ENGINE SERVICES, INC. IntelliStart How to Use This Installation Manual This installation manual contains mechanical and electrical instruction sections, and a set of wiring diagrams. The mechanical and electrical sections are made up of instruction lists that take the following the form: 1.) A heading, which lists the applicable aircraft or engine. Headings look like this: For All Listed Aircraft Models: 2.) Caution notes, which present things to be aware of while performing the installation. Cautions look like this: Installation Caution: Excessive torque on the processor mounting studs can deform the shock mounts. The locking nut should be tightened only to the point of contact with the shock mount. 3.) Numbered assembly and wiring instructions, which include boxes for checking off steps as they are performed. Instructions look like this: Wiring Instructions: Perform the following steps: 010 Trim the cable to length To perform the installation read the system overview. Complete the preparation section checklist. Find the aircraft wiring diagram, then follow the steps for the mechanical and electrical assembly sections. Check off each instruction as it is completed. When finished proceed to post-installation, configuration, and testing sections of the manual

15 P&W ENGINE SERVICES, INC. IntelliStart System Overview The P&W Engine Services IntelliStart+ records and analyzes signals from locations on the engine and aircraft. The signals are obtained from a combination of existing aircraft and supplied sensors. The main system components and the signals required are: System Processor -- The IntelliStart+ processor does not require access during flight. It is mounted in a remote section of the aircraft. The IntelliStart+ processor is 3.5 wide by 6 long by 1.7 deep and weighs 1.1 lbs. An aluminum bracket with Lord Aerospace shock mounts is used to mount the processor to the aircraft. Engine N1 (Ng) Speed -- The processor determines the engine N1 (Ng) speed by spliced connections to the sensor input of the existing cockpit N1 indicator. Engine N2 (Np) Speed -- The processor determines the engine N2 (Np) speed by spliced connections to the sensor input of the existing cockpit N2 indicator. Engine Torque Pressure The processor monitors a supplied torque transducer to determine the engine torque pressure. The transducer is inserted into the existing torque pressure line using a T fitting adapter and a TSO rated pressure hose. Engine T4.5 (TOT) Temperature -- The processor determines the TOT (T4.5) temperature through connections to the Alumel and Chromel terminals of the engine s thermocouple terminal block. Engine Fuel Trim Solenoid Valve (FTSV) The processor limits the engine s start temperatures by modulating a supplied Fuel Trim Solenoid Valve (FTSV). When energized, the solenoid valve bleeds fuel from the engine nozzle line back to the inlet of the fuel pump. This leans the fuel air mix, which serves to reduce the engine temperature. By cycling the FTSV on and off, the processor can proportion the fuel/air mix to provide an optimal starting temperature sequence. The FTSV unit consists of a flow restrictor, an 8vdc solenoid, a check valve (to prevent reverse flow), and screens to protect the restrictor orifice. Aircraft Main Rotor (Nr) Speed -- The processor determines the Main Rotor (Nr) speed by spliced connections to the sensor input of the existing cockpit Nr indicator. Aircraft Outside Air Temperature (OAT) Probe -- The processor determines outside air temperature (OAT) through connection to a supplied RTD type temperature probe. Aircraft Altitude Sensor (Optional) -- The IntelliStart+ system is available with an optional 0-15 PSIA pressure transducer to measure aircraft static pressure. This sensor can be mounted in a remote location of the aircraft. For normal flight monitoring, connection to the aircraft static pressure port is not required. Where higher accuracy monitoring during rapid maneuvers is desired, the sensor may be plumbed into the aircraft static system. Aircraft Airspeed Sensor (Optional) -- The IntelliStart+ system is available with an optional 0-3 PSID pressure transducer to measure aircraft pitot pressure. This sensor can be mounted in a location near the pitot pressure source. The sensor is connected to the aircraft pitot pressure source. Cockpit Fault Lamp / INTEL START Switch -- The IntelliStart+ utilizes a combination INTEL START lamp and switch. The pilot may initiate a manual data sample for the engine through use of the switch. System status and fault indications are displayed to the operator through the on, off, or flashing status of the lamp. The processor may also be connected to an existing aircraft cockpit panel indicator (annunciator) lamp. Data Communication Port -- The IntelliStart+ incorporates a serial data port for communication between the IntelliStart+ and a laptop computer

