GPS 165 Maintenance And Repair Manual
Contents
1. Measure voltage across J101 20 and J101 26 Rotate the outer function knob until the MSG annunciator test is selected With the MSG annunciator OFF verify that the DMM voltage is greater than 4 5 Vdc 23 k Rotate the inner function knob to turn the MSG annunciator ON Verify that the DMM voltage is less than 0 3 Vdc l Measure voltage across J101 12 and J101 26 m Rotate the outer function knob clockwise to select the ARRVL annunciator test n With the ARRVL annunciator OFF verify that the DMM voltage is greater than 4 5 Vdc o Rotate the inner function knob to turn the ARRVL annunciator ON Verify that the DMM voltage is less than 0 3 Vdc 9 External Switches Test a Press the CRSR key b Rotate the outer function knob until the External Switches Test Page is displayed as shown below c Toggle the APPR SELECT switch J101 9 to the grounded position Refer to Figure 13 Verify that the External Switches Test Page indicates APPR ON d Toggle APPR SELECT switch to the open position Verify that the External Switches Test Page indicates APPR OFF e Toggle OBS HOLD switch J2 13 to the grounded position Refer to Figure 12 Verify that the External Switches Test Page indicates HOLD ON f Toggle OBS HOLD switch J2 13 to the open position Verify that the External Switches Test Page indicates HOLD OFF 10 Altitude Decoder Test This test exercises each altitude data2. 012 00031 01 USING THE TWO SWAGED STANDOFFS ON THE INTERFACE BOARD TO LOCATE THE INSULATOR AS SHOWN 5 POSITION BOSS OF RACE 145 00056 00 WITH CORRESPONDING CUTOUT IN INTERFACE 250002100 BOARD 012 00031 01 ATTACH SPACER 252 00004 00 TO BOARD WHERE SHOWN WITH ADHESIVE BACKING OF SPACER ALIGN TWO REAR SPACERS OF BOARD AND TWO BOSSES OF RACE WITH HOLES IN CHASSIS AND FASTEN WITH 4 M1 7 x Smm FLAT HEAD SCREWS 211 56201 05 6 INSTALL MAIN BOARD ASSEMBLY 011 00126 01 INTO CHASSIS USING 1 M3 X Smm SCREW 211 50227 05 AND 1 M3 x 10mm SCREW 211 50227 15 THRU BOARD AND 2 4 HEX STANDOFFS 214 00004 01 THRU CHASSIS INTO D SUBMINIATURE CONNECTOR J101 VERIFY PROPER MATING OF CONNECTIONS BETWEEN MAIN BOARD ASSEMBLY AND INTERFACE BOARD 105 00044 00 410 00001 02 NUT INCLUDED APPLY 291 00003 00 TO THREADS I 211 00030 00 011 00126 XX Dy 211 50227 05 212 00005 00 Ng ka BNC CONNECTOR REF PART OF 011 00126 01 APPLY 291 00003 00 211 50227 15 TO THREADS je Figure 14 GPS 165 Assembly Drawing 1 34 115 00050 00 211 50227 05 2 PLCS 115 00049 00 9 211 50227 05 250 00016 00 DETAIL B 161 00060 XX El i SEE DETAIL B I 161 00093 XX NOTE 14 161 00058 XX NOTE 13 NOTE 16 211 50227 05 Pa 2 PLCS 211 00037 00 s BEN 11 00024 07 SS 2
3. GARMIN ul GPS 165 Maintenance And Repair Manual Part Number 190 00066 06 Revision F June 2003 Garmin International Inc 1200 E 151St Street Olathe KS 66062 TABLE OF CONTENTS SECTION 1 INTRODUCTION Paragraph Page LIXENERATODESCRIPTICUN AA aha sha EE NN eda rto tomas aka usha E 1 t2 DETAILED DESCRIPTION occasu yaaa eet Meter cnt cnn mee eee Cn 2 1251 Contro Display Umt CDU a aasia Rd 2 1 22 Mari Board Assembly Z Saa aa hts ck ta aaye masanna MAN assqa 3 1221 Central Processing Unit CPU e uqaqa ndo e 3 1 222 Power Supply CIIulle caes laia a isa h O 5 1 2 ocr on eet ee NY nobis tcs c 5 1 2 4 Interface Data Cards a een efte 6 1 2 5 Altitude Decoder BOSE ua aasan reos ated beret ebrei FF 6 SECTION 2 TROUBLESHOOTING 2 1 TROUBLESHOOTING EQUIPMENT REGOUIRED Lee ter hp 7 2 2 SPLE TESREAIURE Sierot oa ton wk UR CI a cot aa 7 2 3 INITIAL TROUBLESHOOTING OPERATIONS oed Rd FA PARE 8 2 sl Power Supply ehee ua e e O AF 8 2 32 ternal CLOCK C Dee osioon hoaina 8 24 Troubleshooting AGO ENGAN 10 SECTION 3 DISASSEMBLY INSTRUCTIONS Seb REMOVALIOE THE COVERS P r TEE 12 3 2 BOARD AND MODULE DISASSENIBEY iioii baia ert Rb
4. Printed circuit board which contains the microprocessor LSI power supply circuitry and battery charging components Altitude Decoder Board Printed circuit board which contains the altitude data decoder circuits and interface circuitry Interface Board Printed circuit board which connects the main board to the NavData card and the Altitude Decoder Board RF IF Assembly Module which contains the GPS receiver and high precision crystal oscillator External Battery Pack Provides emergency back up power in case of electrical failure 1 2 DETAILED DESCRIPTION Internally the GPS 165 is divided into six printed circuit boards the main RF IF altitude decoder interface display and keypad circuit boards The block diagram in Figure 1 below shows the relationships between major circuits and modules within the GPS 165 CDU INTERFACE BOARD BATTERY PACK External AIRCRAFT POWER RACKWIRING 1EXTERNAL SWITCHES t ANTENNA DCINPUT HARNESS 1 ANNUNCIATORS Figure 1 GPS 165 Block Diagram 1 2 1 Control Display Unit CDU The Control Display Unit is an assembly consisting of ten keycaps keypad board optical lens front insert panel vacuum fluorescent display VFD and board with drivers display board shock mounting grommets and screws The assembly is housed in a die cast bezel with a dual concentric rotary switch and two knobs The VED is a 3 r
5. Replace Main Board see Section 3 2 4 Unit does not detect external power Check external power communication Replace Main Board see Section 3 2 4 No serial data output Replace Main Board see Section 3 2 4 No external CDI output or external CDI functions improperly Check connections and verify operation in Test Mode see Section 4 3 3 Replace Main Board see Section 3 2 4 Invalid characters displayed Replace ROM see Section 4 2 Replace Main Board see Section 3 2 4 If UTC time is incorrect unit may be reset by holding the CLR key down while turning the unit on The unit must then be attached to an antenna allowed to search the sky and collect new almanac data This process may take 20 30 minutes CAUTION All user waypoints settings will be lost if the unit is reset The GPS 165 will eventually perform an AutoLocate and lock onto satellites however this can add an additional 10 15 minutes to the normal lock on time Display of low velocity numbers when not moving can occur when the unit is in 2D mode and should not be considered a problem However this should seldom occur in 3D mode The Turning Off message appears at below approximately 9 Vdc external power 11 SECTION 3 DISASSEMBLY INSTRUCTIONS To avoid damaging the GPS 165 s circuit boards and assemblies the following procedures should be carefully followed Assembly drawings are included in Section 5
