GPS Apollo GX Series

Service Manual
Apollo GX Series
Confidential, unpublished property of Garmin AT, Inc. Use and distribution is limited
solely to authorized personnel. The use, disclosure, reproduction, modification, transfer,
or transmittal of any portion of this work for any purpose in any form or by any means
without the express written permission of Garmin AT is strictly prohibited.
October 2004 560-7001-501 Rev. --

Garmin AT Rev. --
© 2004 Garmin Ltd. or its subsidiaries. All rights reserved. Printed in the U.S.A.
st
Garmin International, Inc., 1200 East 151 Street, Olathe Kansas 66062, U.S.A.
Tel: 913/397.8200 Fax: 913/397.8282
Garmin (Europe) Ltd., Unit 5, The Quadrangle, Abbey Park Industrial Estate, Romsey, Hampshire
S051 9DL, U.K.
Tel: 44.1794.519944 Fax: 44.1794.519222
nd
Garmin Corporation, No. 68, Jangshu 2 Road, Shijr, Taipei County, Taiwan
Tel: 886/02.2642.9199 Fax: 886.02.2642.9099
Garmin AT, Inc., 2345 Turner Road, S.E., Salem, OR 97302, U.S.A.
Tel: 800.525.6726 Fax: 503.364.2138
Canada Tel: 800.654.3415
International Tel: 503.391.3411
Visit our web pages at http://www.garmin.com
Send comments about this manual by email to: techpubs.salem@garmin.com
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted,
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written permission of Garmin. Garmin hereby grants permission to download a single copy of this
manual and of any revision to this manual onto a hard drive or other electronic storage medium to be
viewed for personal use, provided that such electronic or printed copy of this manual or revision must
contain the complete text of this copyright notice and provided further that any unauthorized
commercial distribution of this manual or any revision hereto is strictly prohibited.
Information in this document is subject to change without notice. Garmin reserves the right to change
or improve their products and to make changes in the content of this material without obligation to
notify any person or organization of such changes or improvements.
Garmin®, Garmin AT®, II Morrow, Apollo, and GNS are trademarks of Garmin Ltd. or its subsidiaries.
These trademarks may not be used without the express permission of Garmin.
ii GX Service Manual © 2004 Garmin AT

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How to Contact Us
Telephone: 800-525-6726 US
800-654-3415 Canada
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.
E-mail Tech Support: techpubs.salem@garmin.com
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.
World Wide Web: www.garmin.com
Need an operation manual or install manual? How about a copy of an STC or flight manual
supplement? You can download most of our printed materials right off our website. This is a good
source of information for you and your customers. We have the latest information about our products.
It also allows end users to find dealers by doing a search in our nearest dealer listings. If you have
your own web site, you can link it to ours.
Navigating Our Phone System

When you call Garmin AT, the first thing you hear is, “Thank you for calling Garmin AT. Our business
hours are…” This is followed by a series of menu choices to help get you to the appropriate
department. Here are some department extensions to get you into our system without having to listen
to the menu choices:
If you need this: Call this extension:
Order Units 3990
Order Accessories 3990
Order Datacard and Field Upgrades 3995
Database Subscriptions 3995
Troubleshooting or Operational Questions 3991
Installation Questions 3991
Check repair status of a unit 3992
Billing or invoice questions 3994
Returning new products or special requests 3990
© 2004 Garmin AT GX Service Manual iii

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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
CHAPTER 4. ANTENNA INSTALLATION GUIDES ................................................................................................ 4-1
CHAPTER 5. AIRCRAFT INSTALLATION TROUBLESHOOTING .......................................................................... 5-1

REDUCING THE EFFECTS OF VHF INTERFERENCE ON GPS INSTALLATIONS ..................................................... 5-1
CHAPTER 6. THEORY OF OPERATION ............................................................................................................... 6-1
NAV BOARD THEORY OF OPERATION ............................................................................................................. 6-1
COMM THEORY OF OPERATION ....................................................................................................................... 6-5
CHAPTER 7. RETURN TO SERVICE PROCEDURES ............................................................................................. 7-1
INTRODUCTION ................................................................................................................................................ 7-1
FINAL TEST/INSPECTION ................................................................................................................................. 7-4
SETUP REQUIREMENTS .................................................................................................................................... 7-4
COMMON TESTS (ALL UNITS) ......................................................................................................................... 7-7
NAV RETURN TO SERVICE PROCEDURES ........................................................................................................ 7-8
COMM RETURN TO SERVICE PROCEDURE ...................................................................................................... 7-15
COMM TEST PROCEDURES............................................................................................................................. 7-25
FINAL UNIT CHECKOUT ................................................................................................................................. 7-55
CHAPTER 8. REPLACEMENT PROCEDURES ....................................................................................................... 8-1
PURPOSE.......................................................................................................................................................... 8-1
BOARD LOCATIONS ......................................................................................................................................... 8-1
CHASSIS COVER REPLACEMENT ...................................................................................................................... 8-4
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BATTERY REPLACEMENT .................................................................................................................................8-5

BEZEL ASSEMBLY REPLACEMENT ....................................................................................................................8-6
CHASSIS REPLACEMENT ...................................................................................................................................8-8
GX60/65 COMM BOARD FUSE REPLACEMENT .................................................................................................8-9
GX60/65 COMM BOARD REPLACEMENT ........................................................................................................8-10
GX50 AND GX55 GPS BOARD REPLACEMENT ..............................................................................................8-14
GX60 & GX65 GPS BOARD REPLACEMENT ..................................................................................................8-15
KEYPAD REPLACEMENT .................................................................................................................................8-16
KNOB REPLACEMENT .....................................................................................................................................8-17
LENS REPLACEMENT ......................................................................................................................................8-18
NAV BOARD FUSE REPLACEMENT ................................................................................................................8-19
NAV BOARD REPLACEMENT .........................................................................................................................8-20
SMART KEY REPLACEMENT ...........................................................................................................................8-21
NAV BOARD SOFTWARE UPGRADE ...............................................................................................................8-22
COMM BOARD SOFTWARE UPGRADE .............................................................................................................8-24
COMPLETE INITIALIZATION ............................................................................................................................8-25
CHAPTER 9. TROUBLESHOOTING ...................................................................................................................... 9-1
PRELIMINARY DATA.........................................................................................................................................9-1
ERROR MESSAGES ............................................................................................................................................9-1
SYMPTOMS .......................................................................................................................................................9-3
EEPROM DATA...............................................................................................................................................9-7
CHAPTER 10. DRAWINGS ................................................................................................................................. 10-1
COMPONENT LAYOUTS ..................................................................................................................................10-1
BLOCK DIAGRAMS .........................................................................................................................................10-9
ASSEMBLY DRAWINGS .................................................................................................................................10-18
CHAPTER 11. PARTS LISTS .............................................................................................................................. 11-1
COMMON PARTS.............................................................................................................................................11-1
GX50 PARTS ..................................................................................................................................................11-2
GX55 PARTS ..................................................................................................................................................11-2
GX60 PARTS ..................................................................................................................................................11-3
GX65 PARTS ..................................................................................................................................................11-4
DATA CARDS..................................................................................................................................................11-5
MAINTENANCE SUPPLIES ...............................................................................................................................11-5
CHAPTER 12. REGULATORY DOCUMENTS ...................................................................................................... 12-1
CHAPTER 13. SERVICE DATA SHEET .............................................................................................................. 13-1
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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
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History of Revisions
July 1999 ....................................................................................................................... Original Release
January 2001 ........................................................................................................................... Revision A

This revision incorporates changes in drawings due to previous ENs. Refer to EN6010,
EN6125, EN6320, EN6393, and EN6432.
October 2004 ...........................................................................................................................Revision --

Changed UPSAT to Garmin AT. Also deleted three chapters to make more web
friendly.
© 2004 Garmin AT GX Service Manual vii

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This Page Intentionally Left Blank
viii GX Service Manual © 2004 Garmin AT

Chapter 1. Service Requirements
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.
Service Authorization and Audits

Only UPS Aviation Technologies authorized Level II service centers can service UPS Aviation
Technologies avionics equipment. A level II service center must meet the following requirements:
• FAA or local civil aviation authority repair station certification in the radio and/or navigation
category.
• Completion of factory sponsored Level II training or passing a written test.
• Possession of the most current version of the maintenance manual and/or applicable USP
Aviation Technologies service literature.
• Fulfillment of the minimum test equipment requirements as listed in the maintenance manual,
including provisions for static control (ESD).
Contact UPS Aviation Technologies for more information.
Updating Service Manuals

It is required that all service centers have the latest revision of the service manuals prior to performing
any maintenance. The manual document numbers and configurations are available via the Internet or
by calling UPS Aviation Technologies at the numbers given in the front of this manual.
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.
© 2004 Garmin AT GX Service Manual 1-1

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Sources for Soldering Standards

Electronic Industries Association
Engineering Dept.
2001 Pennsylvania Ave. N.W.
Washington, DC 20006
Also:
Global Engineering Documents
(800) 854-7179 (US & Canada)
(303) 397-7956 (International)
Institute for Interconnecting and Packing Electronic Circuits.
2125 Sanders Road
Northbrook, IL 60062
Tel (847) 509-9700
Fax (847) 509-9798
(www.ipc.org)
GPS Signal Source

A GPS signal source is required for Return to Service of the GPS Navigation units. See page 7-6.
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
Guide for using hand tools

1. Always use the appropriate size tool.
2. Exterior and interior screws should be tightened only with a torque screwdriver set to the
specified torque. Refer to the instruction manual supplied with the torque screwdriver. The correct
tightening torque is shown in each procedure.
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Guide for Using Fasteners

1. Make sure that you use the proper screw in each location. Note the difference between
countersunk and undercut screws. Use appropriate screws.
2. Be careful not to damage screws. Screws with damaged threads or stripped heads must be
discarded and replaced with the appropriate screws.

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Chapter 2. Introduction
This guide describes the maintenance of the Apollo GX line of products. The GX50 and GX55 are
GPS receivers. The GX60/65 models combine the GPS receiver with a VHF radio in a single
package.
The Apollo GX products are high-performance GPS products with a high-resolution moving map
display configured in a 2-inch high by 6.25-inch wide standard package. The Apollo GX’s use a
powerful, accurate 8-channel GPS engine designed specifically for high-performance aviation use.
The 160 by 80 pixel electroluminescent display uses an automatic intensity control to keep it easily
readable in all conditions from direct sunlight to the dark of night.
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.

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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.
Power/Volume/Squelch Knob (GX60/65)

The knob on the right side of the GX60/65 controls power on/off, volume, and squelch test. Rotate the
knob clockwise (CW) past the detent to turn the power on. Continue rotating the knob to the right to
increase speaker and headphone amplifier volume level. Rotate the knob to the left to reduce the
volume level. Pull the knob out to disable automatic squelch.
Small and Large Knobs

The dual concentric knobs on the right side of the front panel are used to select pages, edit
characters and values, or other options. The large knob moves the cursor and the small knob
changes characters. Either may change pages depending on the function.

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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.
NRST (Nearest Waypoint)

The Nearest Waypoint (Emergency) mode displays the closest waypoints to your position.
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.
MAP (Graphic Moving Map)

The MAP key starts the moving map function. The entire display is used as a graphic map display.
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.