16 P&W ENGINE SERVICES, INC. IntelliStart Mechanical Installation Instructions NOTE: All work to be done in accordance with FAA Advisory Circular B "Acceptable Methods, Techniques and Practices for Aircraft Inspection and Repair" and with FAA Advisory Circular A "Acceptable Methods, Techniques and Practices - Aircraft Alterations" Please read all instructions completely before beginning installation. It is assumed that qualified mechanics or avionics technicians will perform the installation. All aircraft systems interfacing with the P&W Engine Services IntelliStart+ System should be checked for full functionality before installation begins. NOTE: General supplies (solder, crimp splices, heat shrink, tape, etc.) are not included with the installation kit. All mounting locations illustrated are for the 206 A/B/L series and are to be used as a general guide for mounting. The locations shown may be altered to fit special individual installation requirements as needed, provided accepted structural procedures and practices are followed. Refer to the manufacturer s manual for approved locations or cautions for clamping hoses and cables, or modifying aircraft structure. NOTE: All applicable Service Bulletins must be complied with

17 P&W ENGINE SERVICES, INC. IntelliStart SYSTEM PROCESSOR For All Listed Aircraft Models: Installation Caution: Assembly Notes Excessive torque on the processor-mounting studs can over-compress the shock mounts. The locking nut should be tightened just to the point of contact with the shock mount. The system processor may be located in a suitable location, as required. The processor will not require access during normal operation. The recommended position, behind the rear seats and above the cargo area, is illustrated in Figures 4 and 5. This location can be accessed from the cargo compartment or from behind the rear seats. The processor is mounted using the supplied mounting bracket, DPU-D NOTE : ENSURE STANDOFF END OF SHOCK MOUNT FACES PROCESSOR PROCESSOR DPU-A SHOCK MOUNT MOUNTING BRACKET DPU-D WASHER _(4 PL) LOCKING NUT MS (4PL) Figure 2: Processor Mounting Detail MOUNT SCREW MS (4 PL) S E C T IO N V IE W MOUNTING BRAKET DPU-D AIR CR AFT W ASHER AN960-10L (4 PL) N UT MS21044N10 (4 PL) G ROUND ST RAP Figure 3: Bracket Installation Detail

18 P&W ENGINE SERVICES, INC. IntelliStart+ Assembly Instructions 010 Assemble the IntelliStart+ processor and ground strap (DPU-C-050-1) onto the mounting bracket (refer to Figures 2 and 3). 020 Test fit the bracket and processor assembly to the aircraft as required. See Figures 4 and 5 for suggested location. Make sure that the location chosen does not interfere with the wiring or controls. 030 Mark the location of the four mounting holes and drill to accommodate a #10 screw. 040 Mount the system bracket, processor, and ground strap to the aircraft using four screws, four flat washers and four lock-nuts per Figure 3. Figure 4: Suggested Processor Location, Profile View Figure 5: Suggested Processor Location, Plan View

