GPS Apollo GX Series
GPS Apollo GX Series
Apollo GX Series
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© 2004 Garmin Ltd. or its subsidiaries. All rights reserved. Printed in the U.S.A.
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How to Contact Us
Telephone: 800-525-6726 US
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503-391-3411 International
Fax: 503-364-2138
Please feel free to fax us your orders (including account number, purchase order and shipping
method desired), literature requests, or service questions. If sending service questions, please
include serial number of unit, part number, software version, type and location of antenna, and as
much detail as possible about the problem.
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and location of antenna, and as much detail as possible about the problem.
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TABLE OF CONTENTS
HOW TO CONTACT US ........................................................................................................................................III
LIST OF FIGURES ............................................................................................................................................... VI
HISTORY OF REVISIONS .................................................................................................................................... VII
HISTORY OF REVISIONS .................................................................................................................................... VII
CHAPTER 1. SERVICE REQUIREMENTS ............................................................................................................. 1-1
PRELIMINARY DATA ........................................................................................................................................ 1-1
SERVICE AUTHORIZATION AND AUDITS .......................................................................................................... 1-1
UPDATING SERVICE MANUALS........................................................................................................................ 1-1
ESD REQUIREMENTS ....................................................................................................................................... 1-1
SOLDERING REQUIREMENTS ............................................................................................................................ 1-1
SOURCES FOR SOLDERING STANDARDS ........................................................................................................... 1-2
GPS SIGNAL SOURCE ...................................................................................................................................... 1-2
TOOLS REQUIRED ............................................................................................................................................ 1-2
GUIDE FOR USING HAND TOOLS ....................................................................................................................... 1-2
GUIDE FOR USING FASTENERS ........................................................................................................................ 1-3
CHAPTER 2. INTRODUCTION.............................................................................................................................. 2-1
DISPLAY .......................................................................................................................................................... 2-2
EXTERNAL ANNUNCIATORS ............................................................................................................................ 2-2
CONTROLS ....................................................................................................................................................... 2-2
KEYS ............................................................................................................................................................... 2-3
“SMART” KEYS ............................................................................................................................................... 2-3
MAP FUNCTION SMART KEYS ......................................................................................................................... 2-4
MAP WAYPOINT KEYS .................................................................................................................................... 2-4
APOLLO GX FEATURES ................................................................................................................................... 2-6
CHAPTER 3. INSTALLATION MANUALS ............................................................................................................. 3-1
LIST OF FIGURES
FIGURE 7-1. GX55 ASSEMBLY BOARD LOCATIONS ............................................................................................ 8-2
FIGURE 7-2. GX 50/60/65 ASSEMBLY BOARD LOCATIONS.................................................................................. 8-3
FIGURE 7-3. RIBBON CABLE PLACEMENT ON BEZEL ASSEMBLY AND NAV BOARD ........................................... 8-7
FIGURE 7-4. RIBBON CABLE PLACEMENT.......................................................................................................... 8-11
FIGURE 7-5. FLEX CIRCUIT PLACEMENT............................................................................................................ 8-21
FIGURE 9-1. GX55 NAV PCB COMPONENT LAYOUT (REFERENCE ONLY) (SHEET 1 OF 3) ............................... 10-1
FIGURE 9-2. GX 50/60/65 NAV PCB COMPONENT LAYOUT (REFERENCE ONLY) (SHEET 1 OF 2) .................... 10-4
FIGURE 9-3. COMM PCB COMPONENT LAYOUT (REFERENCE ONLY) (SHEET 1 OF 3) ....................................... 10-6
FIGURE 9-4. NAV BLOCK DIAGRAM ................................................................................................................. 10-9
FIGURE 9-5. COMM BOARD BLOCK DIAGRAM................................................................................................. 10-10
FIGURE 9-6. VHF COMM MAIN PCA BLOCK DIAGRAM .................................................................................. 10-11
FIGURE 9-7. MICROCONTROLLER BLOCK DIAGRAM ....................................................................................... 10-12
FIGURE 9-8. VHF COMM SYNTHESIZER BLOCK DIAGRAM .............................................................................. 10-13
FIGURE 9-9. RECEIVER BLOCK DIAGRAM ....................................................................................................... 10-14
FIGURE 9-10. AUDIO CIRCUITS BLOCK DIAGRAM ........................................................................................... 10-15
FIGURE 9-11. VHF COMM TRANSMITTER BLOCK DIAGRAM ........................................................................... 10-16
FIGURE 9-12. VHF COMM POWER SUPPLY/AUDIO AMP BLOCK DIAGRAM ..................................................... 10-17
FIGURE 9-13. GX55 ASSEMBLY (REFERENCE ONLY) (SHEET 1 OF 2).............................................................. 10-18
FIGURE 9-14. GX50, 60, 65 ASSEMBLY (REFERENCE ONLY) (SHEET 1 OF 2) .................................................. 10-20
History of Revisions
July 1999 ....................................................................................................................... Original Release
ESD Requirements
ESD precautions must be followed at all times when handling components or circuit boards. When
working on the unit, you must use a grounded wrist strap and a grounded working surface. Circuit
boards or components must only be carried in a nonconductive, anti-static bag. Reference EIA
Standard # EIA-625.
All components to be shipped require appropriate ESD protective packaging.
Soldering Requirements
Use a grounded tip, temperature controlled solder iron operating at 600 to 700 degrees Fahrenheit.
The solder, wick and flux are “no-clean” products. If others are used, the boards must be cleaned
after servicing to remove residues. See the parts list for these items. Reference the following
standards:
IPC-R-7721 and 7711 (or newer) Guidelines for Rework and Repair of Printed Boards and
Assemblies.
IPC-A-610A (or newer) Acceptability of Electronic Assemblies.
Tools Required
• #1 Phillips screwdriver
• 5 lb.-in. torque wrench with #1 Phillips driver bit
• Needle nose pliers
• ¼" Nut driver
• 0.312" Nut driver
• Solder iron - grounded tip, temperature controlled (600-700 degrees F)
• Solder wick - “no clean,” Tech Spray p/n 1815-100F (0.060" dia) or 1816-100F (0.85" dia) or
equivalent
• Solder - “no clean,” Qualitek p/n NC600 (63/37), or equivalent
• Flux – “no clean,” Qualitek p/n 302 No-Clean flux or p/n rwrk wand, no-clean
• Slotted screwdriver
• 0.050 Hex driver
• Glass cleaner, non-ammonia base
• Cleaning wipes – low lint
• Integrated circuit puller
A wealth of easy to use features serves the needs of today’s demanding aviation requirements. The
large waypoint database has information about airports, VORs, NDBs, intersections, and special use
airspaces that makes the Apollo GX an encyclopedia of aviation. It’s what you’d expect from UPS
Aviation Technologies the first to provide a database in a general aviation navigation aid. The
database can be updated by simply changing the removable data card in the front of the unit. The
database can also include 500 custom waypoints created by the user. Thirty flight plans can be saved
with up to twenty legs for setting up custom tailored routes. The detailed navigation information
displays are also customizable and can be set to automatically scroll through the desired information.
The Nearest/Emergency Search feature, invented by UPS Aviation Technologies, makes it easy to
react to an emergency or change your active flight plan.
GX55
The GX55 is designed to be a simple slide-in replacement for panel-mounted Apollo Loran and
Flybuddy GPS receivers. The GX55 connectors and antenna footprint are the same as the Apollo
Loran and Flybuddy GPS receivers. The GX55 is TSO-C129 Class A2 authorized for IFR en route
and terminal operation.
GX50
The Apollo GX50 GPS receiver possesses all of the performance features of the GX55, plus more.
The GX50 is TSO-C129a Class A1 authorized for IFR nonprecision approach operation. The GX50
uses the same tray size, but different connections on the back to allow for approach capabilities.
GX60
The Apollo GX60 combines the physical package of the GX50 GPS receiver with a revolutionary VHF
Comm transceiver. All of this without the requirement for external cooling.
GX65
The Apollo GX65 possesses the same features as the GX60, except it is not certified for IFR
approaches.
Display
The display is a 160 by 80 pixel electroluminescent graphic display. A photocell is located in the top
left corner of the front panel display. The photocell automatically controls the light intensity of the
display from low brightness at night to high brightness during daylight operation.
External Annunciators
When external indicators are installed, the Apollo GX will also provide an external indication when
Parallel Track (PTK) is activated or a Message (MSG) is received. The GX50/60 also have external
annunciator controls for OBS/Hold and Approach Active.
Controls
The Apollo GX uses a variety of controls to manage the features. The controls include a power knob,
dual-concentric knobs (called large and small), hard keys, and “smart” keys.
Power Knob
The knob on the top right side of the Apollo GX controls power on/off. Rotate the knob clockwise
(CW) past the detent to turn the power on. Rotate the knob fully counterclockwise to turn the power
off. Full rotation and the push-pull capabilities are only used in the GX60/65.
Keys
There are two types of keys that allow you access to the functions in your Apollo GX: permanent
“hard” keys and displayed “smart” keys. Seven backlighted permanent keys are used to reach the
functions or perform other operations of the Apollo GX. The “smart” key labels are shown on the
bottom of the display. There are two categories of “smart” keys: those available for the Map function
and those available at all other times. Press the key below the label to use the displayed function.
Press a function key once to go to the last page viewed or twice to go to its “home” page.
Hard Keys
The “hard” keys are the easy-touch, black, rounded keys with white
lettering on the right side of the display. These keys include, NAV,
NRST, INFO, SEL, MAP, Direct-To, and ENTER.
NAV (Navigation)
Press the NAV key to reach the navigation functions. Press twice to go to the “top” page.
INFO (Information)
The Info function accesses supplementary information about a waypoint. Press INFO a second time
to return to the previous display.
SEL (Select)
The SELECT key activates editing or the selection of options. Editing is active on the items that flash
on the display. Press SEL a second time to deactivate selection.
DIRECT-TO
The Direct-To key is used to define a direct course from your present position to a waypoint. Press
once to select a waypoint. Press twice to enter an OBS desired track To or From the current active
waypoint.
ENTER
The ENTER key enters and saves the information flashing on the display. If the ENTER key is not
pressed after editing, any changes made are not saved. In the GX60/65, the ENTER key flip/flops the
Active and Standby frequencies.
“Smart” Keys
The Apollo GX uses “smart” keys to provide custom controls for specialized functions. Five small,
unlabeled keys are located below the display. The labels appear on the display and can change to
give extra controls for the active function, such as in the MAP function. You can always press the
NAV key to go back to the navigation function and view the normal “smart” keys.
MSG (Message)
Press the MSG key to reach the message functions. The MSG annunciator will flash when a new
message is provided. Press the MSG key a second time to return to the previous display after all new
messages have been viewed. The MSG key will remain highlighted when a message remains.
DB (Database)
The database key provides access to the waypoint database.
In an emergency, press DIRECT-TO and ENTER to fly direct to the highlighted airport. Press the
SCAN key again to return the large knob to normal operation.
COM (GX60/65)
Press the COM key to operate the communications radio functions.
Flip/Flop (GX60/65)
Press the Flip/Flop key to switch between the active (left-most) and standby (right-most) frequency
while in the Comm function. You may use an optional external Flip/Flop key for the same operation as
the front panel control. Switching between frequencies is disabled while you are transmitting or
editing in any function.