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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.
FPL (Flight Plan)

The flight plan key takes you to the flight planning function where you can create, edit, and control
your flight plans.
SYS (System Mode)

Press the SYS key to reach the system mode functions. System mode is used to make system level
adjustments and modify navigation function displays.
SKIP (Start-Up Option)

Press the SKIP key during the start-up procedure to bypass the start-up tests. This is for
emergencies, as the IFR tests must be completed to allow IFR flight.
Map Function Smart Keys

The moving map function uses several “smart” keys to allow you to declutter the map, find waypoint
information, and setup your map information.
Map Waypoint Keys
APT, VOR, INT, NDB, & USR

The map waypoint “smart” keys are present when the Moving Map pages are displayed. Press the
“smart” key to control the display of the waypoint type. There are three selections possible: waypoint
identifier and location symbol, location symbol only, and off. Pressing the “smart” key subsequent
times will control which selection is made. Map waypoint choices are Airport (APT), VOR, NDB,
Intersection (INT), and User (USR).
A solid, reversed waypoint-type annunciator above the “smart” key means the waypoint identifier and
location symbol will both be displayed.
A bold outline of the waypoint type annunciator will show only a symbol on the waypoint location.
A thin outline around the waypoint type means that it is turned off and no information for that waypoint
type will be displayed on the map.
Waypoint LIST Key

Each press of this key scrolls through the available “smart” keys.
Waypoint SCAN Key

When the SCAN key is active (highlighted) in the moving map display, turning the large knob will
move between the nearest airports. You can then press INFO to view information about that airport.

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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.
Map Setup Keys

The Map Setup page displays three “smart” keys that provide a short cut for customizing your moving
map.
The Route Line “smart” key toggles between On and Off.
The Map Orientation “smart” key toggles between Desired Track (DTK), Track, and North.
The Map Reference “smart” key toggles between Plane and Destination (Dest) as the moving map
center point.
Communications Radio Mode Smart Keys - GX60/65

The Recall (RCL), Monitor (MON), Memorize (MEM), and Flip/Flop (↔) keys are available in the
GX60/65 after the COM soft key has been pressed.
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.
RCL (Recall) (GX60/65)

Press the RCL key to recall frequencies stored in the database.
MON (Monitor) (GX60/65)

Press the MON key to listen to the standby frequency. When the active frequency receives a signal,
the GX60 will automatically switch to the active frequency.
MEM (Memorize) (GX60/65)

Press the MEM key to store the current standby frequency.
XIT (Exit) (GX60/65)

The XIT key will appear on the far left of the display, in the MSG key position, if the COM key has
been pressed to allow use of the radio during startup testing. Press the XIT key to return to the start-
up sequence, or wait for test completion. The XIT key will disappear when testing is complete.

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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

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• Automatic waypoint sequencing

• Vectors to final input (GX50/60 only)
• DME arc assist
• Built-in simulator for trip planning and training
• User definable navigation pages with auto sequencing
• 30 reversible flight plans of up to 20 legs with automatic sequencing
• 500 user waypoints created by lat/lon or by radial/distance from a reference waypoint
• Real time clock (time and date) in UTC
• Countdown timer
• Flight timer
• Automatic or manual magnetic variation
• Parallel track offset
• Alerts for -
− Loss of navigation data
− Arrival at waypoint
− Special use airspace
• Full range (10 VDC to 40 VDC) input supply voltage
GPS Receiver Performance Specifications

• 8-channel parallel GPS receiver
− Frequency: 1575.42 MHz L1, C/A code
• Sensitivity (acquisition): -135 dBm
• Sensitivity (drop lock): -142 dBm
• Dynamic range: >20 dB
• Lat/Lon position accuracy
− 15 meters RMS accuracy
− 25 meters, SEP, without SA
− 100 meters 2 DRMS with SA
• Velocity: 999 knots maximum
− Acceleration: 4G maximum
• TTFF (time to first fix)
• 25 sec. (typical) with current almanac, position, time, and ephemeris
• 55 seconds typical with current almanac, position, & time
• Reacquisition: 2.5 seconds typical
• Position update interval: 1 second typical
• Datum: WGS-84

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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
GX50 and GX60/65 Avionics Outputs

• CDI L/R deviation ± 150 mV full scale
• TO/OFF/FROM flag ± 250 mV, TO/FROM indication
• Navigation valid flag +300 mV for valid indication
• Navigation superflag 400 mA source
• VDI up/down ± 150 mV
• VDI valid flag +300 mV
• VDI superflag 400 mA source
• Annunciators
− MSG (message)
− PTK (parallel track)
− OBS/HLD (waypoint sequencing hold) GX50/60 only
− APPRCH (approach enabled) GX50/ 60 only
− ACTIVE (approach active) GX50/60 only

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GX55 Avionics Outputs

• CDI L/R deviation ± 150 mV full scale
• TO/OFF/FROM flag ± 250 mV TO/FROM indication
• Navigation valid flag +300 mV for valid indication
• Annunciators
− MSG (message)
− PTK (parallel track)
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

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VHF Comm Features (GX60/65)

• 760 channels
• Frequency range of 118.000 to 136.975 MHz
• Active and standby frequency display
• Transmit status indicator
• Stuck mic time-out
• Frequency monitor function - listen to standby frequency while monitoring active frequency
for any activity
• Weather channels - National Weather Service channels
• Built-in intercom function
• Frequency memory and recall functions
− From navigation data base
− Ten last used
− Ten user stored
• Two microphone inputs
• 12 watt audio amplifier
VHF Comm Receiver Performance Specifications (GX60/65)

• Class D
• Frequency range - 118.000 to 136.975 MHz, 760 channels
• Sensitivity
− 1 microvolt (2 microvolt hard) for 6 dB S+N/N
− 30% modulation at 1000 Hz
• Selectivity
− <6 dB variation at ± 22 kHz
• Speaker audio output level
− 12 watts into 4 ohms, 8 watts into 8 ohms
• Headphone audio output level
− 280 mW into 100 ohms, 120 mW into 500 ohms
• Distortion - <5% at rated output at 1000 Hz
• AGC characteristics
− <3 dB variation in audio output from 5 to 100 mV input
− 15% to 90% modulation
• Squelch control - automatic with manual override

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VHF Comm Transceiver Performance Specifications (GX60/65)

• Class 4
• Output power
− 8 watts minimum carrier at >12 VDC
− 6 watts minimum at 10 VDC (transmit is locked out below 9 VDC input)
• Modulation capability
− 85% with 100 mv to 1000 mv rms microphone input at 1000 Hz
• Duty cycle 100%
• Stuck mic time out
− 35-second time-out, reverts to receive
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.

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Chapter 3. Installation Manuals
Please refer to the Dealer’s Only website at http://www.garmin.com to download the latest installation
manuals.

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Chapter 4. Antenna Installation Guides

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Chapter 5. Aircraft Installation Troubleshooting
Reducing the effects of VHF Interference on GPS Installations
Why do we test for VHF interference?

Checking for VHF harmonic interference is a requirement called out in the FAA Advisory Circular AC
20-138. The Advisory Circular requires VHF interference checks along with other requirements
needed to gain approval. The GPS signals are transmitted from satellites that are in orbit 10,000
miles above the earth. By the time these signals reach the earth they are weak, buried in noise, and
easily swamped by an interference source. As GPS receivers are susceptible to VHF harmonics and
other interference on the L1 GPS frequency, all GPS receivers approved for use in instrument
conditions must have the VHF interference tests performed.
There are new FAA changes to AC 20-138 that will expose more VHF interference problems than you
have experienced in the past. These changes will require the shops to test each interfering frequency
for a period of 45 seconds. The current requirement calls for a 20-second transmit test. The changes
are intended to identify all interference sources to insure reliable GPS performance in IFR conditions.
Some GPS manufactures have masked VHF interference problems through software techniques like
coasting, and not warning the pilot during temporary signal outages. Coasting is a method for dealing
with momentary outages, but the TSO also requires the GPS receiver to warn pilots within 10
seconds of a signal loss during approach operations. All UPS Aviation Technologies GPS products
will warn the pilot within 10 seconds per the TSO requirements. It is important to isolate potential VHF
interference sources, and eliminate them.
The Advisory Circular states, “Remove any source of VHF interference from the aircraft.” We have
listed some steps that can be taken to reduce the effects of interference. The intent here is to save
you time and money on GPS installations. The following provides some practical steps to help you
identify and minimize GPS interference sources on board aircraft.
What can we do to minimize VHF interference?

Perform a pre-installation check to determine if there is going to be a problem with VHF interference.
Ninety percent of the time when our tech support phone rings with one of these VHF problems, we
hear, “The equipment is installed, antenna bolted down. I’ve tried everything. Can you help?” We
recommend that you perform a pre-installation checkout that will help determine if there is a VHF
interference problem.
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

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also include extra time in installation quotes to allow time to identify and isolate the interference
source(s).
What are the sources of VHF interference?

The main sources of VHF interference fall into one of the categories listed below.
th th
1. VHF harmonic interference broadcast on the 12 and/or 13 harmonic of the fundamental VHF
frequency by Comm and NAV/Comm transceivers.
2. A clean VHF signal can produce interference when it is picked up by an ELT antenna. Non-linear
components in the ELT antenna generate interfering harmonics which are re-broadcast and
interfere with the GPS.
3. A clean VHF signal can produce interference when it is picked up by a direction finding antenna
(used mainly in search and rescue aircraft). Non-linear components in the antenna system or
front end generate harmonics which are re-radiated from the direction finding antenna.
4. VHF harmonic interference emitted from the NAV/Comm radio case and front panel.
5. Inter-coupling between multiple Comms and NAV/Comms. Usually, both Comm antennas are
mounted on the top side in close proximity. In these cases, we’ve seen the Comm 1 transmitter
couple to the Comm 2 receiver or vice versa causing the re-broadcast of L1 interference through
the case and display of Comm 2. For example, let’s say a GPS/Comm is designated as Comm 1
and a NAV/Comm is designated as Comm 2. When the Comm 1 transmitter is keyed on one of
the interfering VHF frequencies, the RF transmit energy is coupled to the Comm 2 receiver and
interference on the L1 GPS frequency can be re-emitted from the case and display of Comm 2.
More than one of these VHF interference problems can occur on the same aircraft at the same time.
The real problem is being able to identify and isolate the interference.
Isolating the sources of VHF Interference

The following steps are to be taken only if you have verified L1 interference during the pre-installation
checkout. Install the GPS unit in the panel according to the manufacturer’s instructions. Run the
antenna coax (RG-142B) and leave some extra lead length, but do no mount the antenna. We
suggest you make up a test coax harness for use during GPS installations. Using the test coax
harness, connect it to the GPS antenna on top as close to the desired location as possible.
Remove Comm 2 and the ELT from the aircraft. Test Comm 1 on all the known interfering
frequencies listed in the AC or the Apollo Installation manual.
If there is GPS signal degradation, re-test Comm 1 on a dummy load to determine if the VHF
harmonic interference is being transmitted out the antenna or radiated from the NAV/Comm unit. If
the VHF interference occurs only during transmitting, install a GPS notch filter in line with the
th
antenna. The GPS notch filters will attenuate the interference by 40 dB, which will suppress the 12
th
and 13 harmonic interference.
If the problem exists only under dummy load, then the interference is radiating from the case and
front panel of Comm 2. Try to re-position the GPS antenna to minimize the effects of the interference.
Additional shielding around the case of the NAV/Comm has been effective in suppressing
interference. Wrap the entire unit in aluminum foil for testing. A metal case with appropriate grounding
may be needed as a permanent fix.
We have experienced interference on a number of installations involving an existing GPS receiver.
Try installing GPS filters and/or appropriate metal shielding, such as 0.020" aluminum, around the
case to suppress the L1 interference. The L1 interference on the GPS receiver emits from the sheet
metal seams in the case. It is important to completely enclose the GPS receiver chassis in
appropriate metal shielding. We have also seen some extreme cases where the interference emits
from the front panel and display area of the GPS receiver. Re-positioning the antenna can usually
correct the problem. If not contact the manufacturer of the GPS receiver for additional help. It’s

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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.