19 P&W ENGINE SERVICES, INC. IntelliStart COCKPIT INTEL START LAMP AND COMMUNICATION PORT For All Listed Aircraft Models: Assembly Notes The IntelliStart+ system utilizes a cockpit mounted INTEL START fault lamp/ trend data switch and a serial communication port receptacle. The lamp may be mounted in the panel, or elsewhere as required. It is desirable to mount the Communication port receptacle where a cable connecting it to a laptop computer will not interfere with flight controls during system tests or calibration. INTEL START COMMUNICATION PORT COMMUNICATIO N PO RT MOUNT LOCATION SHOULD BE SELECTED TO ALLOW ATTACHMENT OF COMMUNICATION CABLE WITHOUT INTERFERING WITH FLIGHT CONTROLS. IT DOES NO T NEED TO BE LOCATED ON THE INSTRUMENT PANEL MOUNTING HOLE PATTERN Figure 6: Cockpit Fault Lamp and Communication Port Assembly Instructions 010 Determine a mounting location for the INTEL START lamp and switch, as needed. Be sure to allow enough clearance to nearby instruments for lamp body. Mark and punch a.75 square hole for mounting of the lamp. 020 Mark and drill out 15/32 hole for the data Communication Port. 030 Install the INTEL START Lamp. 040 Install the Data Communication Port using Loctite 222 on the threads of the receptacle

20 P&W ENGINE SERVICES, INC. IntelliStart TORQUE TRANSDUCER Note: Figure 7 and the description immediately below apply to the standard supplied torque transducer. An optional High Precision torque transducer may have been supplied as an alternate part with your kit. If so, see the High Precision Torque Transducer section further below for installation instructions. Installation Caution: Assembly Notes Care should be taken to keep the pressure transducers away from the engine hot section. The IntelliStart+ determines the engine torque level by monitoring a transducer installed in the torque pressure line, see Figure 7. The transducer can be mounted on an existing stud on the fwd. engine firewall. Standard Torque Transducer (Kit DPU-K-045-1): Assembly Instructions 010 Using Teflon tape, install the PSIG transducer ( ) into adapter ( ). 020 Remove the aircraft torque pressure line at the pressure port connection. 030 Install the swivel end of the supplied T fitting ( ) onto the existing pressure port. 040 Install the existing aircraft torque pressure line onto the opposite end of the T adapter. 050 Install the pressure transducer on one end of the supplied pressure hose (AE B0120) and attach the other end of the hose to the T adapter. 060 Route the supplied torque hose and transducer to the forward engine firewall. 070 Using supplied clamp (MS21919WCJ16), secure transducer to the aircraft firewall. 080 Secure all lines and fittings

21 P&W ENGINE SERVICES, INC. IntelliStart+ PROFILE VIEW ADEL CLAMP MS21919WCJ16 TORQUE TRANSDUCER ADAPTER, PIPE TO 37 FLARE EXISTING AIRCRAFT TORQUE PRESSURE LINE TORQUE PRESSURE HOSE AE B0120 SWIVEL "T" FITTING FIREWALL TORQUE PRESSURE PORT Figure 7: Supplied Standard Torque Transducer Installation

22 P&W ENGINE SERVICES, INC. IntelliStart+ High Precision Torque Transducers (Kit TWIN-K-031-3, -4): 010 Install the High Precision PSIG transducer ( ) and O Ring into the O ring-to-flare adapter ( ). 020 Remove the aircraft torque pressure line at the pressure port connection. 030 Install the swivel end of the supplied T fitting ( ) onto the existing pressure port. 040 Install the existing aircraft torque pressure line onto the opposite end of the T adapter. 050 Install the pressure transducer and adapter on one end of the supplied pressure hose (AE B0120) and attach the other end of the hose to the T adapter. 060 Route the supplied torque hose and transducer to the forward engine firewall. 070 Using supplied clamp (MS21919WCJ14), secure transducer to the aircraft firewall. 080 Secure all lines and fittings. ADEL CLAMP MS21919WCJ14 HIGH PRECISION TORQUE TRANSDUCER PROFILE VIEW "O" RING ADAPTER, "O" RING / 37 FLARE EXISTING AIRCRAFT TORQUE PRESSURE LINE TORQUE PRESSURE HOSE AE B0120 SWIVEL "T" FITTING _ FIREWALL TORQUE PRESSURE PORT Figure 8: High Precision Torque Transducer Installation