Apollo GX Features
Navigation Features
• High resolution, daylight-readable graphics display
• Automatic display intensity
• Back-lit buttons
• Simple “Direct-To” navigation
• Datacard database for easy user update and replacement
• Nearest waypoint and airspace search (includes airports, VORs, NDBs, intersections, and
user waypoints)
• Remote waypoint search
• Navigation displays -
− Lat/Lon to 0.01 minute
− Bearing and distance to waypoint
− Ground speed and track angle
− Track angle error
− Desired track and distance between waypoints
− Cross track error with numeric and graphic CDI
− Display of the “TO” waypoint ident
− ETE and ETA to the “TO” and destination waypoints
− Altitude (from altitude encoder/converter input)
− Minimum safe altitude and en route safe altitude information
• Map Displays -
− Full screen map with bearing, distance to waypoint, and zoom level
− Split screen map with distance, speed, bearing, track, crosstrack error, To waypoint, and
zoom level
− Split screen with navigation data and communication frequency display (GX60/65 only)
− Smart key, 1 button map declutter, Tri-state
− On map waypoint selection for information, direct-to nomination
− Track up, desired track up, and magnetic north up options
− Runway diagrams and runway names displayed
− 5 nm ATC rings around airports with control towers
− Airspaces displayed by sector or outer boundary
− Airspace display controllable by type
− Approach preview page (GX50/60 only)
− Route line displayed
Electrical
• Input voltage
− 10 VDC to 40 VDC, reverse polarity protected
• Input current (GPS navigation input)
− 500 mA typical, 750 mA max at 13.75 VDC
− 250 mA typical, 375 mA max at 27.5 VDC
• Input current (communication input - GX60/65 only)
− 270 mA typical, 2 A max at 13.75 VDC, receive
− 130 mA typical, 900 mA max at 27.5 VDC, receive
− 2.1A typical, 3.2 A max at 13.75, transmit
− 1.0A typical, 1.4 A max at 27.5 VDC, transmit
• Input power (GPS navigation input)
− 7 watts typical
• Input power (communication input - GX60/65 only)
− 3.7 watts typical, receive
− 28 watts typical, transmit
Avionics Inputs
• Serial
• Frequency flip/flop (GX60/65 only)
• Waypoint Sequence (GX50/60 only)
Serial Interface
• 2 RS-232 for GX50/60/65
• 1 RS-232 for GX55
Physical Specifications
• Height: 2.0 inches (5.08 cm)
• Width: 6.25 inches (15.88 cm)
• Depth: 11.125 inches (28.26 cm) behind panel, including mounting frame and connectors
• Weight (with mounting frame):
− GX50 and GX55 - 2.6 pounds (1.179 kg)
− GX60/65 - 3.1 pounds (1.409 kg)
Environmental Specifications
• Operating temperature -20º C to +55º C
• Storage temperature -55º C to +85º C
• Temperature variation 2º C per minute
• Humidity 95% at 50º C for 6 hrs (2 day cycle)
• Maximum altitude 55,000 feet
• Cooling Not required
TSO Authorizations
• GX50
− TSO C129A A1
• GX55
− TSO C129 A2
• GX60
− TSO C129A A1
− TSO C128
− TSO C37d
− TSO C38d
• GX65
− TSO C129A A2
− TSO C128
− TSO C37d
− TSO C38d
Features and specifications subject to change without notice.
Pre-Installation Checkout
Take a few minutes with the aircraft before completing the installation quote to your customer. You
can get a good idea if you need to add a few extra hours to the quote by using a handheld GPS, or,
better yet, a spectrum analyzer. A spectrum analyzer is the preferred tool, if available. When using a
portable GPS, which is available to most shops, turn it on and observe the signal strength display. For
example, the Apollo Precedus shows signal strength for up to eight satellites. Obtain some average
GPS signal strength readings as you walk around the aircraft. Key up Comm 1 on the entire list of
VHF frequencies listed in the Advisory Circular. Observe the effects of VHF transmissions on the
signal strength display of the portable GPS unit. Repeat the test for Comm 2. During the interference
checks, make sure you get the portable GPS antenna as close as you can to the VHF Comm
antennas, the ELT antenna, and the direction-finding antenna. This procedure should also help in
determining the best location for the GPS antenna. Check the interference levels at different top-
mounted locations using the portable GPS antenna. If the interference is too strong, causing a loss of
GPS signals in all possible antenna locations, follow the suppression guidelines below. You should
also include extra time in installation quotes to allow time to identify and isolate the interference
source(s).
important to mention that the RFI interference coming from the GPS receiver, Comms, and
NAV/Comms is not getting into the case of our GPS receivers. The Apollo GPS units are not
susceptible to RFI interference. The problem comes from the interference reaching the GPS antenna.
To prove this, you can walk around the aircraft with the GPS antenna in hand. When you get far
enough away from the aircraft, normal operation of the GPS receiver will resume.
Remove Comm 1 and repeat the above steps for Comm 2.
Install both Comm 1 and Comm 2. Turn on both Comms and repeat the interference checks. If the
interference returns, then Comm 1 transmitter is causing Comm 2 receiver to re-emit interfering L1
frequencies. To verify inter-coupling, you can turn off one of the Comms and repeat the tests. The
quickest way to solve Comm 1 and 2 inter-coupling is to separate the antennas. Place Comm 1 on
the top side and Comm 2 on the bottom side of the aircraft.
Re-install the ELT and repeat the interference tests. If the ELT causes GPS interference, you can
install a GPS notch filter in line with the antenna. Most of the case enclosures for ELTs are plastic
and the case needs to be wrapped in appropriate metal shielding to ground the case and shield of the
antenna. The ELT is a very common source of L1 interference.
Direction finding equipment used in Search and Rescue operations by the CAP and others can also
be a source of L1 interference. The non-linear properties of pin diodes, used to switch between
antenna elements, will generate harmonics when excited by a strong VHF signal like those from a
th th
nearby Comm radio. Interference on the 12 and 13 harmonics is re-broadcast from the direction-
finding antenna. This interference on the L1 frequency causes problems with the GPS. To overcome
this interference, make sure the direction-finding antenna is located on the bottom of the aircraft and
that GPS notch filters are installed.
Test one more time. If the interference has been eliminated, permanently mount the GPS antenna
and re-test. These guidelines can be used to minimize GPS interference problems.
Microprocessor
The microprocessor (U3) used in the GX series NAV boards is an Intel 386EX embedded
microprocessor. The i386EX is based on the static Intel 386 SX processor. The i386 EX has a 16-bit
data bus and 26-bit address bus. Performance of the i386 EX is similar to that of the i386 SX at the
same speeds. The system clock operates at 16 MHz.
In addition to the processor core, the i386 EX includes integrated peripherals such as:
• Interrupt Control Unit (ICU)
• Timer/counter Unit (TCU)
• Asynchronous Serial I/O (SIO)
• Direct Memory Access (DMA) controller
• System Management Mode (SMM)
• Clock and power management unit
• Synchronous Serial I/O (SSIO)
• Chip-select Unit (CSU)
• Refresh Control Unit (RCU)
Memory
SRAM
The NAV board design uses either one or two 1 MBIT (128K x 8) low-power SRAMs (U104 & U105).
The SRAM uses battery backup to save the contents when the unit is turned off.
When using a single SRAM, the device is connected for use in byte mode. The chip select
configuration must be set to byte access by software.
When using both SRAM devices, they are connected to allow word access. The BLE and BHE
connections allow for aligned and non-aligned word access as well as byte access.
Resistor jumpers are used on the board to make the appropriate connections for either one or two
parts. The resistors are installed as listed in the following table.
EEPROM
The GX unit uses a non-volatile EEPROM device to store data, such as pilot name, address, phone
number, aircraft ID information, password and the GX unit serial number. Additionally, the EEPROM
stores configuration information such as +5 V calibration data, CDI and VDI calibration data.
The NAV board includes one 16 KBIT (2K x 8) parallel EEPROM, Atmel part no. AT28C16E. The
board layout also accepts an 8 K x 8 EEPROM, an AT26C64. The EEPROM is an 8-bit memory and
cannot be configured as a 16-bit memory.
Read access can be made from the EEPROM as a standard memory device. Write access can also
be made as a standard memory device, but note that there is a minimum period of 200 µsec between
writes. This period is for the internally timed programming cycle. During the programming cycle,
completion status can be read back from the device.
For more information on the EEPROM, refer to the Atmel Nonvolatile Memory Data Book.
Avionics Outputs
CDI/VDI Outputs
The GX50/60/65 units provide outputs to drive CDI and HSI indicators and an autopilot. These
outputs are to be connected as appropriate for the particular installation. The CDI/HSI outputs may be
connected to a dedicated CDI or HSI or to a shared indicator using an appropriate switching relay.
Flag Outputs
The GX units provide TO/OFF/FROM flag outputs.
Annunciator Outputs
The GX55 provides MSG (message) and PTK (parallel track) annunciator outputs. In addition to
these two outputs, the GX50/60/65 units provide OBS/HLD (waypoint sequencing hold), APPRCH
(approach) and ACTIVE (approach active) annunciator outputs.
Altitude Input
The GX50/60/65 includes an altitude input, which is used for GPS RAIM calculations as well as
providing for altitude assist functions such as altitude preset and hold and 3D airspace alerts. The
altitude input is required for installations approved for non-precision approach operation. It is optional
for other installations. The GX50/60/65 altitude input can be connected from either an altitude
encoder/converter or an air data converter.
Power Supply
The GX60/65 requires two power connections, one for the GPS navigation computer board (P701,
DB37) and one for the communications transceiver board (P400, DB15). The GPS navigation
computer board power input is internally fused at 3 amps. A separate 2 amp (maximum) circuit
breaker or fuse should be installed externally for overload or short circuit protection. The
communications transceiver board power input (GX60/65 only) is internally fused at 7 amps. A
separate 5 amp (maximum) circuit breaker or fuse should be installed externally for overload or short
circuit protection.
The GX50 requires only a power connection for the NAV board (P701) like the GX60/65.
The GX55 requires only a power connection to the 14-pin rear connector.
Design Overview
Module Functionality
The transceiver functions are fully self-contained on the Comm main board printed circuit assembly
(PCA). The Comm PCA is an AM VHF communications transceiver designed for aviation use. The
Comm PCA includes both receive and transmit functions, microphone inputs, and headphone and
speaker outputs.
Circuit Overview
The Comm transceiver is controlled by an Atmel 82C52 8-bit µcontroller. Full power supply circuits
are included. The µcontroller takes inputs from a control panel to determine receive and transmit
frequency, and outputs data to a display for the user.
The µcontroller programs the synthesizer for the selected frequency, adding 21.4 MHz for receive.
The µcontroller monitors status inputs such as synthesizer lock to ensure proper operation and
transmission on valid frequencies.
Complete block diagrams for the Comm module are included in the Drawings Chapter of this manual.
Transmitter
Emission Type
A3E
Frequency Range
The frequency range of the transmitter is 118.000 to 136.975 MHz using 760 channels at 25 kHz
spacing. The user or pilot makes frequency selection.
Output Power
With an input voltage of 12 to 40 volts DC, the transmit output power level is a minimum of 8 watts
and a maximum of 11 watts across the operating frequency range. The output power drops off below
12 volts input to protect the circuit devices and reduce current input during low voltage operation
(aircraft power system failing). The modulation level is held within 5% as the voltage drops, ensuring
the modulation level remains below 95%.
Modulation Level
The modulation level is controlled by the analog circuits and a D/A converter used as a gain control
and is limited by an AGC circuit and calibration.
The microphone inputs are amplified in a preamp, then switched through to an automatic gain control
(AGC) circuit. The AGC circuit provides limiting of the signal level that is provided to the system
calibration gain control D/A. The modulation level is calibrated during equipment test to 90%. The
Comm module requires a microphone input of 100 mV RMS for full (90%) modulation. The audio
frequency response of the modulation signal varies <3 dB from 350 Hz to 2500 Hz, is >3 dB down at
220 and 3000 Hz, and 18 dB down at 4000 Hz.
Frequency Stability
The transmit frequency is controlled by a frequency synthesizer. The synthesizer provides for a
transmit frequency tolerance within 15 ppm (required spec is 30 ppm).
Purpose
The tests described in this chapter are designed to aid service personnel in locating inoperative areas
within the product. They also serve a complete return to service procedure after any field repair work
is completed. Test specifications for Apollo GX50, GX55, GX60 and GX65 products are defined.
Scope
These test procedures affect the GX50, GX55, GX60 and GX65 in the following manner:
• Common Tests are required for all GX products.
• NAV Return to Service is required for all the GX products.
• Comm Return to Service is required for the GX60 and GX65.
• Final Unit Checkout is required for all GX products.
Software verification is not required because the software was tested during development. However,
you must verify that the proper version of software is installed. The hardware must be checked and
verified on each unit.
References
EIA Standard # EIA-625
UPS Aviation Technologies installation manual
TST 10 Test Station
Acronym Definition
dBm a logarithmic power measurement expressed in dB referenced to 1 milliwatt
DC Direct Current
DEMOD demodulation
Dsp display
DSP Digital Signal Processor
E Electromotive force (measured in volts)
EEPROM Electrically Erasable Programmable Read Only Memory
EIA Electronic Industries Association
ESD Electrostatic Discharge
F Fahrenheit (temperature)
FM Frequency Modulation
GEN generator
GPS Global Positioning System (satellite based navigation system)
HDPH headphone
HPF High Pass Filter
HphLv headphone level
Hz Hertz (cycles per second)
I current (measured in amperes)
IcmSq intercom squelch
IF Intermediate Frequency
IFR Instrument Flight Rules
INCR increment
INT intercom
I/O Input and Output
kHz kilohertz (thousands of cycles per second)
LED Light Emitting Diode
LO Local Oscillator
LPF Low Pass Filter
LVL level
MEM memory
MHz megahertz (millions of cycles per second)
MIC microphone
MON monitor
MSG message
mV millivolt
NAV navigation
OSC oscillator
Pk peak
PPM Parts Per Million
PREV previous
PRN
PTK parallel track
PTT Push To Talk
PWR power
R resistance (measured in ohms)
REF reference
RF Radio Frequency
Acronym Definition
RFLVL RF level
RMS Root Mean Squared (an averaging method for measuring time varying
signals)
RX receive
SAR Search And Rescue
SEL select
SidLv sidetone level
SINAD A standard method of measuring the hum and noise level on a received
signal
SPKR speaker
SQ squelch
SRAM Static Random Access Memory
SVN Satellite Vehicle Number
SW software
TX transmit
UC Unit Configuration
V volts
Vac aircraft supply voltage
Vcesat saturation voltage between a transistor’s collector and emitter
VDC Volts Direct Current
VDI Vertical Deviation Indicator
VER version
VFR Visual Flight Rules
VOX voice operated relay
VSWR voltage standing wave ratio
W watts
WPT(S) waypoint(s)
µV microvolts
Ω ohm
Preliminary Data
Fill out the appropriate fields of the Service Data Sheet before starting repair or testing. A copy is
located at the end of this manual. The data will be used to reenter customer configuration and
perform a final test and inspection when service is completed.