6. observing proper pin alignment during the process 9 Turn the GPS 165 on and press ENT to accept NORMAL mode operation Press ENT again to accept the Database Page 10 Verify that the Memory battery low message does not appear on the Message Page by pressing the MSG key 11 Turn the GPS 165 off and carefully turn the unit over 12 Verify that the memory battery voltage from test point to ground see Figure 6 is at least 2 9 Vdc 13 Install the top and bottom covers by reversing the steps followed in Section 3 1 17 4 2 REPLACEMENT If a software update is required it may be performed by replacing the operating system ROM located on the Main Board When replacing the ROM all user waypoints settings will be lost The message Stored Data Lost will be displayed The unit must then be attached to an antenna allowed to search the sky and collect new almanac data before it will be usable again This process may take 20 30 minutes A user data card is available to save use waypoints settings prior to replacing the ROM Refer to page 9 of this manual for more information 1 Turn the GPS 165 off 2 Remove the bottom cover as described in Section 3 1 3 Locate the ROM in the middle of the Main Board as shown in Figure 6 NOTE The ROM removal tool is contoured for insertion into either of the two extraction cavities on the chip carrier socket Remove the chip by inserting the extraction tool with the correct angle se
7. Allow the unit to lock on to the satellites e Then unit must enter 3D navigation mode f Theunit must display the following 1 Four satellites with signal strength greater than 3 2 The average signal strength of 3 5 on satellites above 20 elevation 2T 9 1 Lan a g S S SE EE 29 9000000 00080089 VIEW OF J2 CONNECTOR FROM BACK OF UNIT PIN DESCRIPTION 3 SEQUENCE HOLD LOW OBS 4 ALTITUDE D4 15 ALTITUDE Al 6 ALTITUDE A2 7 ALTITUDE A4 8 ALTITUDE Bl 9 ALTITUDE B2 20 ALTITUDE B4 21 ALTITUDE C1 22 ALTITUDE C2 23 ALTITUDE C4 24 ALTITUDE COMMON Figure 10 J2 Rear Connector Pin Out Definition 28 ee e 66 8 6 8 8 8 6 6 6 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 VIEW OF J101 CONNECTORFROM BACK OF UNIT PIN DESCRIPTION 1 GPS D BAR LEFT 2 GPS TO 3 GPS FLAG 4 GPS FLAG 5 GPS D BAR RIGHT 6 GPS FROM T GPS OBI CLOCK 8 GPS OBI DATA 9 APPROACH ARM LOW 10 GPS SUPERFLAG HIGH 11 RS 422 IN HI 12 ARRIVAL ANNUNCIATE LOW 13 APPRCH ANNUNCIATE LOW 14 GPS ROTOR C 15 ARINC 429 OUT B 16 ARINC 429 OUT A 17 RS 232 IN 1 18 RS 232 IN 2 19 RS 232 OUT 2 20 MESSAGE ANNUNCIATE LOW 21 RESERVED 22 RESERVED 23 GPS OBI SYNC 24 RS 232 OUT 1 25 AIRCRAFT POWER 10 33 Vdc 26 GROUND 27 RS 422 IN LO 28 RESERVED 29 RE
8. Mo Horne Eel debe RESP pl Mte e tats os 12 3 2 1 Control Display Unit Removal atta a Rasa hts Bad subs Sd AR 12 3 2 2 Altitude Decoder Board 1 on d a eve aer Dile es 12 3 23 Matentaee Board Removal WN Aaa ra Ae RR E HIP A RUE 13 3 2 4 Main Board Sub Assembly Removal aan kn UR RU CRURA ERO MY 13 3 2 5 Assembly Removal O O IW abbates edna madusid 14 2 6 Powet Dimmer Switch Removal tos oa e A NCF O 15 3 2 7 Rotary Switch Assembly Removal d ca Cit dea tU QU da 15 3 2 8 Display Board E AR ABIDE RU RM PV amem RUN 15 3 3 REASSEMBEING THE LINI Liam 16 SECTION 4 SERVICE AND TESTING 4 1 MEMORY BATTERY REPLACEMENT teta too d GR act t 42 ROMREPLACEMEN T Gs te ddd GO EINAC Fu MR FE CY M TA Cote os ute d s fides 4 3 1 Test Equipment Required sane alea alad Sd AS 43 5 Final Lest Procedure soia WY GA cc e C ARA SECTION 5 ILLUSTRATED PARTS LIST Sekt ART OR ORE PEACE ABICE PARTS us 2 2 SIGNALS LOAD DIAGRAM L u z sama aa lta Beta 2 97 ASSEMBLY DRAWINGS u u u u annassa eda Hr eb dp hinaqa dd ddd LIST OF FIGURES FIGURE 1 GPS 165 BLOCK DIAGRAM aa andmast FIGURE 2 CONTROL DISPLAY UNIT BLOCK DIAGRAM FIGURE 3 MAIN BOARD BLOCK DDAGRAU R
9. for reference Figures 14 through 16 3 1 REMOVAL OF THE COVERS 1 Remove the NavData card 2 Remove the two M3 x 5mm screws 211 50227 05 retaining the top cover 115 00050 00 3 Remove the top cover by sliding it rearward approximately 1 4 until the retaining lip is fully exposed Thecover can then by lifted off the unit 4 Carefully turn the unit over Caution The GPS 165 contains numerous static sensitive components Always observe proper anti static precautions 5 Remove the two M3 x 5mm screws 211 50227 05 retaining the bottom cover 115 00051 00 6 Remove the bottom cover by sliding it rearward about 1 4 until the retaining lip is fully exposed The cover can then be lifted off the unit 3 2 BOARD AND MODULE DISASSEMBLY 3 2 1 Control Display Unit 011 00129 00 01 Removal 1 Remove the covers as described above 2 Remove the power dimmer control knob and shaft 430 00010 00 by loosening the M3 x 3mm set screw 211 00037 00 on the coupling sleeve 125 00021 00 NOTE On some early versions of the GPS 165 the shaft extension is connected directly to the power dimmer switch without an in line coupler The control knob is glued to this one piece extension and cannot be removed If you are replacing the CDU on one of these units you will need to order a replacement control knob and coupling sleeve as well 3 Remove the four M3 x 5mm flat head screws 211 00024 00 which attach the CDU to the chassis 4 Caref
10. in the fabrication of any Test Fixtures or Panels 4 3 2 Setup 1 Before connecting a test harness to the unit set the power supply to 13 8 Vdc 01 V at pin J101 25 Set the current limiter to 3 A 2 Turn the power supply OFF 3 Connect a test harness see Signal amp Load diagrams on pages 32 33 to the unit and turn the power supply ON 4 3 3 Final Test Procedure l Test Mode Activation Display Test a Hold the ENT key down while rotating the power dimmer knob clockwise from the off position b Verify that the GPS 165 enters test mode There are three test patterns displayed when first activating test mode The first test pattern illuminates all thirty five pixels in the first character column of each row and cycles through the remaining nineteen character columns The second test pattern illuminates the first column of pixels in each of the 20 character columns and cycles through the remaining four pixel columns The third test pattern illuminates the first row of pixels in each of the three character rows and cycles through the remaining six pixel rows C Observe the test patterns and verify that the display is working properly d Rotate the power dimmer knob counterclockwise but not past the detent off position to ensure that the display is dimmable 20 2 CDI Deflection Test a Rotate the outer function knob clockwise The following CDI Test Page will be displayed in View in View Measure
11. of Control Display Unit Replace Rotary Switch Assembly see Section 3 2 7 Replace Control Display Unit see Section 3 2 1 Approach select switch not functioning properly Check connections and verify operation in Test Mode see Section 4 3 3 Replace external switch Replace Main Board see Section 3 2 4 OBS select switch course select or hold not functioning properly Check connections and verify operations in Test Mode see Section 4 3 3 Replace external switch Replace Altitude Decoder Board see Section 3 2 2 Replace Main Board see Section 3 2 4 GPS reception weak or GPS Status Page shows low signal levels Replace Antenna and or antenna cable Replace RF IF Assembly see Section 3 2 5 10 TROUBLESHOOTING CHART Cont PROBLEM RECOMMENDED ACTION No GPS reception Check Date Time Page for correct UTC time Check Position Page for close approximate starting position within 300 nautical miles Replace Antenna and or antenna cable Replace RF IF Assembly see Section 3 2 5 Replace Main Board see Section 3 2 4 Unit displays velocity when not moving Replace RF IF Assembly see Section 3 2 5 Ni Cad battery life is short or Ni Cad battery inop Replace External Battery Pack Replace Main Board see Section 3 2 4 E nit loses memory in spite of new memory battery Replace Main Board see Section 3 2 4 c nit does not detect low battery