23 P&W ENGINE SERVICES, INC. IntelliStart OUTSIDE AIR TEMPERATURE PROBE Assembly Notes: The IntelliStart+ determines the outside air temperature from a supplied transducer installed in the underside of the aircraft behind the cargo compartment. OAT PROBE TW IN-D W ASHER AN L DOUBLER DPU-D AIRCRAFT SKIN NUT AN A W ASHER AN "O" RING SEAL AN6227B-10 W ASHER AN L JAM NUT TW IN-D PROFILE VIEW SAFETY WIRE BOLT, DRILLED AN3-5A Figure 9: OAT Probe and Doubler Profile Detail For All Listed Aircraft Models Assembly Instructions: 010 Gain access to the underside of the aircraft. 020 Refer to Figures 9 and 10. Choose a location for the OAT probe in the bay between Station 167 and 205. The transverse location is not critical, but because a doubler plate is required, try to choose a relatively flat section of the skin for the installation. Generally it is mounted on the centerline. 030 Using the OAT doubler (DPU-D-047-1) as a pattern, mark locations for five smaller holes onto the aircraft skin. Drill through the skin with a #40 drill bit, and then increase the diameter of the four holes in a square pattern using a # 21 drill bit. Increase the diameter of the 5 th hole using a # 10 drill bit. 040 Using the doubler as a pattern, mark and step drill a single.5 dia hole through the aircraft skin. 050 Deburr all the holes in the aircraft skin and the doubler. 060 Using Zinc Chromate Primer, coat all exposed surfaces of the doubler and aircraft skin. 070 Install the doubler on the inside surface of the aircraft skin. 080 Four rivets are to be installed 90 degrees apart from each other, inserted from the outside of the aircraft. Using a Cherrymax Grip Gauge, measure the four # 21 holes for the proper rivet grip length. 090 Coat the end of four (4) CR X Cherrymax rivets with Zinc Chromate Primer. 100 With the Zinc Chromate Primer still wet, install the rivets

24 P&W ENGINE SERVICES, INC. IntelliStart+ 110 Refer to Figure 9. From inside the aircraft, insert the temperature probe (TWIN-D-050-2) with a washer (AN L) through the.5 diameter hole. Install another washer (AN L), O ring (AN6227B-10) and jam nut (TWIN-D-061-1) onto the probe on the outside of the aircraft. 120 Install the safety bolt (AN3-5A), washer (AN960-10), and nut (AN A) in the fifth hole drilled in the doubler / skin. 130 Tighten and safety wire the OAT nut to the safety bolt. Figure 10: Suggested OAT Longitudinal Location, Profile View

25 P&W ENGINE SERVICES, INC. IntelliStart PITOT / STATIC PRESSURE TRANSDUCERS (OPTIONAL) For All Listed Aircraft Models Except TH-67: Assembly Instructions: The IntelliStart+ processor is capable of sensing airspeed and altitude for event and trend monitoring if optional pitot and static transducers are installed. These optional sensors are not required for startup fuel limiting. In its standard configuration, the static (altitude) transducer is open to the atmosphere in the aircraft. For stable flight monitoring it does not need to be plumbed into the aircraft s static port. Where accurate monitoring of rapid altitude changes is required, the transducer may be plumbed into the aircraft static system. The static (altitude) transducer does require connection to the existing static system. Installation Caution: Use Teflon tape on all pipe threads. TRANSDUCER, 0-15 PSIA CLAMP MS21919WDG16 CLAMP MS21919WDG26 COUPLING TRANSDUCER, 0-3 PSID _ FILTER PIPE TO 37 FLARE ADAPTER FITTING EXISTING LINE AIRCRAFT PITOT PRESSURE PRESSURE HOSE "T" FITTING AIRCRAFT PITOT PRESSURE Figure 11: Pitot / Static Transducer Connections