Final Test/Inspection
Record results on the Service Data Sheet after completing all service and return to service tests. A
copy of the Service Data Sheet is located at the end of this manual.
Setup Requirements
ESD Requirements
Follow ESD precautions at all times when handling components or circuit boards. When working on
the unit, you must use a grounded wrist strap and a grounded working surface. Circuit boards or
components must only be carried in a nonconductive, anti-static bag. Reference EIA Standard # EIA-
625.
Test Equipment
Power supply DC Power Supply (12 V at 10 A) or equivalent
Communications test set HP8920 A/B RF Communications Test Set with high stability time base,
Opt 001. Spectrum Analyzer with Tracking Generator, Opt 102 or
equivalent Opt 019*
2 each audio test cables 2 feet RG58A/U BNC-male-to-BNC-male
Test station and cables UPS Aviation Technologies part # 435-0102-000, Apollo TST 10 test
station. Refer to the TST-10 User’s Manual for the test interface cables
and connectors.
SL40 display assembly For test purposes only
Volt ohm meter FLUKE 8010A Digital or equivalent
RF coax test cable 2 feet RG58A/U BNC-male-to-N-male
DVM FLUKE 8010A Digital or equivalent
GPS signal source A-34 GPS Antenna or equivalent
DC power cable User supplied
GPS antenna and coax User supplied
GPS reference unit Factory certified GPS receiver
*If the HP8920 Communications test set is not available, it can be substituted with equivalent test
equipment listed in the table below.
Parameter Type Accuracy
Frequency +/- 1 Hz
RF Power Measurement +/- 5%
(for inputs > 8 mW, <2.4 W):
FM Measurement (residual FM + noise, 0.3 to 3 kHz, +/-4% of reading + residual FM + noise
rms: <20 Hz)
AM Measurement +/-5% of reading
+/-1.5% AM
AC Voltage (>=1 mV): +/- 3%
DC Voltage +/- 1% +/-45 mV DC offset
Spectrum Analyzer Spurious-free Dynamic Range 60 dB for signal <= -30 dBm
Spectrum Analyzer Linearity: +/-2 dB
Spectrum Analyzer Noise Level (<50 kHz spans) -114 dBm
Spectrum Analyzer Level +/-2.5 dB
SINAD (0 to 46 dB SINAD) +/-1 dB
Distortion Measurement +/-1 dB
All test equipment must be current on calibrations before performing these tests.
Power
Environmental
All tests shall be conducted on the test bench with an ambient temperature of 50° to 90° F unless
specified otherwise.
Typical Setup
Typical test setup includes connections for DC power input and avionics outputs. The avionics
outputs shall be connected to specified worst case loads as shown per the appropriate procedure.
For example a 200 ohm resistor should be connected between the CDI+ Right and CDI+ Left outputs.
Voltage measurements for the outputs are then measured across the load resistors. The wiring
diagrams for the avionics connections can be found in the installation manual for the unit.
For Comm equipment setup, see Equipment Setup under the Comm Return to Service Procedure.
Alternate Setup
The avionics outputs may be tested by connecting the outputs to a standard instruments/meters and
connecting the annunciator outputs to lamps. Be sure to include the specified loads in the alternate
setups.
The TST 10 test station, available from UPS Aviation Technologies, contains all of the alternate test
connections for all outputs and inputs.
Other test setups and tests may be used as long as they meet the intent of the tests and test setups
defined in this chapter and verify proper operation and performance of the test units.
1. Display
Specification: Verify that the display operates correctly.
Notes: Use the Display Test function in the built-in test mode.
4. Volume Control
Specification: Verify the volume control can be adjusted from min to max or a count of 000 (full
counter clockwise) to 255 (full clockwise).
Notes: Use the A-to-D Input test in the built-in test mode.
Although the GX50/55 does not use the volume control, it should still be checked.
5. Battery Voltage
Description: A battery backs up The SRAM memory on the NAV board. The SRAM stores the
user waypoints and flight plans.
Setup: Remove the cover from the unit (see Chassis Cover Replacement procedure).
Operation: Measure the battery voltage using a DVM. Replace the chassis cover (see
Chassis Cover Replacement procedure) after verifying proper battery voltage.
Verification: Verify that the battery voltage is in the range of 2.75 V to 3.4 V for an old battery
returning to service. A new battery should measure between 2.95 V and 3.4 V.
1. System Initialization
NOTES
The system initialization function is used to reset non-volatile SRAM (NVRAM) and user
configuration data in EEPROM to their default values, and to clear user waypoints and flight
plans.
The reset USER NVRAM function must be executed if the navigation software is upgraded
(unless instructed otherwise).
CAUTION
Executing the system initialization will clear all customer information. Fill out the Service Data
Sheet located at the end of this manual.
For units returned for service or upgrade, the reset EEPROM and reset PLANS/WPTS functions
should not be executed unless specifically instructed to do so, or all customer configuration,
waypoint, and flight plan data will be lost.
Specification: Turn to the System Initialization page in test mode, and execute the system
initialization by pressing the SEL and ENT buttons.
The system initialization functions are listed in the following table.
1. CDI Output
Description: The CDI output is a differential output intended for driving a meter movement
with a maximum load of 200 ohms.
Setup: If the TST-10 test station is not available, connect a standard CDI (or equivalent
meter) to the TO/FROM outputs.
Operation: Select the CDI left, mid, and right outputs using the CDI Output page in test
mode.
Verification: Verify the left/right indication as follows:
Left: meter full left
Mid: meter centered
Right: meter full right
Alternate: If the TST-10 test station is not available, connect the unit to nominal input supply
voltage. Connect a 200-ohm load between the CDI+ Right and CDI+ Left outputs.
Verification: Verify the differential output voltage between the CDI+ Right and CDI+ Left
outputs as follows:
Left: -150 mV ± 4 mVDC
Mid: 0 mV ± 2.0 mVDC
Right: +150 mV ± 4 mVDC
Verify the CDI+ Left output to ground is 2.05 volts ± 0.1 VDC.
4. Annunciator Outputs
Description: The GX50/60 includes six annunciator outputs intended for turning incandescent
lamps on/off. The six outputs are MSG, PTK, GPS, OBS/HLD, APPRCH, and
ACTIVE.
The GX55/65 includes two annunciator outputs intended for turning incandescent
lamps on/off. The two outputs are MSG and PTK. These are open collector
outputs capable of sinking 400 mA.
Setup: If the TST-10 test station is not available, connect the annunciator outputs to
incandescent lamps, and the other side of the lamps to aircraft supply voltage
(Vac).
Operation: Using the Lamp Outputs page in test mode, select on and off for each of the six
outputs by rotating the small knob.
Verification: Verify that the lamps connected turn on and off as indicated on the GX display.
Alternate: Connect the unit to nominal input supply voltage. Connect a 400 mA load
between each of the annunciator outputs and aircraft supply voltage (Vac). (If
Vac = 13.6 volts, then a load resistor of 33 ohms can be used.)
The load resistor is computed by:
(Vac - Vcesat) / Ioad = (13.6 volts - 1 volt) / 400 mA = 31.5 ohms.
(Rounding to 33 ohms is OK)
Verification: Verify the output voltage of the six annunciator outputs as follows:
Lamp on: 1.0 VDC max
Lamp off: Vac ± 0.1 VDC min
9. Serial Ports
Description: The GX50/60 includes two serial ports. The GX55/65 includes one serial port.
Setup: If the TST-10 test station is not available, connect the unit to nominal input supply
voltage and connect the TxD output to the RxD input.
Operation: Using the Serial Port Test page in test mode, rotate the small knob to select the
two serial ports.
Verification: Verify both serial ports pass the port test
Introduction
Complete the transmitter frequency test before performing the receiver evaluations.
There are no adjustments inside the Comm radio. Several calibration numbers are stored in the
Comm radio EEPROM memory and are factory adjusted for the unit.
Where interference may be a problem, substitute an unused channel as close to the test frequency as
practical. Each test should be performed with the radio channeled on the low, center and high
operating frequencies.
Test Equipment
Test procedures in this manual are described in terms of RF test equipment found in many radio
shops. All test equipment must be current on calibrations. In addition, operating instructions for using
the HP8920 series Communications Test Set, which combines 22 different instruments into one piece
of equipment, are included at the back of the chapter.
Performance Specifications
Parts Required
• SL Display Assembly (Contact UPS Aviation Technologies Sales Dept. for part number and
ordering.)
Installation
1. Power the unit off.
2. Remove the chassis cover (see Chassis Cover Replacement procedure).
3. Unplug the ribbon cable J606 on the Comm board.
4. Plug the SL display into J603 on the Comm board. The red wire on the ribbon cable goes towards
the front of the chassis (pin 1).
5. Turn on the SL display. There may be garbled characters on the right side of the SL40 display.
Ignore them. The left part of the display contains the needed information.
Removal
1. Turn off the SL display.
2. Unplug the SL display from J603.
3. Plug in J606 on the Comm board (see Figure 8-4).
4. Test the unit to verify proper operation (see Return to Service Procedures).
5. Replace the chassis cover (see Chassis Cover Replacement procedure).
Test Configuration
The TST-10 test station is used to interface the power and audio I/O between the Comm radio and
the other bench test equipment. Test configuration for the Comm radio test setup is described for
each model in the TST-10 User’s Manual, 560-0399-00.
TX TEST screen
4. When conducting the transmitter performance test, do not use local frequencies such as tower,
ground ATIS and do not use the emergency frequency - 121.5 MHz.
RX TEST Screen
RF Gen. Freq. 127.5 MHz
Amplitude -50 dBm (1414 µV)
Atten Hold On/Off
Output Port RF Out/Duple
AFGen1 Freq. 1.0000 kHz
AFGen1 To AM 30%
AFGen2 Freq. 1.0000 kHz
AFGen2 To FM Off
Filter 1 50 Hz HPF
Filter 2 15 kHz LPF
Ext. Load R 4Ω
AC Level Watts
Transceiver Presets
1. Set system settings and TEST MODE to factory presets. Record customer presets; use the
Service Data Sheet located in Chapter 21 of this manual.
2. Set primary channel frequency to 127.5 MHz.
The system settings are enabled by pressing the NAV button for about three seconds. The LED
above the NAV button will turn off. Rotate the large knob to select the function. The software
version page will be the initial display.
The front panel buttons will operate normally during display of the system functions. Pressing any
button will revert back to the normal mode defined for the button. The receiver will also operate
normally during display of the system functions.
Note: The noise level is an 8-bit value with a range of 0 to 255 from the noise level detector as
read into the µcontroller through an A/D input.
While viewing the frequency display, use the large and small knobs to select an unused local
frequency. Toggle this frequency to the active channel. Press and hold the MON button for about
3 seconds to reach the System Functions. Use the large knob to select the NOISE function and
view the receive noise level of the selected frequency. The value will change constantly, and has
a range between 0 and 255. On the service bench with the antenna port of the transceiver
connected to a dummy load, NOISE should be between 100 and 125. If the transceiver is
connected to the aircraft antenna and there is no carrier on the channel, expect the reading to be
the same or slightly higher. To confirm that there is no carrier on the monitored channel, pull the
squelch knob and listen.
Note: The RF signal strength is an 8-bit value with a range of 0 to 255 from the IF/RF AGC
voltage as read into the µcontroller through an A/D input.
Transmit Mic
This function allows you to control which microphone is permitted to transmit. You may choose
Mic1, Mic2, or both.
MIC1+MIC2
Note: The Transmit Mic will display MIC1, MIC2, or MIC1+MIC2.
2. Transmitter Tests
Power Out:
1. Connect a wattmeter to the antenna output and record the following unmodulated power
levels.