12. voltage across J101 1 and J101 4 Press the CRSR key If necessary rotate the inner function knob to select CENTERED Verify that the DMM voltage is 0 15 millivolts Rotate the inner function knob clockwise to select FULL RIGHT Verify that the DMM voltage is 150 15 millivolts Rotate the inner function knob clockwise to select MAX RIGHT Verify that the DMM voltage is 300 30 millivolts Rotate the inner function knob clockwise to select MAX LEFT Verify that the DMM voltage is 300 30 millivolts Rotate the inner function knob clockwise to select FULL LEFT Verify that the DMM voltage is 150 15 millivolts 3 CDI To From Flag Test Rotate the outer function knob clockwise Measure voltage across J101 2 and J101 4 If necessary rotate the inner function knob to select FLAG Verify that the DMM voltage is 0 15 millivolts Units with Mod Status 1 DMM voltage is 0 10 millivolts Rotate the inner function knob clockwise to select FROM Verify that the DMM voltage is 83 20 millivolts Units with Mod Status 1 DMM voltage is 190 40 millivolts Rotate the inner function knob clockwise to select TO Verify that the DMM voltage is 83 20 millivolts Units with Mod Status 1 DMM voltage is 190 40 millivolts 4 CDI Flag Test a b Rotate the outer function knob clockwise Measure voltage across J101 3 and J101 4 If necessary rotate the inner function knob to select IN VIEW Verify that the D
13. 5 1 Remove the covers as described in Section 3 1 2 Remove the Control Display Unit as described in Section 3 2 1 3 Remove the Altitude Decoder Board as described in Section 3 2 2 4 Remove the hex nut securing the BNC connector to the chassis This nut is 9 16 and may be removed with a deep 12 point socket 5 Pull the BNC connector out of its cutout on the chassis 6 Remove the heat sink clamping bar 115 00049 00 see Figure 15 Detail B by removing the M3 x 5mm mounting screw 211 50227 05 7 Remove the heat sink insulator 250 00016 00 from regulator 1800 see Figure 15 Detail B and save this piece for later re assembly 8 Carefully turn the unit over 9 The power dimmer switch uses a flexible circuit cable for connection to the Main Board This flexible circuit cable is inserted into a ZIF connector J804 Pull up on the retaining lip of the ZIF connector Gently pull the flexible circuit cable out of the ZIF connector 10 Remove the two 724 40 standoffs 214 00004 00 which hold the 37 pin DSUB connector to the chassis 11 Remove the M3 x 5mm screw 211 50227 05 and the M3 x 8mm screw 211 50207 11 holding the Main Board to the chassis 12 Carefully slide the Main Board upward pulling it away from the power dimmer switch and the Interface Board Connector J702 13 3 2 5 RF IF Assembly 012 00091 00 Removal 1 Remove the covers as described in Section 3 1 2 Remove the Altitude Decoder Boar
14. 91 00 AND INSERT 3 SECURE WITH SCREWS 211 50202 15 THRU SPACERS 233 00012 00 AS SHOWN 4 PLCS 012 00089 00 DETAIL B Figure 7 RF IF Assembly Removal 14 3 2 6 Power Dimmer Switch Removal 1 Remove the covers as described in Section 3 1 2 Remove the Control Display Unit as described in Section 3 2 1 3 Remove the Main Board Sub Assembly as described in Section 3 2 4 4 Remove the coupling sleeve 125 00021 00 by unscrewing the pivot pin screw 211 00030 00 See Figure 14 on page 34 5 Remove the hex nut securing the power dimmer switch to the chassis This nut is 7 16 and may be removed with a deep thin walled 12 point socket 6 Slide the power dimmer switch out of the mounting hole on the chassis 3 2 7 Rotary Switch Assembly Removal 1 Remove the covers as described in Section 3 1 2 Remove the Control Display Unit as described in Section 3 2 1 3 Remove the two rotary switch knobs by loosening the two M3 x 4mm set screws on the inner knob 430 00002 01 After removing the inner knob gently pull the outer knob off of the rotary switch shaft 4 Disconnect the rotary switch wiring harness from the connector on the Display Board 5 Remove the hex nut securing the rotary switch to the Control Display Unit This nut is 1 2 and may be removed with a deep 12 point socket 3 2 8 Display Board 011 00129 00 01 Removal 1 Remove the covers as described in Section 3 1 2 Remove t
15. A eite peel FIGURE BLOCK DIAGRAM ug id Dd est uno YN OG FIGURE 5 MAIN BOARD TESTPOINTS TOP VIEW FIGURE 6 MAIN BOARD TESTPOINTS BOTTOM FIGURE RFEIFASSEMBLY REMOVAL rt FIGURE8 TOOLINSERTION a a tapes AL sessi NA sae tado FIGURE 9 ROM BEMOV Laune tetti uet ad ine ote ceu ped bius FIGURE 10 J2 REAR CONNECTOR PINOUT DEFINITION irri nenne FIGURE 11 OI REAR CONNECTOR PINOUT DEFINITION FIGURE 12 SIGNAL amp LOAD FOR J2 CONNECTOR gebat FIGURE 13 SIGNAL S LOAD FOR J101 CONNECTOR FIGURE14 GPS 165 ASSEMBLY Aanja at FIGURE 15 GPS 165 ASSEMBLY DRAWING 2 FIGURE 16 GPS 165 ASSEMBLY DRAWING d dni ii SECTION 1 INTRODUCTION This manual is intended to provide instructions and guidelines for the maintenance and repair of the Garmin GPS 165 WARNING This unit contains static sensitive devices Service personnel must insure that proper precautions are taken to prevent damage to this equipment from Electro Static Discharge ESD Disassembly and repair should only be accomplished in an approved ESD workstation by properly trained and grounded personnel NOTE Repair centers operated by Garmin Ltd or its subsidiaries are authorized to perform component level repairs to Garmin products Repair centers operated by Garmin Ltd or its subsidiaries are author
16. ASSEMBLY 10 INSERT POWER DIMMER SWITCH FLEX CIRCUIT P804 INTO ZIF CONNECTOR J804 ON BOTTOM OF MAIN BOARD AND CLOSE CONNECTOR 11 INSTALL BOTTOM COVER 115 00051 00 BY INSERTING FRONT LIPS 2 OF COVER INTO SLOTS IN REAR SIDE OF CDU ASSY AND FASTENING TO REAR OF CHASSIS USING USING 2 M3 x 5mm SCREWS 12 INSTALL TOP COVER 115 00050 00 BY INSERTING 2 FRONT LIPS OF COVER INTO SLOTS IN REAR SIDE OF CDU ASSY AND FASTENING TO REAR OF CHASSIS USING USING 2 M3 x 5mm SCREWS 13 ATTACH SERIAL NUMBER TAG 161 00058 XX TO CHASSIS WHERE SHOWN 00 FOR UNITS MADE IN TAIWAN 02 FOR UNITS MADE IN USA 14 ATTACH CONFIGURATION LABEL 161 00093 XX TO SERIAL NUMBER TAG PER TABLE A LABEL COVERS P N SUFFIX 011 00106 00 ON TAG 15 AFTER INSPECTION APPLY TSO TAG 161 00060 XX PER TABLE A 16 MARK WITH PERMANENT BLACK MARKER MOD STATUS FOR UNITS WITH ECO 8281 INSTALLED Figure 15 GPS 165 Assembly Drawing 2 35 410 00002 01 211 00028 00 4 PLACES 252 00005 00 4 PLACES 325 00019 01 SEE DETAIL B 012 00029 00 115 00126 00 211 50227 05 2 PLCS 125 00008 00 231 00003 00 4 PLACES 211 00024 00 arr 145 00060 04 145 00060 08 145 00060 01 145 00060 07 145 00060 02 DETAIL A b gt 211 00024 00 2 PLCS 1450007400 011 00137 00 145 00060 XX 10 PLACES 125 00007 XX SEE NOTE 5 AND D