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Chapter 6. Theory of Operation
Apollo GX50/55/60/65 Description
The Apollo GX50 GPS is a TSO-C129a, Class A1 GPS navigation receiver for IFR en route, terminal,
and non-precision approach operation.
The Apollo GX55 GPS is TSO-C129 en route and terminal approved navigation receiver and is a pin
compatible slide in replacement for Apollo panel mounted LORANs and FlyBuddy GPS models.
The Apollo GX60 GPS/Comm includes the same GPS capabilities as the GX50 and includes a 760
channel VHF Comm transceiver.
The Apollo GX65 includes the same GPS and Comm capabilities as the GX 60, but is TSO-C129a,
Class A2 certified (not for non-precision approach operation).
These units all feature a high-resolution, daylight readable graphics display moving map. A database
is provided by means of a plug-in PCMCIA data card for convenience in changing and updating the
database.
NAV Board Theory of Operation

The navigation functions of the GX series GPS receivers are provided by the navigation computer
board (NAV board) which directly interfaces with an 8-channel GPS receiver module designed
specifically for high performance aviation use. The GPS receiver module provides present position
(latitude and longitude) date, time, RAIM and miscellaneous other satellite data to the NAV board.
The NAV board provides navigation functions between waypoints, such as bearing, range, estimated
time en route, estimated time of arrival, ground speed, course deviation, track angle and desired
track.
The plug-in database provides detailed information about airports, SUA, VORs, NDBs, and
intersections. The NAV board permits storage of user defined waypoints.
The navigation function is always active. When other functions are used (except in Test Mode and
Simulator Mode), the navigation function continues to run in the background.
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)

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• Parallel I/O ports

• Watchdog Timer Unit (WDT)
• JTAG test-logic unit
The two serial I/O ports on the microprocessor connect directly to the GPS receiver (J1) and the
communication Comm board (J4) and are used for direct control and exchange of data between the
CPU and these devices.
The configuration jumper (J2) currently has only one function. The built-in test mode can be accessed
by shorting pins 7 and 8 together, then turning on the GX unit. The built-in test mode can also be
accessed by turning the unit on while depressing the two outermost smart keys, or by issuing a
command by PC through the serial port.
Reset/Watchdog/Battery Backup Circuit

The Maxim Max690A microprocessor supervisory IC (U1) provides a reset output (pin 7) during
power-up, power-down, or during failing power conditions. Additionally, a reset pulse is output (pin 7)
if the watchdog timer input (pin 6) has not been toggled within the specified time period (1-2.25 sec.).
The Max690A also provides Vcc to battery switchover (Vout pin 1) for SRAM backup power when the
GX unit is turned off. Backup power is supplied by a 3 V lithium backup battery.
Memory
Flash Code ROM

The NAV board is designed to accept 2 MBIT (128K x 16), 4 MBIT (256K x 16), or 8 MBIT (512K x
16) flash memories in the standard 48 pin TSOP package. There are two sites on the board (U102 &
U103) that can allow code flash memory in the range of 2 MBIT to 16 MBIT depending on the parts
populated.
The board design allows the use of Intel or AMD flash memories. Software routines are required for
programming the flash memories on the board, and both the Intel and AMD parts are supported. The
flash memories include device and manufacturer codes that can be read. Therefore, the software can
determine the device types and execute the appropriate programming algorithms.
The flash memories are soldered directly to the board; they are not placed in sockets. The flash must
be programmed in-circuit. The 386EX and the on-board hardware supports utilizing the JTAG port for
initial flash programming. The parts are programmed with +5 volts, so a +12 volt power supply is not
required.
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.

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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.
SRAM Configuration Jumpers

SRAMs Configuration R101 R102 R103 R104
1 128K x 8 X X
2 128K x 16 X X
X – indicates installed 0 ohm resistor jumpers
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.
PCMCIA Data Card Interface

All GX models utilize a Flybrary database stored on a standard plug-in PCMCIA FLASH memory card
for easy updating and replacement. Simply plug in the new datacard to update your existing database
or change to a new database.
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

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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.
Dual Uart Serial Interface

The GX50/60/65 includes two RS-232 serial ports for making optional connections. The serial ports
can be used for connecting to such devices as the Apollo SL40 communication, a moving map
display, or an altitude encoder/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.
Front Panel E.L. Graphics Display

The display assembly (UPS Aviation Technologies part no. 145-2341-00) is a custom front panel
consisting of an electroluminescent panel producing an emissive amber display. The EL Display is
mounted on an application specific secondary circuit board containing the display controller, power
supply, dual rotary encoder, volume/power knob, carbon ink contact pad patterns for the 7 push
buttons, 7 LEDs, one photocell and one thermistor.
The display is a 100 fL areal brightness (at 360 Hz) electroluminescent flat panel with a dot pitch of
0.40 mm (64 DPI), a display matrix of 160 by 80 addressable pixels and a pixel aspect ratio of 1:1
(V:H). The assembly includes the DC-DC converter necessary to generate the special voltages used
by an EL display, and includes an 8-bit wide microprocessor interface.
A photocell located in the top left corner of the front panel automatically controls the light intensity of
the display according to ambient light conditions.
The NAV board power supply provides +12.5 VDC to the display assembly DC-DC converter (P202
Pin 1) and +5 VDC to the display assembly digital logic (P202 pin 5).
Service and troubleshooting of the display assembly are limited to whole unit replacement.

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Comm Theory of Operation
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.

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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).

Chapter 7. Return to Service Procedures
Introduction
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
Acronyms and Definitions

Acronym Definition
A Amperes (amps)
AC Alternating Current
A/D analog to digital converter
AF Audio Frequency
AFGen Audio Frequency Generator
AM Amplitude Modulation
ANT antenna
APPR approach
BNC a common RF connector that has a quick bayonet mount
BPF bandpass filter
C Celsius (temperature)
CAL calibration
CDI Course Deviation Indicator
Coax coaxial cable
COMM, or Comm communication
CONFIG configuration
D/A digital to analog converter
dB decibel (a logarithmic expression of ratios)

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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

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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

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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.

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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.

Garmin AT Rev --
Power
Power Supply (HP6038A or equivalent)

Set the DC supply voltage to 13.8 V ± 5%. Any other power supply voltage within the normal
operating range of the unit (10-40 V) may be substituted. Do not exceed 40 V. Set the current limit to
3.2 amps.
Environmental
All tests shall be conducted on the test bench with an ambient temperature of 50° to 90° F unless
specified otherwise.
Reference GPS Unit

The GPS performance verification utilizes a known reference GPS for comparison. The reference unit
for verifying the GPS sensor performance may be any UPS Aviation Technologies unit with an
equivalent Motorola sensor board. The reference GPS unit must be verified using the calibration
procedure defined in PD0944 or an equivalent procedure.
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.
GPS Signal Source

The signal source for testing the performance of the GPS unit-under-test shall be equivalent to the
source used for the reference GPS unit. This may be an equivalent antenna system or a connection
to a signal distribution system (amplifier/splitter) that is shared with the reference unit.
Equivalent antenna systems and their cables shall be matched within 1 dB of each other.
Each output of an amplifier/splitter shall be matched within 1 dB.
NAV Computer Test Mode

A number of the GX NAV tests are conducted using the built-in test mode. To access the built-in test
mode, switch the unit on while holding down the left- and right-most smart key buttons.
Note: Placing a jumper between pins 7 and 8 of J2 on the NAV board, and then turning the unit on
may also access the test mode.

Garmin AT Rev --
Common Tests (All Units)
1. Display
Specification: Verify that the display operates correctly.
Notes: Use the Display Test function in the built-in test mode.
2. Display Brightness Control

Specification: Verify that the display intensity dims when the photocell is covered, and returns
to bright when uncovered.
3. Front Panel Controls

Specification: Verify all front panel buttons and rotary controls work properly.
Notes: Use the Controls 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.

Garmin AT Rev --
NAV Return to Service Procedures

These functions are all accessed in the Test Mode, which is described in the preceding paragraph.
Preliminary Setup for the Following Tests:

If the TST 10 test station is being used, connect the unit under test to the test station in accordance
with the TST-10 User’s Manual, 560-0399-00. If the test station is not being used, follow the
connection instruction in each test step.
Connect the test station to the power supply. Power the test station on.
Power the unit under test on in the test mode by pressing the outermost smart keys while turning
power on.
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.
System Initialization Functions

Reset Description Service Comment
Function
All Resets NVRAM, EEPROM, and No
PLANS/WPTS to default values.
USER Resets all system variables to default values. Yes
NVRAM See Note 1
EEPROM Resets all user EEPROM configuration data No
to default values (not user info). See Note 2
PLANS/WPTS Clears all user flight plans and waypoints. No
See Note 2
Notes: 1. Reset USER NVRAM if the navigation software is upgraded. Otherwise, it
shouldn’t be necessary.
2. Reset EEPROM and PLANS/WPTS only if desired to reset all to default values
or otherwise specified by engineering.

Garmin AT Rev --
2. Seed Position, Time, and Date

Specification: The GX includes a real time clock (RTC) for time and date information that must
be set after the system initialization. The seed time/date are required for
initialization of position sensors.
Operation: During the normal operation startup sequence, enter the current date, time and
seed position on the Date/Time page, or go to the Date/Time page in system
mode and enter the current time, date, and seed position. Refer to the user’s
manual or installation manual.
Notes: The GPS sensor requires the time, date, and position for proper startup. The
position can be selected from the database.
NAV Test Procedures
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.

Garmin AT Rev --
2. VDI Output (Not present on GX55/65)

Description: The VDI 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 VDI (or equivalent
meter) to the Up/Down outputs.
Operation: Select the VDI down, mid, and up outputs using the VDI Output page in test
mode.
Verification: Verify the up/down indication as follows:
Down: meter full down
Mid: meter centered
Up: meter full up
Alternate: Connect the unit to nominal input supply voltage. Connect a 200 ohm load
between the VDI+ Up and VDI+ Down outputs.
Verification: Verify the differential output voltage between the VDI+ Up and VDI+ Down
outputs as follows:
Down: -150 mV ± 4 mVDC
Mid: 0 mV ± 2.0 mVDC
Up: +150 mV ± 4 mVDC
Verify the VDI+ Down output to ground is 2.05 volts ± 0.1 VDC.
3. TO/FROM Flag Output

Description: The TO/FROM flag 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 with TO/FROM
flag (or equivalent meter) to the TO/FROM outputs.
Operation: Select the Off, To, and From outputs using the To/From Flag page in test mode.
Verification: Verify the TO/FROM indication as follows:
Off: Off indication
TO: TO indication
FROM: FROM indication
between the To + and From + outputs.
Verification: Verify the differential output voltage between the TO and FROM outputs as
follows:
Off: 0 mV ± 5 mVDC
TO: +250 mV ± 15 mVDC
FROM: -250 mV ± 15 mVDC
Verify the FROM+ output to ground is 2.05 volts ± 0.1 VDC.

Garmin AT Rev --
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
5. Hold Input (Not present on GX55/65)

Description: The waypoint sequencing hold input is a discrete input intended for connection to
a momentary button to aircraft ground.
Setup: If the TST-10 test station is not available, connect the unit to nominal input supply
and connect a momentary switch from the Hold input to ground.
Operation: Using the Lamp Outputs page in test mode, rotate the small knob to select the
Push WPT SEQ To Toggle OBS/HLD page. Press the Wpt Seq momentary
switch several times.
Verification: Verify the OBS/HLD annunciator and the GX display change when pressing the
momentary switch.