2. 13.8 VDC (+/- 5%) Power supply:
118.00MHz ____8 watts min. 118.00MHz ____7 watts min. 118.00MHz ____7 watts min.
126.5MHz ____8 watts min. 126.5MHz ____ 7 watts min. 126.5MHz ____7 watts min.
135.97MHz ___ 8 watts min. 135.97MHz ___ 7 watts min. 135.97MHz ___ 7 watts min.
118.00MHz ___ 6 watts min. 126.5MHz ____6 watts min. 135.97MHz ___ 6 watts min.
Modulation Capability:
Input a standard modulator test signal (100 mV RMS at 1 kHz) into the microphone audio. Using
a linear detector, measure the AM modulation on the transmitter’s carrier signal.
118.00MHz _______ NLT 85% 126.5MHz ______ NLT 85% 135.97MHz ______ NLT 85%
Sidetone drive capable of 280 mW: _____ OK Sidetone reading for 28 mW _____
Microphone Bias
Measure the voltage across the microphone input with a 1 k ohm load resistor connected in
parallel.
Frequency Tolerance
1. Key the transmitter on a clear channel between 118.000 MHz and 135.95 MHz.
2. Using a frequency counter or spectrum analyzer, measure the output frequency of the
transmitter.
3. Receiver Tests
5. Vary the signal generator output power until 6 dB SINAD is obtained. Record this value below
(reference sensitivity).
Intercom/Monitor
1. Connect a 100 ohm resistor and AC power meter (or voltmeter) across the headphone
output.
2. Connect a 4 ohm resistor and AC power meter (or voltmeter) across the speaker output.
3. Move TEST/MIC1 switch to TEST on the TST-10 test station.
4. Inject a 1000 µV RF signal with a 500 Hz 85% AM modulated tone into the Comm antenna
port.
5. Inject a 50 mV 2000 Hz audio tone into the MIC1 port.
6. Adjust the volume control on the Comm radio so that there are at least 12 watts (1.73 volts
across 4 ohms) on the speaker output.
7. Set the INT/OFF switch on the TST-10 to INT; the speaker should be disabled.
Audio response: 350 Hz = ___ NMT 6 dB 1KHz = ___ 0 dB 2.5 KHz = ___ NMT 6 dB
Audio response: 350 Hz = ___ NMT 6 dB 1 kHz = ___ 0 dB 2.5 kHz = ___ NMT 6 dB
Headset Distortion
1. Inject a 1000 µV RF signal with 85% AM modulation at 1 kHz into the Comm antenna port.
2. Channel the Comm to the same frequency as the signal generator.
3. Connect a 100 ohm resistor and AC power meter (or voltmeter) across the headset output.
4. Turn up the volume control on the Comm radio to make sure the output power can be greater
than 280 milliwatts (5.92 Vrms across 100 ohms).
5. Measure across the headset output using an audio distortion analyzer.
6. Repeat for 350 Hz and 2.5 kHz.
Audio distortion: 350 Hz = ___ NMT 12% 1 kHz = ___ 5% 2.5 kHz = ___ NMT 5%
Speaker Distortion
1. Inject a 1000 µV RF signal with 85% AM modulation at 1 kHz into the Comm antenna port.
2. Channel the Comm to the same frequency as the signal generator.
3. Connect a 4 ohm resistor and AC power meter (or voltmeter) across the speaker output.
4. Turn up the volume control on the Comm radio to make sure the output power can be greater
than 12 watts (6.93 Vrms volts across 4 ohms).
5. Measure across the speaker output using an audio distortion analyzer.
6. Repeat for 350 Hz and 2.5 kHz
Audio distortion: 350 Hz = ___ NMT 12% 1 kHz = ___ 5% 2.5 kHz = ___ NMT 5%
Weather Channel
1. Inject a 1000 µV RF signal with 3 kHz FM modulation on 162.4 MHz into the Comm antenna
port.
2. Channel the Comm to the same frequency as the signal generator.
3. Connect a 4 ohm resistor and AC power meter (or voltmeter) across the speaker output.
4. Turn up the volume control on the Comm radio to make sure the output power can be greater
than 12 watts (6.93 Vrms volts across 4 ohms).
5. Test squelch by pressing NRST to put the WTH into secondary channel.
Squelch test ______ OK (No audio when WTH is put into secondary channel)
Monitor Test _____ OK (Pulsing 1 kHz tones present when MON button is pushed)
7. Measure the audio output with an ocilliscope with the MON button pressed.
Scan time _____ OK (20 mS blank time between the 1 kHz tone)
TX Power
Step General Instruction Specific Instructions Expected Results
1 Set all test No Modulation.
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 Key transmitter. On the test box press, the PTT
switch to TX.
3 Record power. Record TX Power from HP8920. TX PWR >8 watts with no
transmitter audio at 25°C + 4°.
TX PWR >7 w at –20°C and at
+55 °C. Optional: repeat this
test with DC input voltage
between 10 VDC and 40 VDC.
The battery protection circuit is
on below 13.75 V.
At 10 VDC input the transmitter
power should be 6 watts. At 9
VDC the PTT should lock out.
4 On the test box, press the PTT
switch to RX.
5 Repeat this test at frequencies
118.0 MHz and 136.975 MHz.
Modulation Capability
Step General Instruction Specific Instructions Expected Results
1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 Key the transmitter. On the test box, press the PTT
switch to TX.
3 Record % From HP8920, record reading of AM Depth of modulation will be
modulation. the AM depth of modulation. 85% minimum with 100 mV
RMS at 1000 Hz.
4 On the test box, press the PTT
switch to RX.
5 On the test box, Repeat steps 2 through 4 with
move test cable MIC2.
from MIC1
connector to MIC2
connector.
Microphone Bias
Step General Instruction Specific Instructions Expected Results
1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 Remove test Disconnect the 8920 AUDIO
equipment load. OUT cable from the test box. Put
the TEST1 MIC1 switch in MIC1.
3 Measure the DC Use the FLUKE 8010A on DC The voltage at MIC1 and MIC2
voltage at the test scale to measure the voltage at BNC connectors will be 6.3
station MIC1 BNC MIC1 BNC center pin. The volts ± 0.4 V.
connector (1 k ohm positive lead to center pin of
load is in test BNC connector the negative
station). lead to fixture ground.
4 Repeat this test with MIC2.
The following transmitter tests are not required for return to service. They are
included for troubleshooting. Continue on to the receiver tests below.
Frequency Tolerance
Step General Instruction Specific Instructions Expected Results
1 Set all test Set TX Freq. Error on HP8920 to
equipment as PPM.
specified in Test
Equipment Setup on
page 7-17.
2 Key transmitter. On the test box, press the PTT
switch to TX.
3 Record Freq. Error. Record TX Freq. Error from ± 15 PPM from -20° C to +70°
HP8920. C.
4 Un-key transmitter. On the test box, press the PTT
switch to RX.
5 Repeat this test at frequency ± 15 PPM from -20° C to +70°
118.0 MHz and 136.975 MHz. C.
Intercom/Monitor
Step General Instruction Specific Instructions Expected Results
1 Set all test On the HP8920:
equipment as
1. Set AMPLITUDE to 1000
specified in Test
µV.
Equipment Setup on
page 7-17. 2. Set Ext. Load R 4 ohms.
3. Set AFGen1 Freq. to 500
Hz. Set AFGen2 Freq. to
2000 Hz.
4. Set AFGen2 To field to
Audio out at 50 mV.
2 Adjust volume On the Comm radio, adjust the ≥12 watts output into 4 ohm
control on Comm volume control until the AC Level load (mounted in test fixture) at
radio for 12 W. reads 12 watts. a volume level from 0 to 12
watts.
3 Mute speaker test. On the test box, set INT/OFF The speaker audio out will be
switch to INT. 0 W.
When the Intercom switch is on,
the speaker is disabled.
4 Check headset. On the test box: When the Intercom switch is on,
the Comm radio signal is routed
1. Move the SPKR OUT cable
to the headphones.
to the HDPH test jack.
2. Set the TEST HDPH/LOAD
switch to TEST HDPH.
5 Check headset On the HP8920 set: The HP8920 AF Freq. meter
volume. will read 0.500 kHz ± 15 Hz.
1. EXT LOAD TO R to 100
ohms.
2. Adjust the volume control on
the HP8920 to monitor the
0.500 kHz tone.
6 On the Comm radio, adjust
volume control to read 0.280
watts on the HP8920 AC Level
meter.
7 Set to reference. On the HP8920, select the AC The Comm channel is set as
Level Field (W), then press reference audio level.
SHIFT REF SET and push
CURSOR CONTROL knob.
8 Check if microphone On the test box move the The HP8920:
mutes radio. TEST/MIC1 switch to MIC1.
1. AF Freq. meter will read
1500 Hz ± 15 Hz.
2. The AC Level Meter will
read 1 dB greater than
reference.
The following receiver tests are not required for return to service. They are
included for troubleshooting.
Headset Distortion
Step General Instruction Specific Instructions Expected Results
1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 On the HP8920:
1. Ext. Load R 100 ohms.
2. AFGen1 to AM 85%.
3. AMPLITUDE to 1,000 µV.
3 Move test cable. On the test box, connect the
HP8920 audio in cable to HDPH.
4 Adjust volume On the Comm radio, adjust the
control on Comm volume control until the AC Level
radio for 280 mW. reads 0.280 watts.
5 On the HP8920, from the one of Headset at 1000 Hz, distortion
many field, select Distn. should be < 5%.
6 NOTE: Option 019 If Option 019 (the notch filter
required for the option) is not installed, an
HP8920A. external variable notch filter will
be required to complete the
following tests.
7 On the HP8920, push the SHIFT Lock notch filter to AF Gen1
(blue key) CONFIG keys under Freq.
SCREEN CONTROL. Select
Notch Coupl. Set to AFGen1.
Push the PREV key under
SCREEN CONTROL to return to
RX TEST.
8 Notch filter freq. to On the HP8920, set the AFGen1
350. Freq to 350 Hz.
9 Record distortion. Will be <12% distortion at 350
Hz.
10 Repeat steps 7 to 9 for every 200 Audio frequency distortion will
Hz until 2500 Hz. be <12% at AM Depth of
modulation of 85% at 350 Hz to
600 Hz and < 5% from 600 Hz
to 2500 Hz.
Speaker Distortion
Step General Instruction Specific Instructions Expected Results
1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 On the HP8920:
1. Ext. Load R to 4 ohms.
2. AFGen1 to AM 85%.
3. AMPLITUDE to 1,000 µV.
3 Move test cable. On the test box, connect the
HP8920 audio in cable to SPKR
OUT.
4 Adjust volume On the Comm radio, adjust the
control on Comm volume control until the AC Level
radio for 12 W. reads 12 watts.
5 On the HP8920, select Distn Speaker at 1000 Hz distortion
from the one of many field. should be < 5%.
6 NOTE: Option 019 If Option 019 (the notch filter
required for the option) is not installed, an
HP8920A. external variable notch filter will
be required to complete the
following tests.
7 On the HP8920, push the SHIFT Lock notch filter to AF Gen1
(blue key) CONFIG keys under Freq.
SCREEN CONTROL. Select
Notch Coupl. Set to AFGen1.
Push the PREV key under
SCREEN CONTROL to return to
RX TEST.
8 Notch filter freq. to On the HP8920, AFGen1 Freq. 350 Hz.
350.
9 Record distortion. Will be <12% distortion at 350
Hz.
10 Repeat steps 7 to 9 for every Audio frequency distortion will
200 Hz until 2500 Hz. be <12% at AM Depth of
modulation of 85% at 350 Hz to
600 Hz and <5% from 600 Hz
to 2500 Hz.
Receiver Sensitivity
Step General Instruction Specific Instructions Expected Results
1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 Sig. Gen. Mod Lvl. On the HP8920:
to 30%.
1. Set AFGen1 to AM 30%.
Amplitude to 1000
2. Set AMPLITUDE to 1000
µV.
µV.
3. Set Ext. Load R 4 ohms.
3 Move test cable. On the test box, connect the
HP8920 audio in cable to SPKR
OUT.
4 Adjust volume On the Comm radio, adjust the ≥12 watts output into 4 ohm
control on Comm volume control until the AC Level load (mounted in test fixture) at
radio for 12 W. reads 12 watts. a volume level from 0 to 12
watts.
5 Open squelch. On the Comm radio, pull the
Squelch knob out (disable
squelch).
6 Get SINAD reading On the HP8920: <2 µV (hard) for 6 dB S+N/N
and record. with 30% modulation at 1000
1. Set the value field in the
Hz modulation.
SINAD meter reading to
average (AVG) at 10 dB.
2. Set AMPLITUDE using the ↓
down arrow until the SINAD
meter reads 6 dB SINAD.