17. D ASSEMBLY 012 00029 00 TO THE ADAPTER BRACKET MAKING SURE THE 2x8 PIN HEADER ON THE DISPLAY BOARD MATES CORRECTLY WITH THE SOCKET ON THE REAR OF KEYPAD BOARD USE THE M2 3 SHOULDER SCREWS 211 00028 05 THRU THE RUBBER GROMMETS 252 00005 00 AS SHOWN 4 PLACES CONNECT WIRING HARNESS 325 00019 01 TO ROTARY SWITCH 410 00002 01 PER DETAIL B INSERT SHAFT OF ROTARY SWITCH THRU HOLE IN BRACKET 115 00126 00 AND SECURE WITH INCLUDED NUT TORQUE NUT TO 25 IN OZ AND ADD THREADLOCKER PER NOTE 1 ATTACH BRACKET TO STANDOFFS USING M3x0 5x5 PAN HEAD SCREW 211 50227 05 2 PLACES CONNECT WIRE HARNESS 325 00019 01 TO CONNECTOR J500 ON BACK OF DISPLAY BOARD PRESS NON SKIRTED LIGHTED KNOB 430 00006 00 ONTO OUTER ROTARY SWITCH SHAFT SLIDE METAL KNOB 430 00002 01 OVER TEFLON WASHER 212 20007 00 AND ATTACH TO SWITCH INNER SHAFT USING THE TWO M3 SET SCREWS PROVIDED WITH THE SMALL KNOB TRIM BARB FROM BOTTOM OF ROTARY SWITCH USING A BLADE 212 20007 00 430 00002 01 Figure 16 GPS 165 Assembly Drawing 3 36
18. ETAIL B PN 1 k 410 00002 01 249 WIRE ATTACHMENT TYP CONNECTION DIAGRAM 00007 00 470 00006 00 430 00006 00 2 PLCS PART OF 430 00002 01 1 10 11 12 13 REMOVE THIS TAB FROM BOTH SIDES SIDE VIEW KEYCAP SCALE 4 1 NOTES USE THREADLOCKER 291 00003 00 ON ALL THREADED FASTENERS UNLESS PRE APPLIED INSTALL QUARTER TURN FASTENERS 231 00003 00 INTO DZUS ADAPTER BRACKET 125 00008 00 BY FLARING THE SKIRT OF THE FASTENER INTO THE COUNTERSINK ON THE BACK SIDE OF THE BRACKET USING A SPECIAL TOOL 4 PLACES ATTACH STANDOFFS 214 00010 00 TO THE DZUS ADAPTER BRACKET 125 00008 00 WITH M3x0 5 THIN HEAD SCREW 211 00024 00 AS SHOWN 2 PLACES AFFIX LENS 470 00006 00 TO FACEPLATE 125 00007 XX NEATLY USING DIE CUT ADHESIVE TAPE 249 00007 00 IN THE BOTTOM OF THE LENS POCKET IN THE FACEPLATE MODIFY KEYCAP PER DETAIL B PLACE THE KEYCAPS 145 00060 XX INTO THE FACEPLATE PER DETAIL A PLACE THE KEYPAD BOARD 011 00137 00 OVER THE FACEPLATE AS SHOWN USING THE TWO BOSSES ON THE BACK OF THE FACEPLATE AS LOCATING GUIDE PLACE THE KEYPAD SUPPORT 145 00074 00 OVER THE KEYPAD USING THE TWO BOSSES ON THE BACK OF THE FACEPLATE AS LOCATING GUIDE ATTACH THE ADAPTER BRACKET TO THE FACEPLATE USING M3x0 5 THIN HEAD SCREWS 211 00024 00 AS SHOWN FIVE PLACES ATTACH THE DISPLAY BOAR
19. MM voltage is 0 10 millivolts Rotate the inner function knob clockwise to select OUT OF VIEW Verify that the DMM voltage is 375 80 millivolts 21 5 Super Flag Output Test a Rotate the outer function knob clockwise b Measure voltage across J101 10 and J101 26 c If necessary rotate the inner function knob to select IN VIEW Verify that the DMM voltage is less than 0 25 Vdc d Rotate the inner function knob clockwise to select OUT OF VIEW Verify that the DMM voltage is greater than 12 8 Vdc 6 OBI Output Test a Press the CRSR key b Rotate the outer function knob clockwise to display the following OBI Test Page CBI Data valid OBI Value 60680 c Press the CRSR key d Rotate the outer function knob clockwise until VALUE is flashing e Rotate the inner function knob clockwise to select CLOCK f Measure voltage across J101 7 and J101 26 g Rotate the outer function knob clockwise until LOW flashes Verify that the DMM voltage is less than 1 0 Vdc h Rotate the inner function knob to select HIGH Verify that the DMM voltage is greater than 4 5 Vdc i Rotate the outer function knob counterclockwise until CLOCK flashes j Rotate the inner function knob clockwise to select DATA k Measure voltage across J101 8 and J101 26 Rotate the outer function knob clockwise until LOW flashes Verify that the DMM voltage is less than 1 0 Vac m Rotate the inner function knob to select HIGH Verify that t
20. NS FOR OPTIONAL REMOTE BATTERY PACK SEE INSTALLATION MANUAL l lt LOOPBACK gt t J101 7 8 and 23 14V 560 OHMS 0 5 W 200 OHMS X 3 67 OHMS i 14 56 OHMS X 2 5W LOOPBACK 1K X 3 333 OHMS E PTS TB 1 LOOPBACK 1K X 3 333 OHMS BFGOODRICH PRESICION TRACK SELECTOR GA 56 WITH 10dB LOSS CABLE 5 3 Assembly Drawings gt s212 00090 00 012 00031 01 GPS165 CONFIGURATION BOM CDU LABEL TSO TAG Main Board Assembly 250 00015 00 011 00106 00 011 00129 00 NONE 161 00060 00 011 00126 01 011 00106 01 011 00129 01 161 00093 01 161 00060 01 011 00126 01 011 00106 02 011 00129 00 161 00093 02 161 00060 02 011 00126 02 TABLE A 214 00004 01 145 00056 00 2 PLCS PART OF 115 00036 00 011 00126 01 ASSY NOTES NOTE REMOVED 211 56221 05 4 PLCS 2 MOUNT BNC CONNECTOR amp WASHER 212 00005 00 TO MAIN CHASSIS 115 00036 00 USING HEX NUT PROVIDED WITH CONNECTOR 3 MOUNT POWER SWITCH 410 00001 02 TO CHASSIS USING HEX NUT PROVIDED WITH SWITCH ATTACH COUPLING SLEEVE 125 00021 00 TO SHAFT OF SWITCH WITH M3 PIVOT PIN 211 00030 00 SOLDER POWER SWITCH FLEX CIRCUIT 105 00044 00 TO POWER SWITCH 4 REMOVE PEEL OFF LINER FROM INSULATOR 250 00015 00 AND AFFIX TO BACK SIDE OF INTERFACE BOARD
21. PLCS 011 00129 XX 11 00055 00 430 00010 00 REF 1 115 00051 00 CONTROL DISPLAY UNIT 011 00129 00 450 503 0000000004 0000000000000000000000 0000000000000000000009 1 P503 2 2 1 35 P804 _ _ JBO4 B ron 011 00126 os E BH BOARD S amp T To Bj P702 88888888888888888888 105 00044 00 P70 S9999989999999899999 o 012 00090 00 012 00031 01 88 9 00000000000000000000 J702 ALTITUDE 8 INTERFACE BOARD 8 BOARD 8 68 NOTE ALL CONNECTOR REFERENCE DESIGNATORS ON THIS SHEET ARE SHOWN FOR REFERENCE ONLY THE FOLLOWING NOTES APPLY TO SHEET 2 7 SLIDE THE INSULATING TUBING 250 00016 00 OVER THE LM317 COMPONENT 1800 AS SHOWN IN DETAIL B CAREFULLY SECURE THE TWO INDICATED COMPONENTS 1800 1802 TO THE INSIDE CHASSIS WALL WITH HEAT SINK CLAMP BAR 115 00049 00 AND M3 x 5mm SCREW 211 50227 05 AS SHOWN 8 INSTALL ALTITUDE BOARD 012 00090 00 ONTO CHASSIS USING TWO 2 4 40 HEX SCREWS 214 00004 01 CAREFULLY PRESS RIBBON CABLE 2701 ON INTERFACE BOARD ONTO PIN HEADER P701 ON ALTITUDE BOARD 9 ATTACH CDU ASSY 011 00129 XX TO MAIN CHASSIS ASSY BY USING 4 M3 x 5mm THIN HEAD SCREWS 211 00024 07 VERIFY PROPER CONNECTIONS BETWEEN MAIN BOARD ASSEMBLY AND CDU
22. SERVED 30 REMOTE BATTERY 31 REMOTE BATTERY TEMP 32 ARINC 429 IN A 29 PIN cont DESCRIPTION cont 33 ARINC 429 IN B 34 REMOTE BATTERY 35 GPS STATOR D 36 RESERVED 37 GPS STATOR F Figure 11 J101 Rear Connector Pin Out Definition 30 SECTION 5 ILLUSTRATED PARTS LIST 5 1 LIST OF REPLACEABLE PARTS The table below lists the parts that are available to authorized maintenance shops Part Number Description 011 00129 00 CDU Assy GPS 165 011 00129 01 CDU Assy GPS 165 Grey 011 00137 00 Keypad GPS 165 011 CS030 00 Use 012 00091 00 011 C5032 00 Pwr Dim Sw w flex ckt Cble 011 C5032 01 Rtry Swch Assy w wire Hrns 012 00029 00 Display Board Assy 012 00031 01 Interface Assy 012 00089 01 CPU Bd Assy 012 00090 00 Altitude Decoder Bd 012 00091 00 TSO d Assy w BNC Conn 115 00050 00 Top Cover Dzus Mount 115 00051 00 Bottom Cover Dzus Mount 360 00003 01 Lithium Cell 2023 430 00002 01 Knob Inner w o Trim Ring 430 00006 00 Knob Outer 430 00010 00 Knob Power Dimmer 470 00006 00 Lens GPS 165 541 B0034 00 Programmed EPROM NOTE The drawings in this section are for reference only Part numbers listed on drawings are for identification purposes and cannot be supplied by Garmin Only the parts mentio