26 P&W ENGINE SERVICES, INC. IntelliStart+ Figure 12: Suggested Pitot and Static Transducer Locations, Profile View 010 Refer to Figure 11. Apply Teflon tape to the Pitot Transducer threads and install adapter ( ). 020 Apply Teflon tape to the Static Transducer threads and install coupling ( ). 030 Apply Teflon tape to the filter ( ) threads and install into the coupling. 040 Install the Pitot Transducer at an appropriate location in the aircraft near the pitot pressure source using supplied large transducer clamp (MS21919WDG26), bolt (AN3-5A), washer (AN960-10) and lock nut (AN A). Figure 13 illustrates one suggested mounting configuration on the left (port) instrument panel stringer, behind the instrument panel. 050 Install the Static Transducer at an appropriate location in the aircraft near the pitot transducer using the supplied small transducer clamp (MS21919WDG16), bolt (AN3-5A), washer (AN960-10) and lock nut (AN A). Figure 13 illustrates one suggested mounting configuration on the right (starboard) instrument panel stringer, behind the instrument panel. 060 Refer to Figure 12. Locate a suitable connection point in the aircraft pitot pressure line and insert T fitting ( ). 070 Re-attach the aircraft pitot pressure line to the T fitting. 080 Using hose ( ), and fittings ( ), fabricate pressure hose and connect the pitot pressure transducer to the aircraft pitot pressure source. 090 Tighten all hoses and fittings and secure them

27 P&W ENGINE SERVICES, INC. IntelliStart PITOT / STATIC PRESSURE TRANSDUCERS For Model TH-67: Assembly Instructions: The static (altitude) transducer does require connection to the existing static system. Installation Caution: Use Teflon tape on all pipe threads. TRANSDUCER, 0-15 PSIA CLAMP MS21919WDG16 CLAMP MS21919WDG26 COUPLING TRANSDUCER, 0-3 PSID FILTER FITTING, INLET PRESSURE HOSE EXISTING LINE AIRCRAFT PITOT PRESSURE PRESSURE HOSE "T" FITTING NOT TO SCALE AIRCRAFT PITOT PRESSURE Figure 13: Pitot / Static Transducer Connections TH

28 P&W ENGINE SERVICES, INC. IntelliStart+ Figure 14: Suggested Pitot and Static Transducer Locations, Profile View TH Apply Teflon tape to the Pitot Transducer threads and install adapter ( ). 020 Apply Teflon tape to the Static Transducer threads and install coupling ( ). 030 Apply Teflon tape to the filter ( ) threads and install into the coupling ( ). 040 Install the Pitot Transducer at an appropriate location in the aircraft near the pitot pressure source using supplied large transducer clamp (MS21919WDG26), bolt (AN3-5A), washer (AN960-10) and lock nut (AN A). Figure 13 illustrates one suggested mounting configuration on the left (port) instrument panel stringer, behind the instrument panel. 050 Install the Static Transducer at an appropriate location in the aircraft near the pitot transducer using the supplied small transducer clamp (MS21919WDG16), bolt (AN3-5A), washer (AN960-10) and lock nut (AN A). Figure 13 illustrates one suggested mounting configuration on the right (starboard) instrument panel stringer, behind the instrument panel. 060 Locate an appropriate place to splice into the existing pitot system, making sure that the cut is perpendicular to the side of the pitot line. 070 Insert T fitting ( ) into the aircraft pitot line. 080 Using the supplied hose ( ), connect the T Fitting ( ) and the Pitot Transducer / Fitting ( ). Do this by inserting the hose in the 3 rd leg of the T Fitting ( ) and the Fitting ( ). 090 Re-attach the aircraft pitot pressure line to the T fitting 100 Secure and tighten all hoses and fittings