3. Record AMPLITUDE.
7 Repeat. Repeat step 6 for 118.00 MHz
and 136.975 MHz.
Weather Channel
Step General Instruction Specific Instructions Expected Results
1 Set all test On the HP8920:
equipment as
1. Set AMPLITUDE to 1000
specified in Test
µV.
Equipment Setup on
page 7-17. 2. Set Ext. Load R 4 ohms.
3. Set RF Gen Freq. to 162.4
MHz.
4. Set AF Gen1 to Fm and 3.0
kHz.
2 Select WTH. Adjust On the Comm radio: Directly behind the 0.40 on the
Volume for 12 W. primary channel frequency, a
1. Press RCL. Use the large
Test TX inhibit. small x indicates the TX
right-hand knob to select
function is disabled.
WTH162.4.
2. Press NRST to put channel
into primary.
3. Adjust radio volume until AC
Level reads 12 watts.
3 Test squelch. On the Comm radio, press The Comm radio will have no
NRST to put channel the WTH audio out.
into secondary channel.
4 Test monitor. On the Comm radio press the The Comm radio will have
MON button. pulsing 1000 Hz tone.
An arrow (>) will point toward
secondary (M162.4) frequency.
5 Test scan time. On the HP8920: Approximately 20 ms blank
space will be displayed
1. Select from the TO
between 1 kHz.
SCREEN: SCOPE
2. Set the Time/div to 10 ms.
6 Intercom test. On the test box, press the There will be no audio on the
INT/OFF switch to INT. SPKR connector.
7 Head set switch on if Move the SPKR test cable to The Comm radio will have
intercom is on. HDPH test jack and the TEST pulsing 1000 Hz.
HDPH/LOAD switch to TEST
An arrow (>) will point toward
HDPH.
secondary (M162.4) frequency
MON
Field Customer Setting Default Reading
SW VER 2.X MON Not changeable None
RF Level Not changeable None
Noise Level Not changeable None
HDPHONE LVL 000
MIC1 SQLCH 070
MIC2 SQLCH 070
TRANSMIT MIC1+2
INTCOM LVL 000
SIDTON LVL 127
LO DSP LVL 00
HI DSP LVL 50
TEST MODE
Field Customer setting Default Reading
TEST MODE Not changeable
DISPLAY TEST Not changeable 000
CONTROLS Not changeable
A/D CH # 00 = Varies with signal #00= VARIABLE
D/A CH # 00 = Not changeable #00=000L
EEPROM 000= Not changeable 0000=VARIES
SYNTHSZR Factory set Not changeable
REF OSC CAL Not changeable Varies
FRONT END CAL Factory set 0
RCVR SQELCH 065
MIC 1 LEVEL 255
MIC 2 LEVEL 255
1. Avionics Outputs
Check the avionics output connections by using the test mode as follows. Rotate the large knob
to select each test.
1. Select the CDI Triangle page, rotate the small knob to check left, mid, and right.
2. Select the VDI Triangle page, rotate the small knob to check down, mid, and up.
3. Select the To/From Flag page, rotate the small knob to check the Off, To, and From outputs.
4. Select the Lamp Outputs page, rotate the small knob to check all the connected
annunciators.
5. Select the Valid Flag Pages page, rotate the small knob to check all the connected valid flag
outputs.
2. Installation Configuration
The GX50/55/60/65 must be configured to match the operation supported by the installation. This
includes IFR, VFR, approach, and Search and Rescue operation selections.
1. In test mode, rotate the large knob to the Install Options page.
2. Press SEL. Rotate the small knob to select IFR operation (Yes or No). Rotate the large knob
for APPR* selection. Rotate the small knob to select approach operation (Yes or No). Rotate
the large knob for SAR (Search and Rescue) selection. Rotate the small knob to select SAR
operation (Yes or No). Press ENTER when complete. (Note: APPR can only be set to Yes
when IFR is set to Yes).
* (GX50/60 only)
Mic Gain
Set the microphone gain for microphones 1 and 2 for values from 0 to 255.
1. In the Test Mode, rotate the large knob to select Mic Gain.
Receiver Squelch
Preset the receiver squelch level for values from 25-100.
1. In the Test Mode, rotate the large knob to select Receiver Squelch.
2. Press SEL to activate selection. The value will flash.
3. Turn the small knob to select a value.
4. Press ENTER to accept and save the settings.
Receiver/Transmitter Operation
Tune the unit to a local frequency and verify the receiver output produces a clear and
understandable audio output. Verify the transmitter functions properly by contacting another
station and getting a report of reliable communications. Check the remote flip/flop.
Antenna Check
The antenna VSWR can be checked using an inline wattmeter in the antenna coax using
frequencies near both ends of the band. The VSWR should be < 2:1, and is not to exceed 3:1. A
VSWR of 2:1 will cause a drop in output power of approximately 12%, and 3:1 causes
approximately a 26% drop.
Warning
High voltage up to 200VDC is present on the display board. Use extreme caution when
performing maintenance procedures with the cover removed.
Caution
ESD precautions must be followed at all times when handling components or circuit boards.
When working on the unit, you must use a grounded wrist strap. Circuit boards or components
must only be carried in a nonconductive, anti-static bag. Reference EIA Standard # EIA-625.
Preliminary Data
Prior to performing any repair or testing, fill out the appropriate fields of the Service Data Sheet. A
copy is located at the back of this manual. This will be used when service is completed to reenter
customer configuration and perform final test and inspection.
Board Locations
All physical references to the units are as though the user were facing the display.
Inside the chassis are different circuit boards depending on the model number. Refer to Figure 8-1
and Figure 8-2.
The GX55 and GX50 have one circuit board on the right-hand side with a small circuit board on top.
This is the navigation circuit board with the GPS receiver on top.
In the GX60 and GX65, in addition to the NAV board, there is a Comm board on the left with RF
shielding and a small circuit board positioned vertically on top. This is the Comm board with the audio
board vertically mounted on it.
Behind the front bezel assembly with the keypad and smart keys are two stacked boards. The smaller
is the display board, which is attached to the display itself. The larger one has the rotary knobs
attached and is the display controller board. These two boards must be replaced together.
Parts Required
• 224-0403 SCREW UNDERCUT, PAN HEAD PHILIPS, 4-40 X 3/16, 82 DEGREE, STAINLESS
STEEL (7 required)
• 700-0069 CELL, POLYUR, 0.50 x 0.54 x 1/8” W/ ADHESIVE (GX55, 1 required)
• 700-0069 CELL, POLYUR, 0.50 x 0.54 x 1/8” W/ ADHESIVE (GX50, 60, 65, 2 required)
• 700-0068 CELL, POLYUR, 0.75 x 0.5 x 0.062” THK W/ ADHESIVE (GX50, 60, 65, 1 required)
• 565-0569-00 LABEL, WARRANTY WARNING
• ISOPROPYL ALCOHOL
• CLEANING WIPES, LOW LINT
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done.
These are located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the warranty warning label. Clean the label residue using a clean wipe and isopropyl
alcohol.
4. Remove the six screws on the sides near top of chassis.
5. Remove the screw on the back of the chassis near the top center.
6. Remove the chassis cover.
Replacement
1. Place the poly cell sponges on inside of the lid according to the assembly diagram.
2. Replace the chassis cover.
3. Replace the screw (224-0403) on the back of the chassis near the top center. Torque the
screws to 5.0 lb.-in.
4. Replace the six screws (224-0403) on the sides near top of chassis. Torque the screw to 5.0
lb.-in.
5. Test the unit to verify proper operation (see Return to Service procedures).
6. Properly mark a warranty warning label (565-0569-00) with your dealer number and repair station
number. Apply the label across the seam where the rear panel meets a chassis cover side or top.
7. Using the Service Data Sheet, reenter the customer configuration.
Battery Replacement
This procedure describes the removal and replacement of the SRAM battery on the NAV board.
Parts Required
• 148-1702 BATTERY (CF), N/LI, 3V, 1200 mAH
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Remove the chassis cover (see Chassis Cover Replacement procedure).
3. Remove the battery from the battery holder.
Replacement
1. Put the new battery (148-1702) in the battery holder. Orient the new battery with the plus (+)
terminal towards the back of the radio.
2. Initialize the unit (see Complete Initialization procedure).
3. Test the unit to verify proper operation (see Return to Service procedures).
4. Replace the chassis cover (see Chassis Cover Replacement procedure).
5. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 224-0414, SCREW, UNDERCUT, FLAT HEAD PHILIPS, 4-40 X 3/16, STAINLESS STEEL
BLACK OXIDE (4 required)
• 315-2205-20, BEZEL ASSEMBLY, PAINTED, SCREENED (Model GX50)
• 315-2205-30, BEZEL ASSEMBLY, PAINTED, SCREENED (Model GX55)
• 315-2205-10, BEZEL ASSEMBLY, PAINTED, SCREENED (Model GX60)
• 315-2205-40, BEZEL ASSEMBLY, PAINTED, SCREENED (Model GX65)
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the four screws from the sides of chassis near the front.
4. Unplug the 34-pin ribbon cable from the back of the display controller board.
Replacement
1. Plug the 34-pin ribbon cable in the back of the display unit. This header on the display controller
board is not labeled. The red edge of ribbon cable should be on the side closest to the center of
unit. The ribbon cable should go up from the header and loop back over to P202 on the NAV
board. This keeps it up out of the way of the card slot. The red edge of the ribbon cable should go
to P202 pin 1. See Figure 8-3.
2. Position the bezel assembly (see the Parts Required section above for correct part number) in
place on the front of the chassis and replace the four screws (224-0414) on the sides of chassis
near the front. Torque screws to 5.0 lb.-in.
3. Flatten the cable so it does not touch the switch assembly.
4. Test the unit to verify proper operation (see Return to Service procedures).
5. Using the Service Data Sheet, reenter the customer configuration.
Pin 33
Pin 34
Figure 8-3. Ribbon Cable Placement on Bezel Assembly and NAV Board
Chassis Replacement
This procedure describes the removal and replacement of the entire sheet metal case for the unit.
Parts Required
• 310-5182-00, CHASSIS (GX50/60/65)
• 310-5183-00, COVER (GX50/60/65)
• 310-6070-00, CHASSIS (GX55)
• 310-6071-00, COVER (GX55)
• 310-6072-00, FILLER PLATE (GX55)
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Remove the chassis cover (see Chassis Cover Replacement procedure).
3. Remove the bezel assembly (see Bezel Assembly Replacement procedure).
4. For GX60 or GX65, remove the Comm board (see Comm Board Replacement procedure).
5. Remove the NAV board (see NAV Board Replacement procedure).
Replacement
1. Obtain a new chassis, cover and filler plate as required. Refer to the table above for the correct
part numbers.
2. Replace the NAV board (see NAV Board Replacement procedure).
3. For GX60 or GX65, replace the Comm board (See Comm Board Replacement procedure).
4. Replace the bezel assembly (see Bezel Assembly Replacement procedure).
5. Test the unit to verify proper operation (see Return to Service procedures).
6. Replace the chassis cover (see Chassis Cover Replacement procedure).
7. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 172-2701 FUSE 125 V, 7 A, FAST ACTING
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Remove the chassis cover (see Chassis Cover Replacement procedure).
3. Remove the Comm board (see Comm Board Replacement procedure).
4. Locate the fuse (F400) on the top view of the Comm Board component layout.
5. Desolder the fuse.
Note: See Chapter 2 for soldering requirements.
Replacement
1. Install a new fuse (172-2701).
Note: See Chapter 2 for soldering requirements.
2. Replace the Comm board (see Comm Board Replacement procedure).
3. Test the unit to verify proper operation (see Return to Service procedures).
4. Replace the chassis cover (see Chassis Cover Replacement procedure).
5. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 221-0401 PAN HEAD PHILIPS, 4-40 x ¼” w/ SPLIT LOCK WASHER, STAINLESS STEEL (10
required)
• 224-0404 UNDERCUT, PAN HEAD PHILIPS, 4-40 x ¼”, 82 DEGREE, STAINLESS STEEL (2
required)
• 415-7002-00 PRINTED CIRCUIT ASSEMBLY, VHF Comm, MAIN BOARD, 6011
• 664-0009 HEAT SINK COMPOUND
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the chassis cover (see Chassis Cover Replacement procedure).
4. Remove the bezel assembly (see Bezel Assembly Replacement procedure).
5. Remove the nut and lock washer on the BNC connector at the outside back of the chassis.
6. Unplug the ribbon connector from J606 on the Comm board.
7. Remove the two screws on rear of chassis holding the D-sub connector.
8. Remove the two screws from the transistor Q303 on the Comm board. One is accessed through
hole in shielding.