23. d as described in Section 3 2 2 3 Remove the hex nut securing the BNC connector to the chassis This nut is 9 16 and may be removed with a deep 12 point socket 4 Pullthe BNC connector out of its cutout on the chassis 5 Remove the four screws 211 50202 15 and spacers 233 00012 00 which secure the RF IF Assembly to the Main Board 6 Carefully pull the RF IF Assembly upward disengaging it from the Main Board Connector J803 NOTE With the mounting screws removed the cover for the RF IF Assembly will be loose Grip the RF IF Assembly firmly by the sides instead of by its cover when lifting upward mon o 0o0 SOCKET gt gt E R139 211 50202 15 A EPROM 541 B0034 00 ka N y 7 HU 0 905 00000 JO 233 00012 00 Hu ai m SN nt 22 2 i DETAIL A DETAIL B 012 00091 00 BOTTOM VIEW 012 00089 00 REFERENCE ONLY SEE 016 00089 00 ASSY NOTES 1 ADD OR DO NOT ADD R139 AND R142 CHIP RESISTORS 905 00000 J0 ACCORDING TO THE FOLLOWING TABLE UNIT REF ASSEMBLY R139 R142 GPS155 011 00126 00 DO NOT ADD DO NOT ADD lt GPS165 011 00126 01 ADD PER DETAIL B DO NOT ADD GPS165 OSAP O11 00126 02 ADD PER DETAIL B ADD PER DETAIL B 3300094900 GPS155 OSAP 011 00126 03 DO NOT ADD ADD PER DETAIL B 2 ALIGN 2X8 CONN PINS ON MAIN BOARD 012 00089 00 WITH SOCKET ON RF IF BOARD 012 000
24. d the CLR key down while rotation the power dimmer knob clockwise from the off position Verify that the Self Test Page is displayed shows the software version number and copyright notice Also press the MSG key to verify that the Stored data lost message appears on the Message Page and the ROM failed message does not appear Failure to clear memory after ROM replacement can cause unpredictable operating problems Turn the GPS 165 off Install the bottom cover by reversing the steps followed in Section 3 1 Connect an outside antenna to the GPS 165 turn the unit on and allow it to recollect almanac data as described above This process is complete when the Collecting Data message is no longer displayed on the Message Page 19 4 3 FINAL TEST After completing all necessary maintenance or service the following test procedure is provided to ensure that all GPS 165 functions are operating properly 4 3 1 Test Equipment Recommended The following standard equipment or suitable substitutes is needed to perform testing 0 30 Volt DC 3 amp Power Supply Digital Multimeter BF Goodrich Precision Track Selector GPS Antenna Garmin GA 56 P N 010 10040 01 Male to Male BNC cable giving 10 1 dB attenuation P N 320 00088 00 Red and Black Cables with Bananna Plugs 3 ft recommended 60 MHz Oscilloscope NOTE Test Fixtures Test Harnesses are User Supplied Signal amp Load information given in Figures 12 and 13 can aid
25. e Figure 8 and pivoting the tool on its heel against the socket INCORRECT CORRECT ANGLE ANGLE Figure 8 Tool Insertion 4 ROM Extraction Procedure a Orient the socket and tool as shown in Figure 9 CAUTION Do not attempt to completely extract chip from chip carrier socket on the first extraction Lift from one side until the corner is above the socket then repeat the procedure on the opposite corner 18 ROM REMOVAL TOOL Foo 00007 00 ALIGNMENT ROTATE BACK TO REMCWE MAIN BOARD ASSEMBLY Pi G12 00089 01 Figure 9 ROM Removal b Insert the extraction tool into the socket so that the front angle of the tool is perpendicular to the chip carrier NOTE Insertion of the tool with an incorrect angle will result in damage to the chip carrier socket The incorrect angle will bottom under the standoff rather than the bottom of the chip c Lower the extraction tool into the extraction cavity until it bottoms d Using a slight downward pressure rotate the tool away from the chip carrier until the corner of the chip lifts away from the chip carrier socket e Repeat on opposite extraction slot and lift chip out of chip carrier socket Inspect the ROM socket to ensure that the contacts and case are in good condition Insert the new ROM into the socket so that the beveled corned of the ROM chip aligns with the beveled corner of the socket see Figure 6 Make certain that the ROM is well seated Hol
26. e display drivers 12 volts 15 volts 5 volts VCC on off circuits and the battery charger In addition the main board contains comparator circuits for detecting low Ni Cad battery level low memory battery voltage and external power The external power input is through the rear connector J101 and from the AC adapter through a DC power jack located near the rear connector External battery pack power is also applied to the rear connector J101 All of these sources are diode isolated to prevent parallel sourcing The unit is turned on and off by a digital latch circuit operated by a knob located on the front panel adjacent to the NavData card opening The switching circuit is a fly back design The switching regulator operates at a frequency of approximately 40 kHz and uses a high efficiency switching regulator for the switching device The high efficiency switching regulator drives a transformer that is configured in a fly back mode The 15 volt output is post regulated to provide 11 75 to 12 25 volts The 5 volt output is regulated at 4 8 to 5 2 volts All other voltages are 22090 1 2 3 Assembly The RF IF assembly consists of a dual conversion receiver a frequency synthesizer and a high precision crystal oscillator The receiver consists of a ceramic RF filter RF and IF amplifiers mixers and an IF filter The frequency synthesizer uses the high precision oscillator as a reference frequency for the phase detector in the syn
27. e usable again This process may take 20 30 minutes Before beginning replacement of the memory battery transfer all waypoints and routes to a user data card so that they may be transferred back to the unit following battery replacement This process is covered in the user s manual 1 Remove the covers as described in Section 3 1 2 Remove the Control Display Unit as described in Section 3 2 1 3 Remove the four screws 211 50202 15 and spacers 233 00012 00 which secure the RF IF Assembly to the Main Board 4 Carefully pull the RF IF Assembly upward disengaging it from the Main Board Connector J803 Place the RF IF Assembly to the side of the unit NOTE With the mounting screws removed the cover for the RF IF Assembly will be loose Grip the RF IF Assembly firmly by the sides instead of by its cover when lifting upward 5 Remove the old battery by gently pushing it toward the back of the unit and out of the battery clip A tuning tool or similar flat tipped instrument may be used to aid removal of the battery but EXTREME CAUTION should be exercised to prevent damage to the Main Board 6 Immediately install a new battery positive side up into the battery clip 7 Secure the RF IF Assembly to the Main Board using the four screws 211 50202 15 and spacers 233 00012 00 8 Install the Control Display Unit by reversing the steps followed in Section 3 2 1 Gently slide the CDU onto the two Main Board connectors P501 and P502