29 P&W ENGINE SERVICES, INC. IntelliStart ENGINE FUEL TRIM SOLENOID VALVE (FTSV) For All Listed Aircraft Models: Assembly Instructions: The IntelliStart+ limits start temperatures by bleeding fuel from the engine fuel nozzle pressure line back to the fuel pump inlet. This fuel trim function is accomplished with a solenoid valve in the pressure line. The FTSV is mounted on the right side of the engine compartment s rear firewall. Installation Caution: Do not install the FTSV backwards. This is an easy installation mistake to make. The flow direction is along a return bleed loop AWAY from the fuel nozzle, BACK to the fuel pump inlet. Therefore the IN side of the FTSV routes to the fuel nozzle, and the OUT side of the FTSV routes to the fuel pump. Figure 15: Fuel Trim Solenoid Valve Mounting Detail 010 Install fitting ( ) with O Ring into FTSV inlet port. 020 Refer to Figure 16. Install the FTSV (DPU-D-021-1) to the mounting plate (DPU-D-031-1) using flat head screws (MS24693-S273). 030 Install the FTSV assembly on the rear engine firewall or other suitable area near the engine nozzle pressure line using screws (MS ), washers (AN960-10) and nuts, (AN A). A suggested location is shown in Figure 16. The mounting area chosen must allow the included hoses to reach their connection points at the fuel pump and fuel control. 040 Refer to Figures 17 and 18. Remove the engine fuel nozzle pressure hose and install T fitting ( ) and re-install the nozzle pressure hose. 050 Install pressure hose AE6682E for C10, C18, or C20 engines, (or AE6680E for C28 or C30 engines) to T fitting and route to the FTSV inlet port. Note that the inlet port is marked IN 060 Remove engine fuel pump hose and install T fitting ( ) and re-install fuel pump hose. 070 Install reducer ( ) to T fitting

30 P&W ENGINE SERVICES, INC. IntelliStart+ Figure 16: Suggested FTSV Mounting Location, Profile and Section

31 P&W ENGINE SERVICES, INC. IntelliStart+ For C10 /C18 /C20 Equipped Aircraft Only: "T" FITTING TO ENGINE NOZZLE FUEL LINE AE6682E TRIM FUEL TRIM SOLENOID VALVE FUEL LINE DPU-D AE E0306 BYPASS FUEL IN "T" FITTING ADAPTER MAIN FUEL CONTROL FUEL IN (from fuel tank) FUEL PUMP Figure 17: Fuel Trim Solenoid Valve (FTSV) Connection Block Diagram C10 / C18 / C20 For C28 and C30 Equipped Aircraft Only: FUEL LINE AE6210E "T" FITTING TO ENGINE NOZZLE TRIM FUEL TRIM SOLENOID VALVE DPU-D FUEL LINE AE E0306 MAIN FUEL CONTROL "T" FITTING ADAPTER FUEL PUMP TRIM FUEL IN (from fuel tank) Figure 18: Fuel Trim Solenoid Valve (FTSV) Connection Block Diagram C28 / C

32 P&W ENGINE SERVICES, INC. IntelliStart+ 080 Install pressure hose (AE E0306) for all engines to the T fitting and route to the FTSV outlet port. Note that the outlet port is marked OUT 090 Route hoses along existing aircraft hoses, secure and tighten all hoses and fittings. 100 Place the heat shield (DPU-D-051-1) over the FSTV as shown in Figure Mark and drill the 4 mounting holes in the mounting surface using the heat shield (DPU-D-051-1) as a pattern. Remove the shield and deburr the mounting holes. 120 Secure the heat shield using screws (MS ), washers (AN960-10) and nuts, (AN A)

33 P&W ENGINE SERVICES, INC. IntelliStart Electrical Installation Instructions For All Listed Aircraft Models: Installation Caution: Each wire is marked with a shrink-on label near the terminal end to indicate what it is. When you shorten the wire behind the label, be sure to re-label it. The IntelliStart+ cables have shields that connect to the processor chassis ground. When terminating the shielded harness at the airframe connection, these shields must be trimmed back and insulated to prevent possible shorting with the signal wires. Wiring Splices: The use of Raychem hermetic style wire splices is recommended. When making connections between two shielded cables, the shields should also be maintained using Raychem or equivalent shield splices. The entire cable splice should be encased in heat shrink tubing when completed. An example of shield and wire connection splices can be found in Figures 19 and 20. RAYCHEM D OR EQUIVALENT Figure 19: Single or Dual Wire Splice 1. INSERT PREPARED CABLE 2. APPLY HEAT RAYCHEM S01042 OR EQUIVALENT 3. SPLICE WIRE AND SHIELD PIGTAIL Figure 20: Shield Connection (outer heat shrink tubing not shown)