9. Remove the other eight screws holding the Comm board to the chassis.
10. Remove the Comm board from the chassis.
Replacement
1. Put a light coat of heat sink compound on transistor Q303 heat sink.
2. Place the Comm board (415-7002-00) in the chassis with the BNC connector exiting the hole at
the back of the chassis.
3. Replace the two screws (221-0401) for Q303 on the Comm board. One screw is accessed
through hole in shielding. Use needle-nosed pliers if needed to place the screw. Torque screws
to 5.0 lb.-in.
4. Replace the other eight (221-0401) screws holding the Comm board to the chassis. Torque
screws to 5.0 lb.-in.
5. Replace the two screws (224-0404) at the back of chassis holding the D-sub connector P400.
Torque screws to 5.0 lb.-in.
6. Plug in the ribbon cable that goes from J4 on the NAV board into J606. The red side of the ribbon
cable goes towards the front of the radio. The ribbon cable exits each connector towards the
outside of the radio and loops over the connectors to the other board. See Figure 8-4. Note:
Avoid misplacement of the connectors on the headers.
7. Replace the nut and lock washer on the BNC connector at the back of the chassis.
Display Replacement
This procedure describes the removal and replacement of the display board and the display controller
board.
Warning
High voltage up to 200 VDC is present on the display board. Use extreme caution when
performing maintenance procedures with the cover removed.
Parts Required
• 145-2341-00 ELECTROLUMINESCENT DISPLAY, PLANAR, 80 x 160 PIXEL
• 221-0212 SCREW, PAN HEAD PHILIPS, 2-56 X 3/16", STAINLESS STEEL, SEMS, INT (5
required)
• 252-0209 MF, 3/16", HEX, 2-56 x ¼", STAINLESS STEEL (4 required)
• 418-5107-00 FLEX CIRCUIT ASSEMBLY, SOFT KEY
• 664-0042 LOCTITE, 242
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the bezel assembly (see Bezel Assembly Replacement procedure).
4. Unplug the flex cable from the zif socket on the back of the display controller board by gently
unsnapping the collar on the zif socket and removing the flex cable.
5. Remove the three knobs from the rotary switch shafts using the 0.050" hex driver.
6. Remove the five screws holding the display controller board to the bezel.
7. Carefully lift the display controller board off the display board unplugging the connector under the
display controller board.
8. Remove the four standoffs holding the display board to the bezel.
9. Remove the display board from the bezel.
Replacement
Note: When installing a new display board or display controller board, the display board and the
display controller board are to be kept together as a matched pair. They must be replaced
together.
1. The display board and display controller board come fastened together by a plastic standoff.
Carefully remove the plastic standoff and discard.
2. Peel the paper backing off the Soft Key Flex Circuit Assembly. Put the new Soft Key Flex Circuit
Assembly on the new display according to Figure 8-5. With the display facing you, the Flex Circuit
assembly is pressed into place and held by adhesive backing with flex cable to the right.
3. Place the display board in the bezel assembly with the flex cable at the bottom next to the data
card slot. Ensure that the five smart key buttons and keypad are in place. Fasten the display
board in place using four standoffs (252-0209). Torque the standoffs to 4.2 lb.-in.
Caution: Do not exceed 4.2 lb.-in of torque.
4. Carefully plug the display controller board into the connector below on the display board. Ensure
that the photocell fits into the hole in the bezel when positioning the display controller board.
5. Fasten the display controller board in place with five screws (221-0212). Torque the screws to
2.4 lb.-in.
6. Replace the three knobs on the rotary switch shafts. Apply Loctite (664-0042) to the setscrews.
Tighten the setscrews using the 0.050" hex driver. Space the knobs 0.010" off the bezel so they
will turn smoothly. Space the outer knob from the large knob slightly so that it will turn freely while
keeping the bottom of the small knob inside the cavity of the large knob.
7. Insert the flex cable (with the exposed contacts facing away from the rotary switches) into the zif
socket and snap the collar on the zif socket into place.
8. Tape the flex cable together just above the zif socket to prevent it being trapped inside the data
card rail during installation.
9. Put the bezel assembly on the chassis. Ensure that the flex strip does not get trapped inside the
data card reader slot (see Bezel Assembly Replacement procedure).
10. Test the unit to verify proper operation (see Return to Service procedures).
11. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 220-0003 NUT, RND, SLOTTED, 4-40 X 3/16" X 3/16"
• 221-0401 SCREW, PAN HEAD PHILIPS, 4-40 X ¼" W/SPLIT LOCK WASHER, STAINLESS
STEEL (3 required)
• 428-3014-01 PRINTED CIRCUIT ASSEMBLY, 8 CHANNEL GPS SENSOR C129A
• 664-0042 LOCTITE, 242
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual
2. Power the unit off and disconnect power from the unit.
3. Remove the chassis cover (see Chassis Cover Replacement procedure).
4. With the front of the unit facing you, the GPS board is on standoffs on the NAV board on the right
inside the chassis.
5. Remove the three screws and the slotted nut holding the GPS board.
6. Carefully lift the GPS board up and off the NAV board to disconnect it from connector J1.
7. Disconnect the antenna connector from the GPS board.
Replacement
1. Connect the GPS antenna cable to the new GPS board.
2. Carefully plug the GPS receiver board into J1 on the NAV board.
3. Secure the board with the three screws (221-0401) and the slotted nut (220-0003). Apply a drop
of Loctite (664-0042) to the slotted nut before re-assembly. Torque screws to 5.0 lb.-in. Torque
the slotted nut to 2.9 lb.-in.
4. Test the unit to verify proper operation (see Return to Service procedures).
5. Replace the chassis cover (see Chassis Cover Replacement procedure).
6. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 220-0003 NUT, RND, SLOTTED, 4-40 X 3/16" X 3/16"
• 221-0401 SCREW PAN HEAD PHILIPS, 4-40 X ¼" W/SPLIT LOCK WASHER, STAINLESS
STEEL (3 required)
• 428-3014-01 PRINTED CIRCUIT ASSEMBLY, 8 CHANNEL GPS SENSOR C129A
• 664-0042 LOCTITE, 242
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual
2. Power the unit off and disconnect power from the unit.
3. Remove the chassis cover (see Chassis Cover Replacement procedure).
4. With the front of the unit facing you, the GPS board is on standoffs on the NAV board on the right
inside the chassis.
5. Remove the cover from the GPS board by lifting it by the four corners.
6. Remove the three screws and the slotted nut holding the GPS board.
7. Carefully lift the GPS board up and off the NAV board to disconnect it from connector J1.
8. Disconnect the antenna connector from the GPS board.
Replacement
1. Connect the GPS antenna cable to the new GPS board.
2. Place the GPS bottom shield (306-0010-00) with standoffs on the bottom of the GPS board.
3. Carefully plug the GPS board into J1 on the NAV board.
4. Secure the board with the three screws (221-0401) and the slotted nut (220-0003). Apply a drop
of Loctite (664-0042) to the slotted nut before re-assembly. Torque screws to 5.0 lb.-in. Torque
the slotted nut to 2.9 lb.-in.
5. Reinstall the cover (306-0011-00) for the GPS board.
6. Test the unit to verify proper operation (see Return to Service).
7. Replace the chassis cover (see Chassis Cover Replacement procedure).
8. Using the Service Data Sheet, reenter the customer configuration.
Keypad Replacement
This procedure describes the removal and replacement of the keypad mounted in the bezel.
Parts Required
• 315-4110-00 KEYPAD
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the bezel assembly (see Bezel Assembly Replacement procedure).
4. Remove the display (see Display Replacement procedure).
Replacement
1. Insert a new keypad in the bezel.
2. Replace the display (see Display Replacement procedure).
3. Replace the bezel assembly (see Bezel Assembly Replacement procedure).
4. Test the unit to verify proper operation (see Return to Service procedures).
5. Using the Service Data Sheet, reenter the customer configuration.
Knob Replacement
This procedure describes the removal and replacement of the rotary knobs on the front of the bezel
assembly.
Parts Required
• 230-0402 SCREW, SET, 4-40 X 1/8" (3 required)
• 262-0049 KNOB, POWER DZUS RAIL NMC
• 262-0052-00 KNOB, INNER CONCENTRIC
• 262-0053-00 KNOB, OUTER CONCENTRIC
• 664-0042 LOCTITE, 242
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the three knobs from the front of the bezel assembly using the 0.050" hex driver.
Replacement
1. Replace the three knobs (262-0049, -0052,-0053) as needed. Apply Loctite (664-0042) to the
setscrews (230-0402). Tighten the setscrews using the 0.050" hex driver. Space the knobs 0.010"
off the bezel assembly so they will turn smoothly. Space the outer knob from the large knob
slightly so that it will turn freely while keeping the bottom of the small knob inside the cavity of the
large knob.
2. Test the unit to verify proper operation (see Return to Service procedures).
3. Using the Service Data Sheet, reenter the customer configuration.
Lens Replacement
This procedure describes the removal and replacement of the protective lens on the front of the
display.
Parts Required
• ISOPROPYL ALCOHOL
• 308-5505-11 GX50/55 LENS, DISPLAY FILTER
• 308-5505-21 GX60/65 LENS, DISPLAY FILTER
• GLASS CLEANER, NON-AMMONIA BASED
• CLEANING WIPES-LOW LINT
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the bezel assembly (see Bezel Assembly Replacement procedure).
4. Remove the display (see Display Replacement procedure).
5. Press the old lens from the bezel by pushing on it from the back. The adhesive will break loose.
6. Clean the adhesive surfaces on the bezel using a clean wipe and isopropyl alcohol.
Replacement
1. Remove the paper backing from the new lens (see the Parts Required section above for the
correct part number).
2. Press the lens into the bezel noting the orientation so that the hole for the photocell is over the
photocell. Press firmly to make it adhere.
3. Replace the display (see Display Replacement procedure).
4. Replace the bezel assembly (see Bezel Assembly Replacement procedure).
5. Clean fingerprints from the front of the display lens with a clean wipe and glass cleaner.
6. Test the unit to verify proper operation (see Return to Service procedures).
7. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 172-0004-012 FUSE 125 V, 3 A, SLOW BLOW, SMD
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the chassis cover (see Chassis Cover Replacement procedure).
4. Desolder the old fuse from the right rear corner of the NAV board using a grounded tip,
temperature controlled solder iron, and no-clean solder wick. The fuse is located under the leads
for a capacitor. Avoid damaging these surrounding components.
Note: See Chapter 2 for soldering requirements.
Replacement
1. Solder the new fuse (172-0004-012) in place.
Note: See Chapter 2 for soldering requirements.
2. Test the unit to verify proper operation (see Return to Service procedures).
3. Replace the chassis cover (see Chassis Cover Replacement procedure).
4. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 221-0401 SCREW, PAN HEAD PHILIPS, 4-40 X ¼" W/SPLIT LOCK WASHER, STAINLESS
STEEL (8 required for GX55, 4 required for GX50/60/65)
• 224-0403 SCREW, UNDERCUT, PAN HEAD PHILIPS, 4-40 X 3/16", 82 DEGREE, STAINLESS
STEEL (4 required for GX55, 3 required for GX50/60/65)
• 415-7004-00 NAVIGATION COMPUTER BOARD, GX50/60/65
• 415-7004-20 NAVIGATION COMPUTER BOARD, GX55
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the bezel assembly (see Bezel Assembly Replacement procedure).
4. On the GX60/ 65, remove the Comm board first (see Comm Board Replacement procedure).
5. Remove the GPS board (see GX50/55 or GX60/65 GPS Board Replacement procedure).
6. Remove the screws (four on the GX55, three on the GX50/60/65) holding down the NAV board.
7. Remove the outer screw from the right side of the chassis.
8. Remove the screws (four on the GX55, two on the GX50/60/65) that hold the D-sub connector on
the back of the chassis.
9. On the GX55, remove the filler plate by sliding it up out of the rear of the chassis.
10. Lift the NAV board from the chassis.
Replacement
1. Put the new NAV board (see the Parts Required section above for the correct part number) in
place in the chassis on the right side.
2. On the GX55, replace the filler plate on the back of the chassis.
3. Replace the screws (221-0401) (four on the GX55, two on the GX50/60/65) that hold the D-sub
connector on the back of the chassis. Torque the screws to 5.0 lb.-in.
4. Replace the screw (224-0403) on the outside that holds the NAV board. Torque the screw to 5.0
lb.-in.
5. Replace the screws (221-0401) (four GX55, three on the GX50/60/65) that hold down the NAV
board. Torque the screws to 5.0 lb.-in.