28. fy connection of external battery pack to Main Board Replace external battery pack Course input fail Check ARINC 429 RS 422 course input connections Replace Main Board see Section 3 2 4 Data card failed Replace NavData card Replace Interface Board see Section 3 2 3 Data card write fail Replace user data card Replace Interface Board see Section 3 2 3 Fuel Air input fail Check connections to fuel air data system Replace Main Board see Section 3 2 4 Memory battery low Replace memory battery see Section 4 1 No altitude input Verify connections to altitude serializer encoder Replace Altitude Decoder Board see Section 3 2 2 Replace Main Board see Section 3 2 4 Osc needs adjustment Replace RF IF Assembly see Section 3 2 5 Replace Main Board see Section 3 2 4 RAM failed Replace Main Board see Section 3 2 4 Receiver failed Replace Main Board see Section 3 2 4 Replace RF IF Assembly see Section 3 2 5 ROM failed Replace ROM see Section 4 2 Replace Main Board see Section 3 2 4 Stored data lost Replace memory battery see Section 4 1 NOTE Where multiple repair actions are listed they are listed with most likely failure cause first 2 3 INITIAL TROUBLESHOOTING OPERATIONS The first step in troubleshooting the GPS 165 is to remove the top and bottom covers see Section 3 1 Verify that the unit is being properly powered and the internal clock is functiona
29. he Control Display Unit as described in Section 3 2 1 3 Disconnect the rotary switch wiring harness from the connector on the Display Board 4 Remove the four M2 3 x 6mm screws 211 00028 00 that secure the Display Board to the CDU bezel 5 Carefully pull the Display Board away from the CDU bezel disengaging it from the Keypad Board connector Retain the four rubber grommets 252 00005 00 for later assembly 15 3 3 REASSEMBLING THE UNIT NOTE During re assembly coat all threaded fasteners with thread locking compound 1 Attach the power dimmer switch to the chassis by reversing the steps followed in Section 3 2 6 The Switch is correctly installed when the contacts and flexible circuit cable are pointing away from the chassis frame 2 Ensure that the power dimmer switch is in the off position 3 Attach the RF IF Assembly to the Main Board by reversing the steps followed in Section 3 2 5 4 Mount the Main Board Sub Assembly on the chassis by reversing the steps followed in Section 3 2 4 Be sure to pull up on the retaining lip of the ZIF connector J804 before inserting the flexible circuit cable Also ensure that the heat sink insulator 250 00016 00 is installed on regulator 1800 before installing the heat sink clamping bar see Figure 15 Detail B 5 Mount the Interface Board to the chassis by reversing the steps followed in Section 3 2 3 6 Install the Altitude Decoder Board by reversing the steps followed
30. he DMM voltage is greater than 4 5 Vdc n Rotate the outer function knob counterclockwise until DATA flashes o Rotate the inner function knob clockwise to select SYNC p Measure voltage across J101 23 and J101 26 q Rotate the outer function knob clockwise until LOW flashes Verify that the DMM voltage is less than 1 0 Vdc 22 r Rotate the inner function knob to select HIGH Verify that the DMM voltage is greater than 4 5 Vdc 7 RS 232 RS 422 ARINC 429 Loopback Tests a b Press the CRSR key Rotate the outer function knob until the following I O Test Page is displayed Set RS 232 422 Loop back switch to RS232 1 position Refer to Figure 13 Verify that the I O Test Page indicates CH 1 OK and CH 2 OK Set the RS 232 422 Loop back switch to RS 422 position Verify that the I O Test Page indicates RS422 OK Verify that the I O Test Page indicates A429 OK 8 Annunciator Output Test Press the CRSR key Rotate the outer function knob until the following Annunciator Test Page is displayed Annunciators Panel off Mss off Rrrul off Appr off Measure voltage across J101 13 and J101 26 Press the CRSR key Rotate the outer knob counterclockwise to select the APPR annunciator test With the APPR annunciator OFF verify that the DMM voltage is greater that 4 5 Vdc Rotate the inner function knob to turn the APPR annunciator ON Verify that the DMM voltage is less than 0 3 Vdc
31. in Section 3 2 2 Carefully observe proper orientation and alignment when reconnecting the ribbon cable to the board 7 Mount the Display Board to the CDU bezel by reversing the steps followed in Section 3 2 8 Be sure to reinstall the four rubber grommets before mounting the board 8 Mount the Rotary Switch Assembly to the Control Display Unit by reversing the steps followed in Section 3 2 7 The switch is correctly installed when the wiring harness points toward the top of the unit Torque hex nut to 25 3 in oz 9 Install the Control Display Unit by reversing the steps followed in Section 3 2 1 Gently slide the CDU onto the two Main Board connectors J100 and J102 observing proper pin alignment during the process 10 Install the top and bottom covers by reversing the steps followed in Section 3 1 16 SECTION 4 SERVICE AND TESTING 4 1 MEMORY BATTERY REPLACEMENT The GPS 165 utilizes a built in lithium battery to maintain user waypoints settings stored in RAM This battery has an operational life of up to five years Should the battery require replacements as indicated by the Memory battery low message disassembly of the unit will be required to access the battery clip When replacing the memory battery all user waypoints settings may be lost If this occurs the message Stored Data Lost will be displayed The unit must then be attached to an antenna allowed to search the sky and collect new almanac data before it will b
32. is used to keep track of the date and time Other circuits on the board are used for input output functions such as controlling the display reading the keypad and controlling the receiver Discrete input output lines are provided for CDI course deviation CDI to from flag CDI NAV flag Super Flag external annunciators OBS course and to activate the Approach mode Serial communication lines for OBI clock data sync ARINC 429 RS 422 and RS 232 two channels are also included The block diagram in Figure 3 below shows the interaction between the various Main Board circuits or User Data Card Flash Memory Watchdog tow voltage Detector Reset MAIN BOARD DATA lt a interface Board Microprocessor Discrete I O Altitude Board App Acttvate Mic To From PGA Outputs FLAG Left Right i pek Rear GPSSEQ Encoded LITHIUM HOLD Atude PE BATTEI BB Switeh Data we 5 S Blanking 5 E Circult Reg o B Power Supply a 5 Rapid Clreultry Trickle amp Charger j 2 8 t Antenna 5 Y 8 H m Keypad Board External Display RF IF Battery AC Alrcraft Board Inc Dec Board Pack Adaptor Power rotary Switc Figure 3 Main Board Block Diagram 1 2 2 2 Power Supply Circuits The power supply section of the Main Board supplies 60 volts for th
33. isplayed f Press the MSG key and verify that the Message Page is displayed g Press the Direct To key and verify that the GO TO Page is displayed h Rotate the inner function knob to select a letter or number on the display i Press the CLR key and verify that the selected letter number disappears j Press the NRST key Verify that a Nearest Waypoint Page is displayed k Press the SET key Verify that a Set Up Page Satellite Status Page is displayed l Press the RTE key Verify that a Route Page is displayed m Press the WPT key Verify that the Select Waypoint Type Page is displayed n Press the CRSR key and verify that APT flashes o Rotate the outer function knob clockwise and verify that VOR flashes p Press the NAV key Verify that a Navigation Page is displayed q Turn the GPS 165 OFF 26 15 Satellite Tracking Test The Satellite Tracking Test ensures that the GPS 165 has current almanac information and is able to lock onto a sufficient number of satellites to provide a position This test also verifies that the signal strength of the satellites received is at an acceptable level a Turn the unit off b Connect unit to a GA56 antenna mounted outside with a clear view of the sky through a coax with a 10dB 1dB cable loss 1 5 GHZ Note attenuation pads must not be used since the unit supplies the GA56 with DC power c Turnon the unit Go to the satellite Data Page see Pilots Guide for instructions d