Garmin AT Rev --
6. Sim Mode Input

Description: The Sim Mode input is a discrete input intended for connection to a normally
closed momentary button to aircraft ground.
and connect a normally closed momentary switch from the Hold input to ground.
A normally closed switch is required because when the pin is grounded, the unit
should come up in the normal mode. When the pin is ungrounded, or open, the
unit should come up in the Sim mode.
Operation: Hold the Sim Mode switch on (electrically open) while turning on power to the
radio, then release the switch.
Verification: Verify that the unit comes on in the Sim Mode when holding the momentary
switch and turning power on.
7. Super Flag Outputs (Not present on GX55/65)

Description: The GX includes two high-level superflag outputs - NAV superflag and VDI
superflag. These outputs are open collector outputs capable of sourcing 400 mA
from the aircraft supply voltage (Vac) input supply. A valid condition is indicated
by the output source to the input supply.
Setup: If the TST-10 test station is not available, connect the superflag outputs to
incandescent lamps, other side of lamps to ground.
Operation: Using the Valid Flag Pages page in test mode, rotate the small knob to select the
two superflag outputs, each flagged and not flagged.
Verification: Verify that the lamps connected turn on and off as indicated on the GX display.
The lamps should be off for flagged and on for not flagged.
Alternate: Connect the unit to nominal input supply voltage. Connect a 400 mA load
between each of the superflag outputs and ground. (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 two superflag outputs as follows:
Off (Flagged): 0 volts ± 0.2 VDC
On (Not flagged): Vac - 2.8 VDC min

Garmin AT Rev --
8. Valid Flag Outputs

Description: The GX50/60 includes two low-level valid flag outputs - NAV valid and VDI valid.
The GX55/65 includes one low-level valid flag output - NAV valid. These are
differential outputs intended for driving a meter movement with a maximum load
of 200 ohms.
Setup: If the TST-10 test station is not available, connect standard NAV and VDI valid
flags (or equivalent meters) to the valid flag outputs.
Operation: Using the Valid Flag Pages page in test mode, rotate the small knob to select the
two valid flag outputs, each flagged and not flagged.
Verification: Verify indication as follows:
Flagged: Flagged indication
Not flagged: Valid indication
between each of the low-level valid flag outputs to ground.
Verification: Verify the differential output voltage between the NAV+ Valid and NAV/VDI Valid
flag ground and VDI+ Valid and NAV/VDI Valid flag ground outputs as follows:
Off (Flagged): 0 mV ± 5 mVDC
On (Not flagged): +290 mV ± 15 mVDC
9. Serial Ports
Description: The GX50/60 includes two serial ports. The GX55/65 includes one serial port.
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
10. GPS Antenna Voltage

Description: The GPS antenna is an active device receiving power from the GPS receiver
PCB.
Setup: If the TST-10 test station is not available, connect a 100 ohm load to the GPS
BNC connector at the back of the GX unit.
Operation: With power to the unit on, measure the voltages at the GPS antenna BNC
connector on the back of the unit.
Verification: Verify that the output voltage at the rear GPS BNC connector, with a 100 ohm
load connected to ground, is >4.6 VDC.

Garmin AT Rev --
11. GPS Performance

Setup: Connect the unit under test and the UPS Aviation Technologies-certified
reference unit to an antenna or signal source as defined in the GPS Signal
Source section on page 7-6.
Note
This test requires that the seed position, time, and date have been correctly set.
Refer to the System Initialization and Seed Position, Time and Date paragraphs
on page 7-8 and 7-9.
Operation: Turn on power to the GX unit and monitor the GPS status/position pages to
determine time to first fix. Check the lat/lon position accuracy by comparison to
the UPS Aviation Technologies-certified reference unit. Compare the signal
levels of matching satellites to the reference unit. After the unit has acquired the
satellites, the GPS Sensor pages will be updated.
Verification: Verify that the acquisition time is less than 2 minutes.
Verify that the position is within 0.05 NM of the reference unit.
Verify that the signal levels of the unit under test for the same PRN as the
reference unit are similar (normalized reference unit signal level, ± 13) compared
to the normalized signal levels of the reference unit.
Verify elevation and azimuth on the unit under test agrees with the reference to
ensure that the almanac is updated.
Verify that the signal level for each tracked satellite is equal to or greater than the
normalized signal levels of the reference unit.
Verify navigation by entering a direct-to waypoint on both the test and reference
units and seeing that the bearing and range to the selected waypoint matches
the reference unit.
Notes: This test requires that the seed position is set to within 60 NM of the source, and
time and date have been set to within 5 minutes of the source. The specification
allows for a ± 5% tolerance margin between the normalized reference unit and
the unit under test. The acquisition time may take longer than two minutes if the
GPS receiver does not have current almanac data. If this is the case, after the
unit has acquired current almanac data, it may take up to 25 minutes to acquire a
complete almanac once the receiver has started tracking a satellite. The
acquisition time should be re-verified to meet the two-minute specification.
12. Equipment Marking

Description: The configuration and marking for the GX unit is defined on the unit configuration
drawing and the unit assembly drawing. The versions of all assemblies must be
valid as described on the drawings.
Setup: N/A
Operation: Using the current unit configuration drawing, check the hardware configuration
and the equipment marking (UC tag).
Verification: Verify the hardware/software configuration is valid and the UC tag marking is
correct. Verify that labels are installed as defined on the unit assembly drawing.

Garmin AT Rev --
Comm Return to Service Procedure
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.
Using the HP8920 Communications Test Set

Test set screens are accessed through the front panel CURSOR CONTROL knob. Turning the knob
clockwise or counterclockwise moves the cursor between fields and screens. Pushing the CURSOR
CONTROL knob selects either the field or screen.
Units of measure can be changed to display different measurements in different values or
magnitudes. To change a unit of measurement, position the cursor at the unit field on the display,
press a key labeled with the desired unit of measurement (such as W for watts). If the new units are
valid, the measurement value displays in those units.
To change an underlined entry, use the CURSOR CONTROL knob or the ENTER key to move the
underline to the desired choice.
To make a choice, position the CURSOR CONTROL knob at the field you wish to choose. Push the
CURSOR CONTROL knob or the ENTER key to display the choices. Move the cursor control through
the choices by turning the knob. Push the CURSOR CONTROL knob or the ENTER key to select the
choice.
To change a value, position the cursor at the desired field and key in the value using the DATA
keypad and press Enter or the CURSOR CONTROL knob. The CURSOR CONTROL knob can also
be pushed and rotated to the desired value.
HP8920 Operating Considerations – Measurement Techniques

Applying power to the RF In/Out connector increases the temperature of the internal circuits. This
causes changes in the TX Power measurement especially when measuring low power levels
immediately after high power level measurements. To obtain the best measurement accuracy when
alternately measuring high and low power levels, always zero the power meter immediately before
making low power measurements.
All RF voltages are specified in hard microvolts. Hard microvolts are obtained by inserting a 6 dB (50
ohm) attenuator between the signal generator and the receiver. To obtain hard microvolts when using
the HP8920, use the SHIFT CONFIG keys. Then use the CURSOR CONTROL knob to select RFGen
volts. Push to select EMF. Press PREV in the SCREEN CONTROL menu to return to TX TEST.

Garmin AT Rev --
Performance Specifications
Transmitter Performance Specifications

Parameter Specification
Class D
Output Power 8 W minimum carrier at > 12 VDC in 6 W minimum carrier at 10 VDC
in. Transmit is locked out below 9 VDC input (no modulation).
Frequency range 118.000 MHz to 136.975 MHz, 760 channels
Frequency tolerance ±15 PPM from -20° C to +70° C
Microphone input Two inputs: standard carbon or dynamic MIC with integrated pre-amp
providing minimum of 70 mV RMS into 1000 Ω load.
Modulation capability 1. 85% with 1000 Hz at 100 mV to 1000 mV RMS microphone input
Audio frequency distortion <10% at 85% modulation at 350 Hz to 2500 Hz
Audio frequency response <4 dB variation with 350 Hz to 2500 Hz, 85% modulation
Carrier noise >35 dB down
Sidetone output Up to 280 mW into 100 Ω load, 120 mW into 500 Ω load
Duty cycle 100%
Stuck mic time-out 35 seconds, reverts to receive
Transmit key Input pull low to enable transmitter
Receiver Performance Specifications

Parameter Specification
Frequency range 118.000 MHz to 136.975 MHz, 760 channels
Sensitivity 1 µV (2 µV hard) for 6 dB SINAD with 30% modulation at 1000 Hz
Selectivity <6 dB variation at ±7 kHz, > 60 dB at ± 22 kHz
Speaker audio output level 12 watts into 4 Ω, 8 watts into 8 Ω
Headphone audio output 2. 280 mW into 100 Ω,120 mW into 500 Ω
level
Distortion <5% at rated output at 1000 Hz
AGC characteristics < dB variation in audio output from 5 µV to 100 mV input 15% to 90%
modulation
Squelch control Automatic squelch with manual override

Garmin AT Rev --
Test Equipment Setup
Installing the SL Display on the GX Unit for Comm Testing

An SL display assembly must be temporarily installed on a GX60 or GX65 for test purposes only.
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).

Garmin AT Rev --
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.
Transmit Presets for HP8920

1. Press PRESET on the HP8920:
2. Press the TX function key from the SCREEN CONTROL.
3. Using the CURSOR CONTROL knob and the DATA keypad set:
TX TEST screen
Tune Mode AUTO MANUAL

Tune Freq 127.5 MHz
TX Pwr Zero Zero
Input Port RF IN/ANT
IF Filter 15 kHz
Ext TX Key On/off
AF Anl In AM Demod
Filter1 50 Hz HPF
Filter2 15 kHz LPF
De-EMPHASIS Off
Detector Pk ± 2
AF GEN1 Freq 1 kHz
AF GEN LVL 100 mV
TX Freq Error PPM
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.

Garmin AT Rev --
HP8920 Receiver Presets

1. Press the RX function key.
2. Press PRESET on the HP8920.
3. Using the CURSOR CONTROL knob and the DATA keypad set:
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
Comm Transceiver Set up
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.

Garmin AT Rev --
Comm Software System Functions

The following software functions are available in the normal operating mode and are provided here as
information to assist in isolating problems:
Comm Software Version 1.X Comm Software Version 2.X

Software version display Software version display
Signal strength display Signal strength display
Audio noise level display Audio noise level display
Headphone level display and adjustment Microphone 1 VOX
Microphone 2 VOX
Intercom squelch threshold display and Microphone transmit inhibit
adjustment
Intercom audio level display and adjustment Intercom level adjust display and adjustment
Sidetone audio level display and adjustment Sidetone audio level display and adjustment
Base station lockout mode display and Low display light level adjustment limit
adjustment
Hi display light level adjustment limit
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.
System Functions for Software Version 1.X:
Software Version Display

This function displays the COM software version.
SW VER 1.X
Signal Strength Display

This function is used to display the signal strength of received signals.
RFLVL 087
Full transceiver functions are operational during this function, including transmit.
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.
Audio Noise Level Display

This function is used to display the noise level of the received audio.
NOISE 005

Garmin AT Rev --
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.
Headphone Level Display and Adjustment

This function is used to display and adjust the headphone audio level. Turning the small knob
changes the value. Setting the value to 0 slaves the headphone audio level to the volume control
knob. Setting to a non-zero value gives a fixed headphone audio level.
HphLv 015
Note: The headphone level is an 8-bit value with a range of 0 to 255.
Intercom Squelch Threshold Display and Adjustment

This function is used to display and adjust the intercom squelch threshold level. Turning the small
knob changes the threshold.
IcmSq 200
Note: The intercom squelch threshold level is an 8-bit value with a range of 0 to 255.
Intercom Audio Level Display and Adjustment

This function is used to display and adjust the intercom audio level. Turning the small knob
changes the value. Setting the value to 0 slaves the intercom level to the volume control knob.
Setting to a non-zero value gives a fixed intercom audio level.
IcmLv 000
Note: The intercom level is an 8-bit value with a range of 0 to 255.
Sidetone Level Display and Adjustment

This function is used to display and adjust the sidetone audio level. Turning the small knob
changes the value. Setting the value to 0 slaves the sidetone audio level to the volume control
knob. Setting to a non-zero value gives a fixed sidetone audio level.
SidLv 000
Note: The sidetone level is an 8-bit value with a range of 0 to 255.