34 P&W ENGINE SERVICES, INC. IntelliStart J1 HARNESS 010 Connect the J1 harness to the J1 connector on the IntelliStart+ processor. 020 Route the AAV00B22 cable to the aircraft battery and ground connections. The connection must supply continuous battery power (uncontrolled by the Master Battery Switch). The recommended location for the BATTERY POWER connection is the battery side of the Battery Relay. This power source will be protected by a 1 Amp fuse and does not need to be accessible by the pilot and/or crew. 030 Route the AAV10A22 cable to a suitable location to install a two Amp breaker for connection to the aircraft switched power source. The breaker should be positioned to be accessible to the pilot and/or crew. Install the breaker. 040 Route the AAA22D22 cable to the previously installed Pitot and Static transducers. 050 Route the AAC00B22 cable to the previously installed Fuel Trim Solenoid Valve J2 HARNESS 010 Connect the J2 harness to the J2 connector on the IntelliStart+ processor. 020 Route the AAA20D22 cable to the previously installed Torque transducer. 030 Route the AAP10B22 cable to the existing N1 (Ng) cockpit instrument connector or engine tachometer. 040 Route the AAP11B22 cable to the existing N2 (Np) cockpit instrument connector or engine tachometer. 050 Route the AAA10B22 cable to the existing TOT (T4.5) terminal block J3 HARNESS 010 Connect the J3 (Comm) harness to the J3 connector on the IntelliStart+ processor. 020 Route the AAV30D24 cable to the previously installed Fault Lamp. 030 Route the AAV30D24 cable to the previously installed Communication Port receptacle. 040 Route the AAV31A24 cable to the aircraft switched power connection. This power source will be protected by a one Amp fuse and does not need to be located in an area accessible during flight. 050 Route the AAA00D24 cable to the installed OAT sensor. 060 Route the AAP02B24 cable to the existing aircraft rotor speed cockpit instrument connector or rotor tachometer. 070 Route the AAD20B24 cable to the aircraft igniter relay

35 P&W ENGINE SERVICES, INC. IntelliStart PITOT AND STATIC TRANSDUCERS (OPTIONAL) STATIC TRANSDUCER RED WIRE BLK WIRE WHT/GRN WIRE WHT/BLU WIRE GRN WIRES Fold back shield and insulate with shrink sleeve W HT/ORG WIRE WHT WIRE RED WIRE PITOT TRANSDUCER BLK WIRE Wiring Instructions Figure 21: Pitot / Static Final Wiring 010 Trim the PITOT/STATIC AAA22D22 cable to length. Fold back the cable shield and slide on shrink sleeve to insulate it. Prepare the cable for splicing to the transducer wires using the following wire connection configuration: Harness Wire to Transducer Wire WHT/ORG GRN Wire Pitot Pressure Transducer WHT RED Wires (both transducers) WHT/BLU BLK Wires (both transducers) WHT/GRN GRN Wire Static Pressure Transducer 020 Splice the processor wires to the transducer wires. 030 Shrink sleeves. Secure all wiring