34. ized to use Garmin proprietary documentation as references during any component level repairs performed 1 4 GENERAL DESCRIPTION The GPS 165 is a full featured aviation GPS navigation instrument designed for a fixed panel mounted installation The GPS 165 utilizes the patented Garmin MultiTrac system for tracking up to eight satellites simultaneously The unit features a GPS receiver a 3 line 20 character high brightness vacuum fluorescent display and a front loading NavData card The unit is constructed from high quality materials and uses the latest techniques in manufacturing technology In order to achieve the desired reliability size and power requirements surface mount components are used extensively Specialized equipment and procedures are required to repair circuit boards having surface mounted components Garmin does not authorize the repair of GPS 165 circuit boards All circuit boards and assemblies for the GPS 165 can be economically replaced through the Garmin board exchange program if necessary The following modules and printed circuit board assemblies are field replaceable Display Board Assembly Contains the vacuum fluorescent display and display circuit board Rotary Switch Assembly Contains dual concentric switch and its assembled wiring harness Control Display Unit Contains bezel buttons lens keypad board light pipes front insert plus the Display Board Assembly and Rotary Switch Assembly Main Board
35. l NOTE Remove the NavData card before disassembling the unit 2 3 1 Power Supply Check 1 Check the DC voltage between D805 and ground as shown in Figure 5 The voltage should be between 9 60 and 14 40 If the voltage is outside of these limits replace the Main Board Check the DC voltage between L800 and ground as shown in Figure 5 The voltage should be between 4 8 and 5 2 If the voltage is outside of the limits replace the Main Board Check the DC voltage between D804 and ground as shown in Figure 5 The voltage should be between 48 00 and 72 00 If the voltage is outside of these limits replace the Main Board Check the DC voltage between 1806 pin 1 and ground as shown in Figure 6 The voltage should be between 11 75 and 12 25 If the voltage is outside of these limits replace the Main Board 2 3 2 Internal Clock Check Check the clock speed by placing an oscilloscope probe at 1112 pin 25 as shown in Figure 6 The frequency should be approximately 16 4 MHz If the clock is not operational replace the RF IF Board If the clock still fails to function replace the Main Board Cathode 50 YDC DEDS Anodn 12 VDC LEDD 5 VDC 1 y Donant Standoff Mounte for Assembly Figure 5 Main Board Testpoints Top View Test Point B200 Memory 12 YDC Ceo I 4 ep pa 1 103 pn Zi 08 9 ll L PO es auo 3 L p 7 o 20000000 cem a n
36. line individually Most altitude codes presented will be invalid however ALTITUDE DECODER LINE SELECT switch positions C1 input line C1 valid and C2 input line C2 valid indicate altitude readings of 800 and 1000 feet respectively a Rotate the outer function knob until the Altitude Decoder Test Page is displayed duagubaucau b Close the switch for input line D4 Verify that D4 on the Altitude Decoder Test Page indicates 1 All other altitude inputs should indicate O 24 11 12 c Continue to step through input lines A1 A2 A4 B1 B2 B4 C1 C2 and C4 Verify that only one input line A1 A2 A4 B1 B2 B4 C1 C2 or C4 indicates 1 for each switch position All other altitude inputs should still indicate 0 OBS Selected Course Test a Rotate the outer function knob until the OBS Selected Course Test Page is displayed Selected course set to 1549 b Attach OBS Signals to respective pins on Precision Track Selector Set Track Selector to 150 Verify that the input course is 150 9 and CALIB appears in the lower right corner of the test page c Press the CRSR key d Press the ENT key on the GPS 165 to calibrate the unit There will be a brief delay while the unit performs the calibration Verify that the input course is now 150 0 2 e Set the Track Selector to the 60 240 and 330 positions Verify that in each instance the in
37. ned in Section 5 1 are still supplied by Garmin 5 2 Signal amp Load Diagrams GPS 165 RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED RESERVED ALTITUDE D4 ALTITUDE A1 ALTITUDE A2 ALTITUDE A4 ALTITUDE B1 ALTITUDE B2 ALTITUDE B4 ALTITUDE C1 ALTITUDE C2 ALTITUDE C4 ALTITUDE COMMON SEQ HOLD LOW GROUND I S a y 085 HOLD push button switch O Figure 12 Signal amp Load for J2 Connector 32 t 1o uuo2 T01 10 pvo 29 IeuSr cq GPS 165 RS 232 DATA IN 1 RS 232 DATA OUT 1 RS 422 IN LOW RS 422 IN HI POWER GROUND MESSAGE ANNUNCIATE ARRIVAL ANNUNCIATE APPROACH ACTV ANNUNCIATE APPROACH ARM LOW BATTERY BATTERY RS 232 DATA IN 2 RS 232 DATA OUT 2 GPS OBI CLOCK GPS OBI DATA GPS OBI SYNC GPS SUPERFLAG ARINC 429 OUT A ARINC 429 OUT B ARINC 429 IN A ARINC 429 IN B GPS FLAG GPS TO GPS D BAR LEFT COMMON GPS ROTOR C GPS ROTOR H GROUND GPS STATOR F GPS STATORG GPS STATOR D GPS STATOR GPS ANTENNA J101 17 2L 27 11 2 26 20 12 13 30 34 19 u 26 37 35 J5 RS232 1 Loopback e 422 Loopback Switch Linear Tech LT1181 exas Instr SN75179 14 Vdc 2 Amp POWER SUPPLY J101 12 13 AND 20 15V 51 OHMS LW _l_ APPR SELECT push button switch CONNECTIO
38. ow by 20 column unit with variable intensity This display provides excellent day and night visibility from wide viewing angles The front panel provides function selection and alphanumeric input to the Main Board Assembly via 10 push buttons and the dual concentric rotary knob There are two LEDs behind each keycap providing backlighting for use at night The block diagram in Figure 2 shows the interaction between components on the Control Display Unit TW VACUUM FLUORESCENT DISPLAY DUAL CONCENTRIC SWITCH CHARACTER CHARACTER DRIVER DRIVER DRIVER DISPLAY KEYPAD KEYPAD BOARD SCAN LIGHTING VFD CONTROL TO MAIN BOARD Figure 2 Control Display Unit Block Diagram 1 2 2 Main Board Assembly The Main Board Assembly contains the CPU operating system ROM system memory discrete I O serial communication drivers receivers and the power supply These items are discussed in further detail below 1 2 2 1 Central Processing Unit CPU The Main Board is a microprocessor based computer board This board contains an Intel 80L186EB microprocessor running at 16 MHz a plug in read only memory chip ROM and random access memory chips RAM Data stored in RAM is maintained by a 3 volt lithium battery when the unit is switched off and by the regulated 5 volt supply when the unit is powered on A custom LSI is used to decode the signals from the GPS satellites A real time clock IC