Garmin AT Rev --
Base Station Lockout Mode Display and Adjustment

This function is used to display and adjust the lockout mode. Improperly set, the lockout can
disable various Comm functions giving the appearance of a malfunctioning unit. Turning the small
knob changes the mode. The modes are summarized as follows.
Locks 000
• Mode 0: Normal pilot mode, no disabled functions

• Mode 1 & 3: Toggle lock, only the Flip/Flop (NRST) button is disabled
Fixed Primary frequency
Variable standby frequency
Frequencies cannot be swapped
• Mode 2 & 6: Primary frequency protected
Fixed primary frequency
Variable standby frequency
Frequencies can be swapped
Primary is not modifiable when it is the standby frequency
(displayed as Mode 6)
• Mode 4: Fixed two-channel radio
Both frequencies are fixed
Frequencies CAN be swapped
• Mode 5 & 7: Toggle lock w/ fixed standby frequency
Both frequencies are fixed
Frequencies CANNOT be swapped
Note that it is possible to put the unit into mode 8, but on re-entry to the system functions, it will
show mode 0.
Note: The lockout mode has a range of 000 to 008.
System Functions for Software Version 2.X:
Software Version Display

This function displays the COM software version.
SW VER 2.X
Signal Strength Display

This function is used to display the signal strength of received signals.
RFLVL 087

Garmin AT Rev --
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.
Audio Noise Level Display

This function is used to display the noise level of the received audio.
NOISE 005
Note: The noise level is an 8-bit value with a range of 0 to 255 from the noise level detector as
Headphone Level Display and Adjustment

This function is used to display and adjust the headphone audio level. Turning the small knob
changes the value. Setting the value to 0 slaves the headphone audio level to the volume control
knob. Setting to a non-zero value gives a fixed headphone audio level.
HphLv 015
Note: The headphone level is an 8-bit value with a range of 0 to 255.
Microphone 1 Squelch (VOX)

This function is used to display the input level required to break squelch by microphone1.
Mic1 Sqlch 005
Note: The VOX level is an 8-bit value with a range of 0 to 127 from the noise level detector as
Microphone 2 Squelch (VOX)

This function is used to display the input level required to break squelch by microphone2.
Mic2 Sqlch 005
Note: The VOX level is an 8-bit value with a range of 0 to 127 from the noise level detector as
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.
Intercom Audio Level Display and Adjustment

This function is used to display and adjust the intercom audio level. Turning the small knob
changes the value. Setting the value to 0 slaves the intercom level to the volume control knob.
Setting to a non-zero value gives a fixed intercom audio level.
IcmLv 000
Note: The intercom level is an 8-bit value with a range of 0 to 255.

Garmin AT Rev --
Sidetone Level Display and Adjustment

This function is used to display and adjust the sidetone audio level. Turning the small knob
changes the value. Setting the value to 0 slaves the sidetone audio level to the volume control
knob. Setting to a non-zero value gives a fixed sidetone audio level.
SidLv 000
Note: The sidetone level is an 8-bit value with a range of 0 to 255.
Low Display Light Level Adjustment Limit

This function controls the lower brightness level in the automatic adjustment range. This is the
brightness used when in total darkness.
Lo Dsp Lvl 00
Note: The light level is adjustable from 0 to 50.
High display light level adjustment limit

This function controls the lower brightness level in the automatic adjustment range. This is the
brightness used when in total darkness.
Hi Dsp Lvl 50
Note: The light level is adjustable from 0 to 50.
The automatic dimming function can be disabled by setting the high display level to 0. Then the
low level adjustment will set the brightness of the display directly with no automatic adjustment
made based on ambient light.

Garmin AT Rev --
Comm Test Procedures

Tests and procedures for troubleshooting a defective GX Comm board and returning it to service are
described in this section. The first section, a test data sheet, is presented in a generic format and lists
and summarizes the tests that are needed to return the unit to service. The second section describes
the return to service procedures specifically when using the HP8920 test set.
Test Data Sheet – Comm Return to Service
1. Display and Controls

Display and controls are accessed using the test mode. Test mode can also change calibration
functions stored during manufacture or service. Do not change or adjust any functions while in the
test mode unless specifically instructed to do so in this manual.
The SL display is used during display and control tests. The SL display can be connected
standalone. Refer to Test Equipment Setup on page 7-17 for details.
Test Mode Page

Enable the built-in test mode by pressing the NRST and SYS buttons on the SL display while
switching the unit on.
In test mode operation, the large knob is used to select the different test functions; the small knob
is used to select additional pages for each test function.
The Test Mode Page is the first page displayed in the test mode.
TEST MODE
When this page is displayed, pressing the MSG button will return the COM to normal mode
operation.
The large knob is not tested in this function. It is tested by default by selecting the various test
functions.
Display test function: _____ OK
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:
25°C + 4° -20°C + 4° +55°C + 4°
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.
3. 10.0 VDC (+/- 5%) Power supply:
118.00MHz ___ 6 watts min. 126.5MHz ____6 watts min. 135.97MHz ___ 6 watts min.

Garmin AT Rev --
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 Audio Level Adjustment:

1. Connect a 100 ohm resistor and AC power meter (or voltmeter) across the headphone
output.
2. Press and hold NAV button (about 3 seconds) until the SW VER X.X is displayed.
3. Rotate the large knob until SIDTONE LVL is displayed. Record reading in customer defaults
on the service data sheets.
4. Transmit with a standard modulator test signal injected into the microphone audio.
5. Turn up the sidetone level value (small knob right side) to make sure the output power can be
greater than 280 milliwatts (5.29Vrms across 100 ohms).
6. Adjust the sidetone level (small knob right side) to 28 milliwatts (1.67 Vrms across 100
ohms).
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.
6.3 volts +/- 0.4 V: ______ OK
Modulation Audio Frequency Response

This is an optional test not required for returning a unit to service
1. Inject a 20 mV 1 kHz audio signal into the MIC1 input
2. Key the transmitter and adjust the audio generator’s amplitude to obtain 85% carrier output.
3. Measure and record the audio frequency depth at 1 kHz.
4. Change the audio frequency input (MIC1) to 350 Hz.
5. Measure and record the AF Depth difference with respect to 1 kHz.
6. Change the audio frequency input (MIC1) to 2.5 kHz.
7. Measure and record the AF Depth difference with respect to 1 kHz.
350 Hz Depth: __________ LT 4dB 2.5 kHz Depth: __________ LT 4 dB
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.
Frequency tolerance: ______ NMT ± 15 PPM from -20° C to +70° C.

Garmin AT Rev --
Spurious Emission without Modulation

This is an optional test not required for returning a unit to service.
1. Key the transmitter on a clear channel near 127.5 MHz.
2. Observe the carrier output with a spectrum analyzer and record for reference.
nd
3. Measure power level at 2 harmonic (255 MHz).
rd
4. Measure the power level of the 3 harmonic (382 MHz).
th
5. Measure the power level of all harmonics up to the 10 harmonic.
Note: If the dynamic range of the spectrum analyzer is not great enough, insert a high pass filter
(188 MHz) between the transmitter and spectrum analyzer. Be sure to calibrate out the high pass
filter’s insertion loss.
Harmonic energy: ______ down at least 65 dBc
3. Receiver Tests
Headset Output Level

1. Inject a 1000 µV RF signal with 85% AM modulation into the Comm antenna port.
2. Channel the Comm to the same frequency as the signal generator.
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).
Headphone drive capable of 280 mW: _____ OK
Speaker Audio Level

1. Inject a 1000 µV RF signal with 85% AM modulation into the Comm antenna port.
3. Connect a 4 ohm resistor and AC power meter (or voltmeter) across the speaker output.
than 12 watts (6.93 Vrms volts across 4 ohms).
Speaker drive capable of 12 Watts: _____ OK

Garmin AT Rev --
Receiver Sensitivity and Squelch Threshold

1. Inject a 2 µV (-104 dBm) standard (1 k tone 30% modulated) test signal into the Comm
antenna port.
2. Open the Comm squelch by pulling the squelch knob out.
3. Measure SINAD on the speaker output with a 4 ohm load resistor.
4. SINAD should be greater than 6 dB.
SINAD: 118.000 MHz __________ NLT 6 dB
126.500 MHz __________ NLT 6 dB
135.950 MHz __________ NLT 6 dB
5. Vary the signal generator output power until 6 dB SINAD is obtained. Record this value below
(reference sensitivity).
Reference sensitivity: 118.000 MHz __________
126.500 MHz __________
135.950 MHz __________
6. Close squelch by pushing the squelch knob in.

7. Increase the signal generator signal level until the squelch opens.
Squelch sensitivity: 118.000 MHz __________ NLT 2µV (-104 dBm)
126.500 MHz __________ NLT 2µV (-104 dBm)
135.950 MHz __________ NLT 2µV (-104 dBm)

Garmin AT Rev --
Intercom/Monitor
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.
Speaker disabled with INT switch ON __________ OK
Headset operational with INT switch ON __________ OK
8. Move TEST/MIC1 switch to MIC1 on the TST-10.

9. Connect a test box to the headphone output line, adjust volume to a reasonable level, and
listen for the two tones. The low tone is from the radio receiver and the high tone is from the
intercom.
Intercom and receiver tones present __________ OK
Speaker Output Response

1. Inject a 1000 µV RF signal with 85% AM modulation at 1 kHz into the Comm antenna port.
than 12 watts (6.93 Vrms volts across 4 ohms). Record this level.
5. Change the modulation frequency to 350 Hz and record the output power at the speaker.
6. Change the modulation frequency to 2.5 kHz and record the output power at the speaker.
7. The audio power at 350 Hz or 2.5 kHz should not be down greater than 6 dB with respect to
the power at 1 kHz.
Audio response: 350 Hz = ___ NMT 6 dB 1KHz = ___ 0 dB 2.5 KHz = ___ NMT 6 dB

Garmin AT Rev --
Headset Output Response

than 280 milliwatts (5.92 Vrms across 100 ohms). Record this level.
5. Change the modulation frequency to 350 Hz and record the output power at the headset.
6. Change the modulation frequency to 2.5 kHz and record the output power at the headset.
7. The audio power at 350 Hz or 2.5 kHz should not be down greater than 6 dB with respect to
the power at 1 kHz.
Audio response: 350 Hz = ___ NMT 6 dB 1 kHz = ___ 0 dB 2.5 kHz = ___ NMT 6 dB
Headset Distortion
3. Connect a 100 ohm resistor and AC power meter (or voltmeter) across the headset output.
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
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%

Garmin AT Rev --
Receiver Dynamic Range

5. Open the Comm squelch by pulling the squelch knob out.
6. Measure SINAD on the speaker output with a 4 ohm load resistor.
7. Adjust the RF level of the signal generator until the SINAD reads 6 dB.
8. Increase the signal generator RF level +107 dB from the level necessary to obtain 6 dB
SINAD.
9. Measure audio distortion; it should not exceed 5%.
Dynamic range _____ OK
Weather Channel
1. Inject a 1000 µV RF signal with 3 kHz FM modulation on 162.4 MHz into the Comm antenna
port.
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)
6. Press MON button on the Comm radio
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)
8. Press the INT/OFF switch to INT
Speaker audio _____ OFF
Headset audio _____ Pulsing 1 kHz tone present

Garmin AT Rev --
1. Transmitter Tests Using the HP8920 Test Set

This test will require MON and Test Mode adjustments. Record MON and Test mode settings
before proceeding. See the Service Data Sheet located in chapter 21 of this manual.
Flip/Flop Input (Not present on GX50/55)

Description: The frequency flip/flop input is a discrete input intended for connection to a
momentary button to aircraft ground.
Setup: Connect the unit to nominal input supply. Connect a momentary switch from the
flip/flop input to ground.
Operation: After powering the unit on, press the COM smart key to see the frequencies.
Ensure that the active and standby frequencies are not the same. Push the
flip/flop momentary switch several times.
Verification: Verify the frequencies flip/flop when pressing the momentary switch.
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.