6. Replace the GPS board (see GX50/55 or GX60/65 GPS Board Replacement procedure).
7. On the GX60/ 65, replace the Comm board (see Comm Board Replacement procedure).
8. Replace the bezel assembly (see Bezel Assembly Replacement procedure).
9. Completely reinitialize the unit (see Complete Initialization procedure).
10. Test the unit to verify proper operation (see Return to Service procedures).
11. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 418-5107-00 FLEX CIRCUIT ASSEMBLY, SOFT KEY
Removal
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual.
2. Power the unit off and disconnect power from the unit.
3. Remove the bezel assembly (see Bezel Assembly Replacement procedure).
4. Remove the display (see Display Replacement procedure).
5. Peel off the soft key flex circuit assembly.
Replacement
1. Peel the paper backing off the soft key flex circuit assembly (418-5107-00).
2. Put the new soft key flex circuit assembly on the display according to Figure 8-5. Improper
placement will result in smart key malfunction.
3. Replace the display (see Display Replacement procedure).
4. Replace the bezel assembly (see Bezel Assembly Replacement procedure).
5. Test the unit to verify proper operation (see Return to Service procedures).
6. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 139-0235-022 GX NAV SOFTWARE
Note: If the unit’s current software version is less than 2.1, the unit must be sent into the factory for all
upgrades.
Procedure
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual
2. Power the unit off and insert software card into the database card slot.
3. Put the unit into test mode by powering the unit back on while holding the outermost two smart
keys down. The screen should read: Application card detected Reload?
4. Turn the small knob to select YES and press ENTER. The screen will display Please
Wait...Software is being updated.
5. When it is done, it will go through its normal self-test. If a memory failure is reported, disregard it.
6. Power the unit off when self-test is done.
7. Remove the software card.
8. Turn the unit back on in test mode by pressing the outermost two smart keys while turning power
on as above.
9. Turn the large knob counterclockwise 6 clicks until SYSTEM INITIALIZATION screen appears.
10. Press the SEL button. ALL will appear on the screen. DO NOT press ENTER at this point or all
user waypoints will be lost.
11. Turn the small knob until USER NVRAM appears on the screen.
12. Press ENTER. When NVRAM reset is complete, Hexadecimal numbers should appear on the
screen in the bottom left and bottom right corners. These are checksums The same checksums
should show on both sides. If it doesn’t show the same checksums at the bottom corners of the
screen, try loading software again. If that fails, perform the Complete Initialization procedure. If
that doesn’t resolve the problem, replace the NAV board (see NAV Board Replacement
procedure) and perform the Complete Initialization procedure. Return the unit to the factory if that
fails to correct the problem.
13. Press SEL to go back to the Reset screen. DO NOT press ENTER at this point or all user
waypoints will be lost.
14. Turn the small knob 2 clicks until EEPROM shows on the screen.
15. Press ENTER.
16. The same checksums should show as above. If it doesn’t show the same checksums at the
bottom corners of the screen, try loading software again. The new software version should also
show on the system screen in the normal mode. If that fails, perform the Complete Initialization
procedure. If that doesn’t resolve the problem, replace the NAV board (see NAV Board
Replacement procedure) and perform the Complete Initialization procedure. Return the unit to the
factory if that fails to correct the problem.
17. Turn the large knob clockwise to Install Options. Press ENTER.
18. Turn the large knob clockwise to CH RX TX screen. This is where serial port settings are
entered. The screen should display NONE for RX and NONE for TX. If it shows GPS and GPS, go
back to step 6 of this procedure and continue from there. If that doesn’t solve the problem,
perform steps 6, 7,8 and 9 above and press ENTER at the RESET ALL screen. If that doesn’t
resolve the problem, replace the NAV board (see NAV Board Replacement procedure) and
perform the Complete Initialization procedure. Return the unit to the factory if that fails to correct
the problem.
19. Cycle power and let the unit go through its self-test and startup procedure.
20. Using the Service Data Sheet, reenter the customer configuration.
Parts Required
• 138-0312-012 PROGRAMMED MICROCONTROLLER, VHF Comm
• INTEGRATED CIRCUIT PULLER TOOL
Procedure
1. Before starting this procedure, fill out a Service Data Sheet if this has not already been done. A
copy is located at the back of this manual
2. Power the unit off.
3. Remove the chassis cover (see Chassis Cover Replacement procedure).
4. Locate the socketed integrated circuit near the front of the Comm board. No number shows
designating which chip this is. It is the only socketed integrated circuit on the Comm board.
5. Using the chip puller, carefully remove the integrated circuit from the socket.
6. Insert the new integrated circuit with the arrow on the top of the chip lined up with the arrow inside
the bottom of the socket. Press it gently, but firmly, in place.
7. Cycle power and let the unit go through its self-test and startup procedure.
8. Using the Service Data Sheet, reenter the customer configuration.
Complete Initialization
This procedure describes the initializing of all the memory on the NAV board. This erases all data in
memory (not the database) including the user waypoints, flight plans and configuration.
Parts Required
• NONE
Procedure
1. Power the unit off.
2. Put the unit into test mode by powering the unit back on while holding the outermost two smart
keys down.
3. Power the unit off.
4. Turn the unit back on in self-test mode by pressing the outermost two smart keys while turning
power on as above.
5. Turn the large knob counterclockwise 6 clicks until SYSTEM INITIALIZATION screen appears.
6. Press the SEL button. ALL will appear on the screen.
7. Press ENTER.
8. When initialization is complete, hexadecimal numbers should appear on the screen in the bottom
left and bottom right corners. These are checksums The same checksums should show on both
sides. If it doesn’t show the same checksums at the bottom corners of the screen, try initializing
again by repeating this procedure. Return the unit to the factory if that fails to correct the problem.
9. Turn the large knob clockwise to Install Options. Press ENTER.
10. Turn the large knob clockwise to CH RX TX screen. This is where serial port settings are
entered. The screen should display NONE for RX and NONE for TX. If it shows GPS and GPS, try
initializing again by restarting this procedure. If that doesn’t work, replace the NAV board and
repeat this procedure.
11. Cycle power and let the unit go through its self-test and startup procedure.
12. Using the Service Data Sheet, reenter the customer configuration.
Preliminary Data
Prior to performing any repair or testing, fill out the appropriate fields of the Service Data Sheet. A
copy is located at the back of this manual. This will be used when service is completed to reenter
customer configuration and perform final test and inspection.
Error Messages
ERROR MESSAGE CAUSE ACTION
Battery failure message 1. Low battery voltage 1. Check battery voltage. Replace if
below 2.75V. (See Battery
2. Fracture between
Replacement procedure.)
solder fillet and leads
on battery holder 2. Replace NAV board. (See NAV
board replacement procedure.)
3. NAV board
GPS self-test failure 1. GPS receiver board 1. Initialize unit. (See Complete
Initialization procedure).
2. NAV board
2. Replace GPS receiver. (See the
GPS Board Replacement procedure
for the unit.)
3. Replace the NAV board. (See NAV
Board Replacement procedure.)
GPS position sensor 1. Insufficient satellites 1. Ensure 3D fix.
cannot compute LAT/LON available
If the problem persists:
En route GPS RAIM not 2. GPS receiver board
2. Initialize unit. (See Complete
available
3. NAV board Initialization procedure).
Terminal GPS RAIM
3. Check antenna/coax.
alarm
4. Replace GPS receiver. (See the
GPS Board Replacement procedure
for the unit).
5. Replace the NAV board (See NAV
Board Replacement procedure).
GPS Communications 1. GPS receiver 1. Initialize unit. (See Complete
failure Initialization procedure).
2. NAV board
2. Replace GPS receiver. (See the
GPS Board Replacement procedure
for the unit.)
3. Replace the NAV board. (See NAV
Board Replacement procedure.)
Symptoms
SYMPTOM CAUSE ACTION
Hold or flip/flop input 1. External switch 1. Check continuity of external switch.
failure
2. Nav board 2. Replace the NAV board. (See NAV
Board Replacement procedure.)
Squelch open or close Factory alignment not to Replace Comm board. (See Comm
failure current specification Board Replacement procedure.)
Can’t access data card 1. Data card 1. Reinsert data card (make sure it is
right side up).
Data card failed 2. NAV board
2. Try another data card.
3. Replace the NAV board. (See NAV
Board Replacement procedure.)
Loss of communication 1. Serial port 1. In the Test mode, check that the
with peripheral device configuration serial port setup is correct.
2. Serial port 2. Check the Serial port. (See Serial
communication Ports on page 7-13).
3. NAV board 3. Replace the NAV board. (See NAV
Board Replacement procedure.)
Comm is interfering w/ 1. Harmonics from 1. Install notch filter part # 162-1059
GPS Comm on GPS antenna coax connector on
the back of the chassis.
(Some of the action steps 2. Proximity of antennas
are assuming that there 2. Try new RG-142 instead of RG-58
3. Aircraft component
are separate GPS and coax for Comm and GPS antennas.
interference
Radio units.)
3. Ground Nav/Comm and GPS racks
together and to A/C ground.
4. Rearrange the stack to get
maximum distance between the
GPS and Nav/Comm.
5. Separate the GPS and Nav/Comm
wiring at the back of the rack. Wrap
shielding around each bundle of
wires, then ground these to A/C
ground.
6. Minimize any extra wire lengths.
7. Try grounding wire shields at both
ends of the wire.
8. Separate Comm and GPS
antennas.
9. Isolate to interfering component.
10. Move GPS antenna from line of
sight with interfering equipment.
Comm not changing 1. Channels locked 1. Replace Comm board. (See Comm
frequencies Board Replacement procedure.)
2. Comm board
EEPROM Data
The GX50/60 includes an EEPROM device on the main NAV computer board. During normal
operation, several items useful for system debug and performance monitoring are logged into
EEPROM. Some of those items are listed in the following table.
Figure 10-1. GX55 NAV PCB Component Layout (Reference Only) (Sheet 1 of 3)
Figure 10-1. GX55 NAV PCB Component Layout (Reference Only) (Sheet 2 of 3)
Figure 10-1. GX55 NAV PCB Component Layout (Reference Only) (Sheet 3 of 3)
Figure 10-2. GX 50/60/65 NAV PCB Component Layout (Reference Only) (Sheet
1 of 2)
Block Diagrams
© 2004 Garmin AT
+3.3 volts RS-232 I/O
(9600 baud)
(131.7KHz clock)
microwire interface
Lock Detect
Synthesizer
IF AGC Voltage
Speaker Enable
RX/TX
Mic Select
AGC Disable
Headphone Enable
Receiver Select
RX LO Ref Dac
(139.4 to 158.375MHz)
Mic Input
Receiver Audio Circuits
GX Service Manual
Antenna
Speaker
Transmitter Audio Audio Amp Output
Modulation
Rev --
10-11
10-12
Garmin AT
GX Service Manual
Speaker Enable (9600 baud)
Headphone Enable
AGC Disable RS-232 RxD
(9600 baud)
IF AGC Voltage
Audio AGC Voltage EEPROM
Noise Detect Voltage
Input Voltage A to D
Photo Cell
DisplayThermistor
Converter
Volume Control Pot
Intercom Select 3.8 volts A to D
Crystal Thermistor
+12 volt Supply
Reference
+28 volt Supply
© 2004 Garmin AT
Rev --
Buffer Amp Synthesizer IC
Garmin AT
Ref Dac
Oscillator Reference
© 2004 Garmin AT
Divider
19.65MHz
(25KHz)
microwire (25KHz)
Interface (131.7KHz clock)
GX Service Manual
Voltage Loop
TX LO (118.000 to 158.375MHz)
Controlled Filter
Oscillator
RF Amp
Rev --
10-13
10-14
Garmin AT
GX Service Manual
Varactor AM/FM
IF AGC IF AGC
Amplifier Voltage
Varactor
Control
DAC
RF AGC
RF AGC
Amplifier
Rx RF µwire Rx LO
interface (134 40 to
© 2004 Garmin AT
Rev --
Mic Preamp
Garmin AT
AGC Bandpass
Mic Input Filter
© 2004 Garmin AT
Mic Select Audio AGC
Voltage
Detected Audio AGC Disable
Receiver Select
Noise Detect
Noise
Voltage Detector Speaker/Modulator
Preamp
Detected Audio
Sidetone Headphone
GX Service Manual
Output
*RX/TX +2v
Headphone
Enable
microwire
(131.7KHz clock) Ref Dac
Interface
Rev --
10-15
10-16
Garmin AT
Rx/Tx
GX Service Manual
(118.00 to LPF
136.975 MHz)
R
S
Audio R
Modulation
© 2004 Garmin AT
Rev --
Garmin AT
© 2004 Garmin AT
27.5 VDC Supply
Power Sync
Supply
(307 kHz)
Power Input Filter 27.5 VDC Max Boost 27.5 VDC 5 / 3.3 VDC +5 Volts
Buck
Input and Protection Supply Supply Supply +3.3 Vo
(10-40 VDC)
+27.5 V
Speaker
Enable
GX Service Manual
Figure 10-12. VHF Comm Power Supply/Audio Amp Block Diagram
Rev --
10-17
Garmin AT Rev --
Assembly Drawings
NOTES:
1. ITEM 45 INCLUDES THE DISPLAY BOARD AND THE DISPLAY CONTROLLER
BOARD AS A MATCHED PAIR AND MUST BE KEPT TOGETHER.