39. pnaang 0 D Figure 6 Main Board Testpoints Bottom View 2 4 TROUBLESHOOTING CHART PROBLEM RECOMMENDED ACTION Unit will not power on Check External Power Connection Check External Battery Pack Check Pwr Dimmer Switch Connection Replace Main Board see Section 3 2 4 Replace Pwr Dimmer Switch see Section 3 2 6 Unit will not power off Replace Main Board see Section 3 2 4 Replace Pwr Dimmer Switch see Section 3 2 6 Display has horizontal or vertical lines Replace Display Board see Section 3 2 8 Replace Main Board see Section 3 2 4 Display has missing or dark pixels Replace Display Board see Section 3 2 8 e Display brightness not adjustable Replace Pwr Dimmer Switch see Section 3 2 6 Replace Main Board see Section 3 2 4 Keycaps have no backlighting Replace Control Display Unit see Section 3 2 1 Replace Main Board see Section 3 2 4 Keycap backlighting not uniform Replace Control Display Unit see Section 3 2 1 No external annunciator output s message arrival approach Check connections and verify operation in Test Mode see Section 4 3 3 Replace Main Board see Section 3 2 4 Keycaps do not function properly Replace Control Display Unit see Section 3 2 1 Replace Main Board see Section 3 2 4 Dual concentric rotary knobs do not function properly Check wiring harness connection from rotary switch to back
40. put course is within 2 External Power Battery Tests a Rotate the outer function knob until the Battery Test Page is displayed Ext Pur Rarid charse Memors Batt ok Intrnl Batt ok b Verify that line two of the display indicates External Power and the voltage reading is approximately 13 8 0 3 Vdc c Connect the wall charger to the unit and verify that line two of the display now indicates Charger Trickle Chrg d Unplug the wall adapter Line two of the display should go back to indicating External Power e Verify that line 2 of the display indicates Rmt Pak none f Verify that line 3 of the display indicates Mem Bat ok 25 13 14 GPS Receiver Noise Test a Rotate the outer function knob until the GPS receiver test page is displayed b Terminate the GPS receiver s antenna connection into a 50 ohm load c The bottom line of the display represents the receiver noise level Verify that this number is within the range of 1800 and 2200 Operational Test a Turn the GPS 165 OFF b Insert a Jeppesen NavData card c Turn the GPS 165 ON normally without entering the test mode Verify that the GPS 165 passes its self test A failure is indicated by one of the messages listed in Section 2 2 d Verify that the GPS 165 correctly reads the NavData6 card and indicates the type effective date and expiration date e Press the ENT key and verify that the Satellite Status Page is d
41. thesizer The resultant frequency is used in the mixer section to produce the first IF After further amplification and mixing with a product of the crystal oscillator the baseband IF is passed to the CPU Board for processing The crystal output is also used for the system clock pulse The RF IF assembly is contained within a shielding fence cover and connection to the antenna is made via a BNC connector The RF IF supplies 5 volts to the antenna s preamplifier through this BNC connector The block diagram in Figure 4 below shows the interaction between components on the RF IF Assembly Antenna CRYSTAL Figure 4 RF IF Block Diagram 1 2 4 Interface Board and Data Cards The Interface Board provides two way data transfer capability between the Main Board and a data card NavData cards allow for data transfer to the Main Board only User data cards with 128 kilobytes of flash memory data storage may be used to save user data settings from the GPS 165 or restore that information to the GPS 165 Address and data lines from the Main Board route through the Interface Board s output buffers to the data card A plastic race secures the Interface Board at the front of the unit and serves to guide the data card onto the 40 pin connector NOTE When servicing the GPS 165 user defined waypoints routes settings etc may be saved on a user data card 010 10032 03 first In the event these data are lost they may then be restored from the
42. ully remove the CDU from the chassis pulling the assembly away from the two Main Board connectors J100 and J102 and the power dimmer switch 3 2 2 Altitude Decoder Board 012 00090 00 Removal 1 Remove the covers as described in Section 3 1 2 Remove the two 74 40 standoffs 214 00004 00 which hold the 26 pin DSUB connector to the chassis 3 Carefully pull the Altitude Decoder Board toward the front of the unit approximately 1 4 until the 26 pin DSUB connector is clear of its cutout on the chassis Lift the Altitude Decoder Board away from the Main Board and chassis 4 Remove the ribbon cable connector J701 from the Altitude Decoder Board 12 3 2 3 Interface Board 012 00031 01 Removal 1 Remove the covers as described in Section 3 1 2 Remove the Control Display Unit as described in Section 3 2 1 3 Remove the Altitude Decoder Board as described above 4 Remove the four M1 7 x 5mm flat head screws 211 56201 05 retaining the data card race 145 00056 00 and Interface Board 5 Slip the data card race off the Interface Board connector J700 6 Carefully pull the Interface Board out of the unit upward disengaging it from the Main Board Connector J107 3 2 4 Main Board Sub Assembly 011 00126 xx Removal The Main Board Sub Assembly consists of the CPU Main Board 012 00089 01 and the RF IF Assembly 012 00091 00 If required this sub assembly may be further disassembled by following the steps in Section 3 2
43. user data card before the unit is returned to service Refer to Appendix A of the GPS 165 Pilot s Guide for additional information on user data card operation 1 2 5 Altitude Decoder Board The Altitude Decoder Board contains the 26 pin rear connector J2 discrete parallel inputs and Gillham Greycode decoder circuitry Encoded pressure altitude data from a parallel altimeter device is received as a 10 bit data word at the 26 pin rear connector Diode isolation on these input lines prevents damage to the GPS 165 The data is then decoded and output to the Main Board data bus via the Interface Board The Altitude Decoder Board also provides a discrete input for the GPS SEQ switch When grounded this line activates the GPS 165 s HOLD mode This input is sent to the Main Board data bus via the Interface Board SECTION 2 TROUBLESHOOTING 2 1 TROUBLESHOOTING EQUIPMENT REQUIRED 0 30 Volt DC 3 Amp Power Supply Digital Multimeter 20 MHz Oscilloscope 2 SELF TEST FAILURES The GPS 165 monitors many of its internal functions and displays a message to alert the user should a failure occur The table below shows the recommended repair for each self test failure message MESSAGE RECOMMENDED REPAIR Altitude input fail Verify connections to altitude serializer encoder Replace Altitude Decoder Board see Section 3 2 2 Replace Interface Board see Section 3 2 3 Replace Main Board see Section 3 2 4 Battery requires service Veri
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