Garmin AT Rev --
Modulation Capability
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.
switch to RX.
5 On the test box, Repeat steps 2 through 4 with
move test cable MIC2.
from MIC1
connector to MIC2
connector.
Sidetone Audio Level and Adjustment

1 Set all test equipment On the HP8920, set AF ANL to
as specified in Test Ext Load R to 100 Ω.
Equipment Setup on
page 7-17.
2 Connect HP8920 1. On the test box, move
audio out to MIC1. (HP8920 AUDIO IN cable)
from SPKR OUT to HDPH.
2. Put the TEST HDPH/LOAD
into the TEST HPHD
position.
switch to TX.

Garmin AT Rev --

4 Adjust audio level Using the CURSOR CONTROL Confirm the AF Freq. meter
input to obtain 85% knob or the ↑ arrows adjust the reads 1 kHz at 85 % modulation
modulation ± 1%. AFGen1 Lvl until 85% modulation ± 1%.
is viewed on the HP8920 (AM
Depth). NOTE: Always approach
the desired modulation from
lowest audio input level and stop
when desired modulation is
obtained. It may be necessary to
set INCR +divide10, or INCR
SET or INCR X10 to obtain a
reading of I=0.00100 for fine
adjustment.
NOTE: Due to the 35-second
time out, the PTT switch may be
toggled from RX to TX to
maintain TX power during
adjustment.
switch to RX.
6 1. On the HP8920, set the AF
Anl. In to Audio In.
2. Set AC Level to W.
7 On SL display, press and hold Example: 45.
the NAV button (about 3
seconds) until SW VER X.X is
displayed. Rotate the LARGE
knobs until the SIDTONE LVL
reading is displayed. Record this
reading.
8 NOTE: Use the Service Data
Sheet to record and display
factory and customer defaults
before proceeding.
9 On the test box press the PTT
switch to TX.
10 On the Comm radio, adjust the ≥0.280 watts output into 100
small knob on the right side until ohm load.
the AC Level reads 0.280 watts.
11 On the HP8920, select the AC Set 1 kHz tone to reference
Level in the W field. Select the reading 0.00 dB.
SHIFT (BLUE KEY) REF SET.
Push CURSOR CONTROL.
12 On the Comm radio, adjust the Adjust Sidetone level until the
small knob on the right side until output level is –10 dB down into
the AC Level reads 10 dB down. 100 Ω load.

Garmin AT Rev --

13 On the test box, press the PTT This reading may be modified
switch to RX by customer
Microphone Bias
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.

Garmin AT Rev --
The following transmitter tests are not required for return to service. They are
included for troubleshooting. Continue on to the receiver tests below.
Modulation Audio Frequency Response

1 Set all test On HP8920, set AFGen1 to 20
equipment as mV.
specified in Test
Equipment Setup on
page 7-17.
switch to TX.
input to obtain 85% knob or the ↑ arrows, adjust the reads 1 kHz at 85 % modulation
modulation ± 0.5%. AFGen1 Lvl until 85% modulation ± 0.5%.
is viewed on the HP8920 (AM
Depth). NOTE: Always approach
the desired modulation from
lowest audio input level and stop
when desired modulation is
obtained. It may be necessary to
set INCR +divide10, or INCR SET
or INCR X10 to obtain a reading of
I=0.00100 for fine adjustment.
NOTE: Due to the 35-second time
out, the PTT switch may be
toggled from RX to TX to maintain
TX power during adjustment.
4 Set AM Depth On the HP8920, select the AM The AM Depth field will read
measurement to Depth field. Then, select %. Press 0.00 ± 0.05 dB.
reference. the SHIFT (BLUE KEY) REF SET.
Push CURSOR CONTROL knob.
5 On the test box press the PTT
switch to RX.
6 NOTE: Option 019 If Option 019 (the notch filter
required HP8920A. option) is not installed, an external
variable notch filter will be
required to perform the following
test.
7 Lock notch and Use the SHIFT CONFIG keys Lock notch filter to AF Gen1
audio generator. under SCREEN CONTROL. Use Freq. and return to TX TEST.
the CURSOR CONTROL knob to
select the Notch Coupl. Set to
AFGen1. Push the PREV key
under SCREEN CONTROL to
return to TX TEST.

Garmin AT Rev --

8 Change AF Freq. to Using the CURSOR CONTROL
350 Hz. knob and the DATA keypad, set
AFGen1 Freq. to 0.350 kHz.
switch to TX.
10 Read the difference. Read and record the AF Depth The variation will be <4 dB at
difference. 85% modulation from 350 Hz to
2.5 kHz.
switch to RX.
12 Repeat steps 9 to 12 for every 200 The variation will be ≤4 dB at
Hz until 2500 Hz is obtained. 85% modulation from 350 Hz to
2.5 kHz.
Modulation Audio Frequency Distortion

1 Set all test On HP8920, set AFGen1 to 20
equipment as mV.
specified in Test
Equipment Setup on
page 7-17.
switch to TX.
input to obtain 85% knob or the ↑ arrows, adjust the reads 1 kHz at 85% modulation
modulation ± 1%. AFGen1 Lvl until 85% ± 1%.
modulation is viewed on the
HP8920 (AM Depth). NOTE:
Always approach the desired
modulation from lowest audio
input level and stop when
desired modulation is obtained.
It may be necessary to set INCR
+divide10, or INCR SET or INCR
X10 to obtain a reading of
I=0.00100 for fine adjustment.
NOTE: Due to the 35-second
time out, the PTT switch may be
toggled from RX to TX to
maintain TX power during
adjustment.
4 Read distortion. On the HP8920 set the AF Freq. The distortion will be <10% at
field to Distn. Record distortion. 85% modulation.

Garmin AT Rev --

5 On the HP8920 DIST field, Set 1 kHz tone to reference
select the % field; then SHIFT reading 0.00 dB.
(BLUE KEY) REF SET. Push
CURSOR CONTROL knob.
switch to RX.
required HP8920A. option) is not installed, an
external variable notch filter will
be required to perform the
following test.
8 On the HP8920, use the SHIFT Lock notch filter to AF Gen1
(blue key) CONFIG keys under Freq.
SCREEN CONTROL and set the
Notch Coupl. to AFGen1. Push
the PREV key under SCREEN
CONTROL to return to TX TEST.
9 Change notch filter On the HP8920, set the AF
freq. to 350 Hz. Gen1 Freq. to 350 Hz.
switch to TX.
11 Record distortion. Will be <10% distortion at 85%
modulation.
switch to RX.
13 Repeat steps 9 to 13 for every Audio frequency distortion will
300 Hz until 2500 Hz is reached. be <10% at AM Depth of 85%
at 350 Hz to 2500 Hz.
Frequency Tolerance
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.

Garmin AT Rev --
Spurious Emission No Modulation

1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 Select Spectrum On the HP8920, use the The Spectrum Analyzer screen
Analyzer. CURSOR CONTROL knob to is displayed.
select from the To Screen:
SPEC ANL. Push the CURSOR
CONTROL knob in to select.
3 Set Spectrum Spectrum Analyzer Screen: ** If transmitter power is too
Analyzer. high, the REF Level will be too
Using the CURSOR CONTROL
close to noise floor of HP8920.
knob and the DATA keypad set:
Adding an external 10 dB
Controls Main RF In/Ant attenuator will be necessary to
get lower noise floor.
Center Freq. 127.5 MHz
Ref Level 40 dBm**
Span 0.03 MHz
4 Get to Marker Menu. Using the CURSOR CONTROL
knob, select Main. Push and
rotate the knob clockwise to
Marker.
switch to TX.
6 Peak carrier and set In the Markers Menu, select The marker should be on top of
to reference. (Marker To) Select Peak. the carrier.
Using the CURSOR CONTROL The marker value will go 0.00
knob, highlight Lvl dBm. Press dBm reference.
SHIFT (Blue key) REF SET.
switch to RX.
8 Put in filter to Install the 188 MHz high-pass See Appendix B for HPF
suppress the carrier. filter in series with the Comm Calibration Curve.
radio antenna coax directly on
the HP8920 RF IN/OUT port.
9 Set to first harmonic. Using the CURSOR CONTROL
knob, select Marker. Push and
rotate knob counterclockwise to
MAIN select. From the Main
Menu, select Center Freq. and
set to 255 MHz using the DATA
key pad.
10 Go to Marker Menu. Using the CURSOR CONTROL
knob, select Main. Push and
rotate the knob to Marker.

Garmin AT Rev --

switch to TX.
12 Peak marker. In the Markers Menu, select The marker should be on top of
nd
Marker To. For the marker, the 2 harmonic carrier.
select Peak.
13 Record level. Harmonic frequency will be
down ≥65 dB.
switch to RX.
15 Test all harmonics Repeat steps (9 to 15) for 382.5 All harmonic power is ≥65 dB.
up to limit of MHz, 510 MHz, 637.5 MHz, 765
equipment. MHz, and 892 MHz.
16 For harmonic testing frequencies
1020 MHz, 1147.5 MHz and
1275 MHz, these must be
accomplished utilizing an HP
8560A or equivalent spectrum
analyzer. See appendix A for
test.
17 Remove the high-pass filter.

Garmin AT Rev --
Spurious Emission Modulated

Step General Instruction Specific Steps Expected Results
1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 Set AF Generator Using the CURSOR CONTROL
Freq. to 2.5 kHz. knob, select AF Gen1 Freq.
Push the CURSOR CONTROL
knob. Rotate until 2.5 kHz or use
DATA keypad.
Push the CURSOR CONTROL
knob.
3 Turn on Mic1. On the test panel toggle
TEST/MIC 1 to MIC 1.
4 Key transmitter. On the test panel, press the PTT The modulation should be
switch to TX. ≥85%. This is displayed as AM
Depth on the top right of the
screen.
5 Un-key the On the test panel, press the PTT
transmitter. switch to RX.
6 Activate Spectrum Turn the CURSOR CONTROL The Spectrum Analyzer will
Analyzer. knob to the To Screen menu. appear.
Select SPEC ANL. Push the
7 Set Span to 0.03 Turn the CURSOR CONTROL
MHz. knob to the SPAN field. Push the
CURSOR CONTROL knob. Use
the CURSOR CONTROL knob
or the DATA keypad to input
0.03 MHz. Push the CURSOR
CONTROL knob.
8 Set Ref Level to 50 Turn the CURSOR CONTROL
dBm. knob to Ref Level. Push the
CURSOR CONTROL knob to
select. Use the CURSOR
CONTROL knob or DATA
keypad to input 50 dBm. Push
the CURSOR CONTROL knob.