2. CONNECT THIS END OF CABLE TO J4 ON THE NAV MAIN COMPUTER BOARD
(ITEM #8).
3. POSITION POLY. CELL. PADS ON THE “Z” BRKT AS SHOWN.
4. SEE DETAIL A.
5. SEE UNIT CONFIGURATION DRAWING FOR NAMEPLATE INFO.
6. SEE B.O.M. ITEM TEXT FOR APPLICABLE TOOLING AND/OR FIXTURES.
7. APPLY THIN LAYER OF THERMAL COMPOUND (664-0009) TO BOTTOM
SIDE OF HEAT SINK ON VHF COMM. MAIN BD (ITEM #9) PRIOR TO
INSTALLING INTO CHASSIS (ITEM #3).
8. APPLY THREAD LOCKER ADHESIVE (664-0042) TO THE THREADED STUD
ON PCB PRIOR TO INSTALLING ITEM #37 AND ORIENT SLOT UPWARD SO
FLAT HEAD SCREWDRIVER CAN SECURE IN PLACE.
10. WHEN INSTALLING ITEM #32, INSTALL WITH GATE OF PART FACING TOWARD
BOTTOM OF BEZEL. TRIM OFF EXCESS GATE IF NECESSARY.
11. WHEN INSTALLING BEZEL ASSEMBLY TO CHASSIS ASSEMBLY, MAKE SURE
SOFT KEY FLEX TAIL IS LOCATED AS SHOWN IN DETAIL B.
12. PLUG END OF THE FLEX-CIRCUIT, ITEM #31, INTO THE ZIF SOCKET ON THE
BACK OF THE DISPLAY CONTROLLER BOARD.
13. SECURE FLEX CIRCUIT USING TAPE, ITEM 44, WHERE SHOWN. TAPE MUST
NOT INTERFERE WITH CONNECTOR.
14. DISPLAY SURFACE NEEDS TO BE CLEAN. SEE COMPONENT SPECIFICATION
SHEET FOR CLEANING INSTRUCTION.
15. ENSURE SENSOR DOES NOT PROTRUDE ABOVE EDGE OF BEZEL.
16. ALIGN EDGES OF LABELS ALONG CENTER PUNCH MARKS AS SHOWN.
17. REMOVE NYLON SHIPPING SPACERS PRIOR TO PLACING PERMANENT
SPACERS.
18. INSTALL ITEM #30 WITH RED STRIP FACING PIN 1.
19. TORQUE SCREWS PER II MORROW TORQUE STANDARD IIM-2007-01.
-FOR ITEM #12, TORQUE 2.4 LB.-IN.
-FOR ITEM #13, 14, 15, AND 39: TORQUE 5.0 LB.-IN.
20. PART OF ITEM #42.
GX50 Parts
Part Num Qty Description
500-3124-00 1 CABLE, 2mm IDC RCPT-RCPT, 2X4,2”
*2
700-0068 ½” CELL, POLYUR, 0.750” X 0.062: THK. WITH ADHESIVE
*2
700-0069 1” CELL, POLYUR., 0.50” X 0.54” X 1/8” WITH ADHESIVE
310-5182-00 1 CHASSIS, GX50/60/65
500-0247-02 1 CONNECTOR, BNC, GPS WITH CABLE.
*2
310-5183-00 1 COVER, CHASSIS, GX50/60
172-2701 1 FUSE 125V, 7A, FAST ACTING,
308-5505-11 1 GX50/55 LENS, DISPLAY FILTER
415-7004-XX 1 NAV COMPUTER BOARD, GX50/60/65, 6013 For board
replacement compatibility, please call Garmin AT Service
Department at 800.525.6726 ext 3992. Please have the following
information: Unit model number, unit part number, unit mod level
and unit software version. Also have all your board part numbers,
board serial numbers, and rev levels available.
310-5189-10 1 PLATE, D-SUB COVER, (15 PIN), SL/GX
224-0403 7 SCREW UNDERCUT, PAN HEAD PHILIPS, 4-40 X 3/16, 82
DEGREE, STAINLESS STEEL
224-0404 5 SCREW UNDERCUT, PAN HEAD PHILIPS, 4-40 X ¼, 82DEG,
STAINLESS STEEL
251-9407 1 SPACER, 3/16” X ½” LG., RND, ALUM.
252-0414 3 STANDOFF, MF, 3/16” HEX, 4-40 X ½ AL.
315-2205-20 1 BEZEL ASSEMBLY, PAINTED, SCREENED
GX55 Parts
Part Num Qty Description
700-0068 1 CELL, POLYUR, 0.750” X 0.062: THK. WITH ADHESIVE
*3
700-0069 0.75” CELL, POLYUR., 0.50” X 0.54” X 1/8” WITH ADHESIVE
*3
310-6070-00 1 CHASSIS, GX55
500-0247-02 1 CONNECTOR, BNC, GPS WITH CABLE.
*3
310-6071-00 1 COVER, GX55
308-5505-11 1 GX50/55 LENS, DISPLAY FILTER
238-0227-00 1 MOUNTING ROD, RETROFIT, GX55
415-7004-xx 1 NAV COMPUTER BOARD, GX55 For board replacement
compatibility, please call Garmin AT Service Department at
800.525.6726 ext 3992. Please have the following information:
Unit model number, unit part number, unit mod level and unit
software version. Also have all your board part numbers, board
GX60 Parts
Part Num Qty Description
500-3124-00 1 CABLE, 2mm IDC RCPT-RCPT, 2X4,2”
*4
700-0068 ½” CELL, POLYUR, 0.750” X 0.062: THK. WITH ADHESIVE
*4
700-0069 1” CELL, POLYUR., 0.50” X 0.54” X 1/8” WITH ADHESIVE
310-5182-00 1 CHASSIS, GX50/60/65
*4
310-5183-00 1 COVER, CHASSIS, GX50/60
664-0009 A/R HEAT SINK COMPOUND
308-5505-21 1 LENS, GX60/65 DISPLAY FILTER
415-7004-xx 1 NAV COMPUTER BOARD, GX50/60/65, 6013 For board
replacement compatibility, please call Garmin AT Service
Department at 800.525.6726 ext 3992. Please have the following
information: Unit model number, unit part number, unit mod level
and unit software version. Also have all your board part numbers,
board serial numbers, and rev levels available.
220-3002 1 NUT, JAM, BNC, ½ X 28, BRS, NP
221-0440 3 SCREW PAN HEAD PHILIPS 4-40 X 7/8” STAINLESS STEEL, WITH
LOCK PATCH
224-0404 5 SCREW UNDERCUT, PAN HEAD PHILIPS, 4-40 X ¼, 82 DEGREE,
STAINLESS STEEL
224-0403 7 SCREW UNDERCUT, PAN HEAD PHILIPS, 4-40 X 3/16, 82
DEGREE, STAINLESS STEEL
306-0010-00 1 SHIELD, BOTTOM, GPS ENGINE
306-0011-00 1 SHIELD, COVER, GPS ENGINE
251-9612-00 4 SPACER, GPS ENGINE
415-7002-xx 1 VHF COMM MAIN BOARD, 6011 For board replacement
compatibility, please call Garmin AT Service Department at
800.525.6726 ext 3992. Please have the following information:
Unit model number, unit part number, unit mod level and unit
software version. Also have all your board part numbers, board
serial numbers, and rev levels available.
GX65 Parts
Part Num Qty Description
500-3124-00 1 CABLE, 2mm IDC RCPT-RCPT, 2X4,2”
*5
700-0068 ½” CELL, POLYUR, 0.750” X 0.062: THK. WITH ADHESIVE
*5
700-0069 1” CELL, POLYUR., 0.50” X 0.54” X 1/8” WITH ADHESIVE
310-5182-00 1 CHASSIS, GX50/60/65
*5
310-5183-00 1 COVER, CHASSIS, GX50/60
308-5505-21 1 GX60/65 LENS, DISPLAY FILTER
664-0009 A/R HEAT SINK COMPOUND
415-7004-xx 1 NAV COMPUTER BOARD, GX50/60/65, 6013 For board
replacement compatibility, please call Garmin AT Service
Department at 800.525.6726 ext 3992. Please have the following
information: Unit model number, unit part number, unit mod level
and unit software version. Also have all your board part numbers,
board serial numbers, and rev levels available.
220-3002 1 NUT, JAM, BNC, ½ X 28, BRS, NP
221-0440 3 SCREW PAN HEAD PHILIPS 4-40 X 7/8” STAINLESS STEEL, WITH
LOCK PATCH
224-0403 7 SCREW UNDERCUT, PAN HEAD PHILIPS, 4-40 X 3/16, 82
DEGREE, STAINLESS STEEL
224-0404 5 SCREW UNDERCUT, PAN HEAD PHILIPS, 4-40 X ¼, 82 DEGREE,,
STAINLESS STEEL
306-0010-00 1 SHIELD, BOTTOM, GPS ENGINE
306-0011-00 1 SHIELD, COVER, GPS ENGINE
251-9612-00 4 SPACER, GPS ENGINE
415-7002-xx 1 VHF COMM MAIN BOARD, 6011 For board replacement
compatibility, please call Garmin AT Service Department at
800.525.6726 ext 3992. Please have the following information:
Unit model number, unit part number, unit mod level and unit
software version. Also have all your board part numbers, board
serial numbers, and rev levels available.
240-1202 1 WASHER, LOCK, BNC, 0.509” ID, 0.623” OD, INT
315-2205-40 1 BEZEL ASSEMBLY, PAINTED, SCREENED
Data Cards
Part Num Qty Description
138-0424 1 DATA CARD, WORLDWIDE
138-0425 1 DATA CARD, AMERICAS
138-0426 1 DATA CARD, INTERNATIONAL
Maintenance Supplies
Part Num Qty Description
998-0083 A/R NO CLEAN WIRE SOLDER
998-0475 A/R NO CLEAN SOLDER FLUX PEN
565-0569-00 A/R LABEL, WARRANTY WARNING
998-5152 A/R NO CLEAN SOLDER WICK
435-0102-000 1 TEST FIXTURE KIT
TEST MODE NAV INFO ______Unit and Board Configuration Correct (See Unit
Configurations)
Serial Ports: Channel RX TX
______Verify UTC Time
1: ___________ ____________
2: ___________ ____________ ______Covers, Rods and Screws Installed
IFR APPROACH SAR ______Verify customer setup with Service Data Sheet
YES ________ ________ ________
______Replaced cover screws
NO ________ ________ ________
Page 1 of 2
P/N: 561-6001-50
11/4/04
GX Service Data Sheet (Manual P/N 560-7001-5XX)
Procedure: Procedure (cont’d.)
NOTE: CW = Clockwise COMM TEST MODE
CCW = Counterclockwise
29. Plug in COMM display cable from fixture into COMM J603.
NOTE: If you miss the desired page, keep turning the specified Red side to pin 1.
knob until the page is found. All the pages are continuously 30. Disconnect NAV/ COMM cable from COMM J606.
looped under each knob. Record all values noted in spaces
31. Power COMM display on in test mode by pressing NRST
provided.
and SYS buttons while turning power on.
21. Turn the large knob CW to Noise Level page. 54. Record the final Part Number and Mod.
22. Turn the large knob CW to Intercom Squelch page. RE-ENTERING/ADJUSTING USER DATA
23. Turn the large knob CW to Intercom Level page. 1. To reenter data, follow the procedures above to get to the
desired page.
24. Turn the large knob CW to Sidetone Level page.
2. Press the SEL button to activate the edit mode.
25. Turn the large knob CW to Headphone Level page.
3. Use the large knob to select which field to edit.
4. Use the small knob to change the data.
TEST MODE
5. Press ENTER when finished or SEL to cancel and restore
26. Power the unit off. Turn the unit back on while holding the previous data. (When re-entering or adjusting user data on
outermost smart keys to enter test mode. the SL display, pressing any key will save and exit.)
27. Turn the large knob CCW to Serial Port Setup page. Record serial
port settings in the space provided. If, after upgrading software or
servicing the unit, the RX & TX channels show GPS in both
positions, go back and perform the Software Upgrade Procedure
starting at step 8.
28. Turn the large knob CCW to Install Options page.
Page 2 of 2
P/N: 561-6001-50
11/4/04