36 P&W ENGINE SERVICES, INC. IntelliStart OUTSIDE AIR TEMPERATURE (OAT) WHT/BLU WIRE WHT/GRN WIRE SHIELD CONNECTION WHT WIRES OAT PROBE SHRINK SLEEVE Fold back shield and cover with sleeve WHT/ORG WIRE WHT WIRE RED WIRES Figure 22: OAT Probe Final Wiring Wiring Instructions Wiring Instructions: The OAT probe may be supplied with or without an installed EMF shield over the leads. Where a probe with unshielded leads is supplied, a shielding kit and instructions (P&W Engine Services SB-0003) are included. For an unshielded probe, install the shield first before performing the wiring steps, below. 010 Trim the OAT PROBE AAA00D24 cable to length. Prepare the cable for splicing to the transducer wires using the following connection configuration: Harness Wire to OAT Wire WHT/ORG one RED OAT Probe Wire WHT the remaining RED OAT Probe Wire WHT/BLU one WHT OAT Probe Wire WHT/GRN the remaining WHT OAT Probe Wire SHIELD SHIELD 020 Splice the processor wires to the OAT wires. 030 Shrink sleeves. Secure all wiring

37 P&W ENGINE SERVICES, INC. IntelliStart ENGINE TORQUE TORQUE TRANSDUCER W H T/BLU W IR E W H T/G R N W IRE BLK W IR E SHRINK SLEEVE Fold back shield and cover with sleeve W H T/ORG W IRE W H T W IR E GRN W IR E R ED W IR E Figure 23: Torque Final Wiring Wiring Instructions 010 Trim the Torque AAA20D22 cable to length. Fold back the cable shield and apply shrink sleeve to insulate it. 020 Splice the cable wires to the torque transducer using the following wire splice configuration. Note that the black transducer wire connects to both the WHT/BLU and WHT/GRN harness wires. Harness Wire to Transducer Wire WHT/ORG WHT WHT/BLU and WHT/GRN 030 Secure all wiring. GRN (Signal) RED (Power) BLK (Ground)

38 P&W ENGINE SERVICES, INC. IntelliStart ENGINE FUEL TRIM SOLENOID VALVE Figure 24: FTSV Connector Wiring Wiring Instructions: 010 Trim the SOLENOID VALVE AAC00B22 cable to length. Fold back and insulate the cable shield with a length of shrink sleeve. 020 Refer to Figure 24. Install the 3 pin FTSV connector (10SL-3 type) to the cable using the wiring configuration shown. 030 Shrink sleeves, attach the connector to the FTSV and secure all wiring

39 P&W ENGINE SERVICES, INC. IntelliStart COCKPIT INTEL START SWITCH / LAMP CONNECTOR WIRING For All Listed Aircraft: Wiring Notes: ConXall connectors are installed in this and the next section. The following tools are recommended by the vendor for use with these connectors (vendor P/Ns): Insertion Bit (356-20), Pin Removal Bit ( ), Socket Removal Bit ( ), Handle (356-1), Crimp Tool (359-21), Locator ( ). The vendor address is: ConXall Corporation. 601 East Wildwood, Villa Park, IL Installation Caution: The INTEL START / Trend switch and the Communication Port cables both use 6 pin connectors. The INTEL START switch cable uses a socket connector (6SG type) and the Communication Port cable uses a pin connector (6PG type). Be sure to use the correct connector with the appropriate cable. Wiring Instructions Figure 25: INTEL START (Trend) Switch and Fault Lamp Connector Wiring 010 Trim the FAULT LAMP AAV30D24 cable to length, and slide the correct ConXall connector backshell parts onto the cable. 020 Refer to Figure 25. Connect the cable to the included ConXall connector using the illustrated socket configuration. Splice a short wire lead to the cable shield with a shrink-on solder sleeve to make the Pin 6 shield connection (Figure 21, upper and middle). 030 If an optional aircraft indicator (annunciator) display is required, connect a length of cable to Socket 5 of the connector. Route and connect the other end of the cable to the indicator lamp. NOTE: The IntelliStart+ lamp output provides a ground signal when the lamp is active. If an existing aircraft lamp is used, it must have 28 VDC supplied continuously to the opposite lead. 040 Assemble the backshell to the connector, connect it to the lamp, and secure all wiring