Garmin AT Rev --

9 Set to Marker Menu. Turn the CURSOR CONTROL
knob to Main in the Controls
Field. Push the CURSOR
CONTROL knob. Turn the
CURSOR CONTROL knob CW
to Marker. Push the CURSOR
CONTROL knob. Turn the
CURSOR CONTROL knob CW
to Peak on the first Marker To
menu.
10 Turn on the On the test box, press the PTT The RF modulation mask
transmitter. switch to TX. should display on the screen.
11 Marker to peak of Press CURSOR CONTROL Puts the marker on top of the
carrier. knob. carrier.
12 Marker to Center Turn the CURSOR CONTROL
Freq. knob to Center Freq. in the
second Marker To menu.
13 Carrier to center of Press CURSOR CONTROL This center carrier on the
screen. knob. screen.
14 Turn CURSOR CONTROL knob
to Lvl field on the right side of
the display.
15 Set carrier reference Press SHIFT REF SET. Press This sets the amplitude
level. CURSOR CONTROL knob. reference to the peak of the
carrier.
16 Turn CURSOR CONTROL knob
back to Marker. Push CURSOR
CONTROL knob.
17 Select Main with the CURSOR
CONTROL knob. Push to select.
18 Move CURSOR CONTROL knob
to Center Freq.
19 Get exact center Record center freq. Example 127.499639 MHz.
freq.
20 Add or subtract 12.5 Add 0.0125 MHz for the upper Example: 127.499639 MHz +
kHz to get new side band, or 0.0125 = 127.512139 +upper
center freq. side band.
Subtract 0.0125 MHz for the
lower side band. Example: 127.499639 MHz -
0.0125 = 127.499639 lower
side band.
21 Set Spectrum Enter the result as the center
Analyzer to new frequency using the keypad.
center frequency. Push CURSOR CONTROL knob
to enter new Center Freq.

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22 Check to see if On the test box, press the PTT The Lvl field should read ≥25
emission meets switch to TX. dB down minimum from marker
specification. to right edge of screen (typical
> 52 dB down).
switch to RX.
24 Add or subtract 25.0 Add 0.025 MHz for the upper Example: 127.499639 + 0.025
kHz to get new side band, or = 127.524712 upper side band.
center freq.
Subtract 0.025 MHz for the lower Example: 127.499639 - 0.025 =
side band. 127.4746390 lower side band.
25 Enter the results as the new
center frequency.
26 Check to see if On the test box, press the PTT Lvl field should show ≥25 dB
emission meets switch to TX. down minimum across the
specification. entire screen (typical > -52 dB).
switch to RX.
28 Add or subtract 62.5 Add 0.0625 MHz for the upper Example: 127.499639 + 0.0625
kHz to get new side band, or = 127.562139 across the entire
center freq. screen (typical > -52 dB).
Subtract 0.0625 MHz for the
lower side band.
29 Enter that as the new center
frequency.
switch to RX.
32 Add or subtract 500 Add 0.500 to recorded center Example: 127.499639 + 0.500
kHz to get new freq. = 127.999636 upper side band.
center freq.
Example: 127.499639 - 0.500 =
126.9996390 lower side band.
33 Enter that as the new center
frequency.
switch to RX.

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2. Receiver Tests Using the HP8920 Test Set
Headset Output Level

1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 Sig. Gen. Mod Lvl. On the HP8920:
To 85%.
1. Set AFGen1 to AM 85%.
Amplitude to 1000
2. Set AMPLITUDE to 1000
µV.
µV.
3. Set Ext. Load R 100 ohms.
4. Set the Comm radio
HDPHONE Lvl to 000.
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 ≥0.280 watts output into 100
control on Comm volume control until the AC Level ohm load (mounted in test
radio for 0.280 W. reads 0.280 watts. fixture) at a volume level from 0
to 280 mW.
Speaker Audio Level

1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
To 85%.
Amplitude to 1000
µV.
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 ≥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.

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Reference Sensitivity and Squelch Threshold Sensitivity

1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
To 30%.
Amplitude to 1000
µV.
µV.
OUT.
watts.
5 Open squelch. On the Comm radio, pull the
Squelch knob out (disable
squelch).
6 Get 6 dB SINAD On the HP8920: <2 µV (hard) for 6 dB S+N/N
reading and record with 30% modulation at 1000
1. Set the value field in the
reference sensitivity. Hz modulation.
SINAD meter reading to
average (AVG) at 10.
2. Set AMPLITUDE using the ↓
down arrow until the SINAD
meter reads 6 dB SINAD.
3. Record AMPLITUDE as
reference sensitivity.
4. The volume on the HP8920
can be adjusted to monitor
the Comm radio audio.
7 Close squelch. On the Comm radio push the The Comm radio will have no
Squelch knob in (close squelch). audio out.
8 Get squelch On the HP8920: Will start to break at greater
sensitivity. than:
1. Set AMPLITUDE using the ↑
up arrow until the SINAD 2 µV (-104 dBm).
meter reads squelch opens.
Note: Will be full open if signal
2. Record AMPLITUDE as is increased by 3 dB.
squelch sensitivity threshold.

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Intercom/Monitor
1 Set all test On the HP8920:
equipment as
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.
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
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.

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9 Check for the two Connect a headset to the test
tones box and adjust Comm radio
volume to a reasonable level
and monitor the two tones.
The following receiver tests are not required for return to service. They are
included for troubleshooting.
Speaker Output Response

1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 On the HP8920:
1. AFGen1 to AM 85%.
2. AMPLITUDE to 1,000 µV.
3. Ext. Load R to 4 ohms.
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 Set AF Level as On the HP8920, Select AC AF Level will be 0 dB.
reference. Level. Push SHIFT (Blue key)
push REF SET, then push the
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
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, select AFGen1 Set to 350 Hz.
350. Freq.
9 Record AC Level. Will be <3 dB 350 Hz.

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10 Repeat steps 8 to 10 for every Audio frequency level vary <3
200 Hz until 2500 Hz and at dB at AM Depth of modulation
4000 Hz. of 85% at 350 Hz to 2500 Hz
and at 4000 Hz the level will be
down ≥15 dB.
Headset Output Response

1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 On the HP8920:
1. Set AMPLITUDE to
1,000 µV.
2. Set AFGen1 to AM
85%.
3. Set Ext. Load R 100
ohms.
3 Move test cable. On the test box, connect
the HP8920 audio in
cable to HDPH.
4 Adjust volume On the Comm radio,
control on Comm adjust the volume
radio for 280 mW. control until the AC
Level reads 0.280 watts.
5 Set AF Level as On the HP8920, select AC Level reads 0.00 dB.
reference. AC Level. Push SHIFT
(Blue key). Push REF
SET, then push the
CURSOR CONTROL
knob.
6 On the HP8920, select
AFGen1 Freq. Set to
350 Hz.
7 Record AC Level. The level will not vary more than 3 dB at
350 Hz.
8 Repeat steps 8 to 10 for Audio frequency level will not vary more
every 200 Hz until 2500 than 3 dB from reference level of 1000
Hz, and then at 4000 Hz. Hz at AM Depth of modulation at 85%
from 350 Hz to 2500 Hz, and will be
greater than 15 dB down at 4000 Hz.

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Headset Distortion
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.
HP8920 audio in cable to HDPH.
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%.
following tests.
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.

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Speaker Distortion
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.
OUT.
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%.
following tests.
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.

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Receiver Sensitivity
1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
to 30%.
Amplitude to 1000
µV.
µV.
OUT.
watts.
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.

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Receiver Dynamic Range

1 Set all test
equipment as
specified in Test
Equipment Setup on
page 7-17.
2 RF Out to Dupl. Sig. On the HP8920:
Gen. Mod Lvl. To
1. Set RF OUT/Dupl.
30%.
Amplitude to 1000
µV. 3. Set AMPLITUDE to 1000
µV.
3 Move RF cable. On the HP8920, move the
RFIN/OUT cable to DUPLEX out
connector.
watts.
squelch).
6 Find 6 dB SINAD On the HP8920, set the value Reference signal level ≤2 µV
reading. field in the SINAD meter reading (hard) for 6 dB S+N/N with 30%
to average (AVG) at 10. modulation at 1000 Hz.
Set AMPLITUDE using the ↑ ↓
arrows until the SINAD meter
reads 6 dB SINAD.
7 Add 107dB. On the HP8920: Converts µV to dBm.
1. Select the AMPLITUDE field. Example: –107 dBm +107 = 0
Press the GHz/dBm key. dBm.
2. To calculate upper dynamic
range, add 107dB to
reference signal level.
8 Set HP8920 to 224 On the HP8920: Dynamic range is 107 dB with
mV. <5% distortion.
1. Set the AMPLITUDE field to
upper dynamic range.
2. Select the SINAD field and
change to Distn.
9 Record as pass or fail.

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Weather Channel
1 Set all test On the HP8920:
equipment as
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

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Appendix A. Default Comm Parameters
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

Garmin AT Rev --
Final Unit Checkout

After the unit has passed both the NAV and Comm return to service procedures, perform the
following final unit test procedures. The unit must be fully assembled and properly connected to the
TST 10 test station. Operate the GX50/55/60/65 in the test mode by holding down the leftmost and
rightmost “smart keys” while switching on the power. To return to normal operation, switch the power
off, then back on.
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)
3. Serial Interface Configuration

The GX50/55/60/65 RS-232 serial ports can be configured for several input and output formats.
To select the serial port configurations:
1. In test mode, rotate the large knob to the serial port configuration “CH RX TX” page.
2. Press SEL (the selection fields will start flashing), rotate the large knob to select the port, rotate
the small knob to select the desired configurations, then press ENTER when complete.
4. Comm Radio Setup

The Test Mode settings may also be used to preset the Microphone (Mic) Gain and the Receiver
Squelch levels.
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.

Garmin AT Rev --
2. Press SEL to activate selection. The Mic 1 value will flash.

3. Turn the small knob to change the value.
4. Turn the large knob to the Mic 2 value. Turn the small knob to change the value.
5. Press ENTER to accept and save the settings.
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.
5. VHF Comm Checkout (GX60/65)
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.
Sidetone Level Adjustment

The sidetone volume was preset at the factory to a typical audio level. The level can be adjusted
using one of the built-in system functions. To adjust the sidetone level:
1. Press SYS, rotate the large knob to the COM Info page, and press ENTER.
2. Rotate the large knob to the Sidetone Level page.
3. Press SEL, rotate the small knob to adjust the sidetone level, then press ENTER when
complete. The sidetone level is displayed in a range of 000 to 255, with 255 the highest level.
The sidetone level can be adjusted during transmit.
Comm Flight Test Check

A flight test is recommended as a final installation verification. The performance may be verified
by contacting a ground station at a range of at least 50nm while maintaining an appropriate
altitude and over all normal flight attitudes. Performance should be checked using low, high, and
mid band frequencies.

Garmin AT Rev --
6. Final System Check

The GX50/55/60/65 GPS navigation functions should be complete at this time. The final check
includes checking database, entering a direct to waypoint, and checking the navigation functions.
Start with the unit turned on and operating in the normal mode. Refer to the user’s manual for
operating instructions.
1. Verify a valid position is displayed.
2. Check the database to ensure it is for the right coverage area and check the expiration date.
To check the database:
a. Press SYS, rotate the large knob to the System Info page, and press ENTER.
b. Rotate the large knob to the Apollo GX Software Version page
c. Rotate the small knob to display the database information. The database name,
expiration date, and version will be displayed.
3. Enter a direct to waypoint. Press the Direct-To button, use the large and small knobs to select
a nearby waypoint, then press ENTER. Or use the nearest search function to select a
waypoint.
4. Verify the bearing and distance to the selected waypoint.

Garmin AT Rev --

Chapter 8. Replacement Procedures
Purpose
This section provides replacement procedures for all serviceable assemblies and parts. These
include the battery, battery holder, bezel assembly, chassis, Comm board, display, fuse, GPS board,
keypad, lens, chassis cover, NAV board and soft keys.
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
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.

Garmin AT Rev --
Figure 8-1. GX55 Assembly Board Locations

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Figure 8-2. GX 50/60/65 Assembly Board Locations

Garmin AT Rev --
Chassis Cover Replacement

This procedure describes the removal and replacement of the sheet metal chassis cover on the unit.
Note: Every unit leaving the factory or authorized service center has a warranty warning label applied
to the rear panel and chassis cover. Removing this label leaves a distinctive checkerboard residue on
the unit. Before removing the chassis cover, verify the integrity of the label. Removal of this label by
anyone other than an authorized service center voids the warranty.
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.

Garmin AT Rev --
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.
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).

Garmin AT Rev --
Bezel Assembly Replacement

This procedure describes the removal and replacement of the front bezel assembly.
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)
Removal
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.

Garmin AT Rev --
Pin 33
Pin 34
Figure 8-3. Ribbon Cable Placement on Bezel Assembly and NAV Board

Garmin AT Rev --
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
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).

Garmin AT Rev --
GX60/65 Comm Board Fuse Replacement

This procedure describes the removal and replacement of the fuse on the Comm board.
See Component Layouts – Comm Board in the Drawings chapter for the location of the fuse.
Parts Required
• 172-2701 FUSE 125 V, 7 A, FAST ACTING
Removal
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).
2. Replace the Comm board (see Comm Board Replacement procedure).

Garmin AT Rev --
GX60/65 Comm Board Replacement

This procedure describes the removal and replacement of the Comm board.
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
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.

Garmin AT Rev --

Figure 8-4. Ribbon Cable Placement

Garmin AT Rev --
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
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.

Garmin AT Rev --
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).

Garmin AT Rev --
GX50 and GX55 GPS Board Replacement

This procedure describes the removal and replacement of the GPS receiver board on the NAV board
for the GX50 and GX55.
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
copy is located at the back of this manual
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.

Garmin AT Rev --
GX60 & GX65 GPS Board Replacement

This procedure describes the removal and replacement of the GPS receiver board on the NAV board
for the GX60 and GX65.
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
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).

Garmin AT Rev --
Keypad Replacement
This procedure describes the removal and replacement of the keypad mounted in the bezel.
Parts Required
• 315-4110-00 KEYPAD
Removal
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).

Garmin AT Rev --
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
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.

Garmin AT Rev --
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
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.
5. Clean fingerprints from the front of the display lens with a clean wipe and glass cleaner.

Garmin AT Rev --
NAV Board Fuse Replacement

This procedure describes the removal and replacement of the surface mount 3 A fuse on the NAV
board.
See Component Layouts – NAV Board in the Drawings chapter for the location of the fuse.
Parts Required
• 172-0004-012 FUSE 125 V, 3 A, SLOW BLOW, SMD
Removal
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.
Replacement
1. Solder the new fuse (172-0004-012) in place.

Garmin AT Rev --
NAV Board Replacement

This procedure describes the removal and replacement of the NAV board.
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
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
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).
9. Completely reinitialize the unit (see Complete Initialization procedure).

Garmin AT Rev --
Smart Key Replacement

This procedure describes the removal and replacement of the smart key flex strip under the display.
Parts Required
• 418-5107-00 FLEX CIRCUIT ASSEMBLY, SOFT KEY
Removal
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.
Figure 8-5. Flex Circuit Placement

Garmin AT Rev --
NAV Board Software Upgrade

This procedure describes the loading of a newer version of software for the NAV board.
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
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.

Garmin AT Rev --
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.

Garmin AT Rev --
Comm Board Software Upgrade

This procedure describes the loading of a newer version of software for the Comm board. It involves
replacing the software EEPROM on the Comm board.
Parts Required
• 138-0312-012 PROGRAMMED MICROCONTROLLER, VHF Comm
• INTEGRATED CIRCUIT PULLER TOOL
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.

Garmin AT Rev --
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
2. Put the unit into test mode by powering the unit back on while holding the outermost two smart
keys down.
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.

Garmin AT Rev --

Chapter 9. Troubleshooting
Note: When using these tables, check all listed error messages and symptoms before deciding which
to pursue.
Preliminary Data
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
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
for the unit.)

Garmin AT Rev --
ERROR MESSAGE CAUSE ACTION

Altitude encoder 1. Altitude encoder unit 1. Check altitude encoder.
communications failure
2. Wiring between units 2. Check wiring from encoder to GX.
3. NAV board 3. Replace the NAV board. (See NAV
Fuel/Air Data 1. Fuel/air data unit 1. Check fuel/air data unit.
Communications Failure
2. Wiring between units 2. Check wiring from F/ADC to GX.
Memory Failure; User 1. Software 1. Initialize unit. (See Complete
Setups Have Been Reset Initialization procedure).
2. NAV board
(repeats on every startup)
2. Upgrade software to v 2.2.
Low Battery Voltage: Unit 1. Low battery voltage 1. Check battery voltage. Replace if
Needs Service below 2.75V. (See Battery
2. Fracture between
Replacement procedure.)
solder fillet and leads
on battery holder 2. Replace the NAV board. (See NAV
3. NAV board
Internal Battery Failure: NAV board Replace the NAV board. (See NAV
Turn off Unit/Needs Srvc! Board Replacement procedure.)
COM Radio FAILURE! 1. No connection 1. Verify 8-pin NAV to Comm
Service Now between boards connector (Comm J4 - NAV J606).
2. No radio power (blown 2. Verify A/C power at F400. Replace
fuse) fuse if blown (See Comm Board
Fuse Replacement procedure).
3. Comm board
3. Replace Comm board. (See Comm
4. NAV board
Software Test Failed: NAV board 1. Initialize unit. (See Complete
Contact UPS Aviation Initialization procedure).
Technologies
User Database Memory Board Replacement procedure.)
Failure…
Flight Plan Memory
Failure…
Memory Test Failure…

Garmin AT Rev --
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
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.
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).
Comm is interfering w/ 1. Harmonics from 1. Install notch filter part # 162-1059
GPS Comm on GPS antenna coax connector on
(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

Garmin AT Rev --

Data/list knob inoperative, Display assembly Replace display assembly. (See Display
OR Replacement procedure.)
skips windows when
turning knobs
Display reset 1. Intermittent A/C power 1. Verify A/C power & ground
connections connections.
2. NAV board 2. Initialize the unit.
Power cycles on and off 1. Aircraft power 1. Verify aircraft wiring.
connections.
2. Test the unit on the bench.
2. Power supply.
3. NAV board. Board Replacement procedure.)
Resets itself in flight See power cycles on and See power cycles on and off – above.
off – above.
Intercom not keying 1. User setup not 1. Verify user set-ups and squelch
properly configured levels to current spec. (See user
setup procedure in the user’s
2. A/C installation
manual).
3. Comm board
Low transmit power 1. Antenna connections 1. Check antenna and cable.
No Tx 2. Antenna 2. Replace Comm board. (See Comm
No Rx 3. Comm board
No antenna voltage 1. Connections 1. Check antenna coax connections.
2. Short in antenna cable 2. Check for coax short to shield.
3. GPS receiver 3. Replace GPS receiver. (See the
4. Antenna
for the unit.)
5. Comm board
4. Replace GPS antenna.
No aviation output (CDI, 1. Connections/ 1. Check installation.
To/Fr) installation
2. Check the output device (CDI, etc.).
2. Annunciator
3. NAV board Board Replacement procedure.)
No power/dead 1. No aircraft power 1. Check A/C power and ground.
2. Fuse 2. Check NAV fuse F701.
3. Display 3. Check display (swap it out). (See
Display Replacement procedure.)
4. NAV board

Garmin AT Rev --

No serial data out 1. User configuration 1. Verify user configuration.
2. A/C Installation 2. Check A/C installation.
Noise in headset 1. Connections 1. Verify headset with another.
2. User configuration 2. Verify user configuration.
3. Comm board 3. Replace Comm board. (See Comm
Not flip/flopping 1. Remote frequency 1. Check remote switch operation.
frequencies switch
2. Verify A/C power and ground to
2. No power to Comm Comm board.
board
3. Check fuse (F400) on Comm board.
3. Comm to NAV cable
4. Verify 8-pin NAV to Comm
4. Comm board connections (Comm J4 to NAV
J606).
RX audio distortion 1. Radio interference 1. Verify area/instrument interference
is not the cause.
2. Antenna connections
2. Check the antenna.
3. Comm board
Stuck in simulation mode 1. A/C installation 1. Verify pin 7 of 37 pin D-sub
connector (P701) is grounded.
2. NAV board
Soft key inoperative 1. Software version 1.0 1. Check all soft keys in normal
operation.
2. Soft key flex cable or
connection 2. Ensure that soft key flex cable is
connected.
3. Display assembly
3. Replace display assembly. (See
Display Replacement procedure).
Resets on low map Software version 1.0 Replace the NAV board. (See NAV
settings Board Replacement procedure.)
Unit intermittent below 20 Software version 1.0 Replace the NAV board. (See NAV
on the map scale Board Replacement procedure.)
When in approach, will Software version 1.0 1. Replace the NAV board. (See NAV
not display baro & give alt Board Replacement procedure.)
error
2. Verify good 3-D fix.
Display flashes Software version 1.0 Replace the NAV board. (See NAV
continuously under Board Replacement procedure.)
certain light conditions

Garmin AT Rev --

Erases flight plan memory 1. Battery connections 1. Follow Battery Failure Message
procedure above
2. Software version 1.0
Locks up when changing Software version 1.0 Replace the NAV board. (See NAV
map scales Board Replacement procedure.)
Photocell is very sensitive Software version 1.0 Replace the NAV board. (See NAV
Won’t hold date & time 1. Battery connections 1. Follow Battery Failure Message
procedure above.
Wont retain memory 2. NAV board
Smart keys disappeared Software version 1.0 Replace the NAV board. (See NAV

Garmin AT Rev --
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.
Address Bytes Data Type Description Comment

0219 4 Hexadecimal Equipment run time in hours 0219 is 1s byte
0224 4 Hexadecimal Turn on cycle count, increments by one 0224 is 1s byte
each time the unit is reset (or turned on)
0229 1 Hexadecimal EEPROM failures, checked each time unit
is turned on
0230 1 Hexadecimal NVRAM failures, checked each time unit is
turned on
0231 1 Hexadecimal Minor math error count
0232 1 Hexadecimal Major math error count
0233 1 Hexadecimal Exception interrupt error count
0234 1 Flag Map task time-out
0235 1 Flag User interface time-out
0236 1 Flag NAV SW time-out
Note: The EEPROM data listed in this table will be reset to 0x00 when a serial number is input using
the RS-232 serial number input command.

Garmin AT Rev --

Chapter 10. Drawings
Component Layouts
Figure 10-1. GX55 NAV PCB Component Layout (Reference Only) (Sheet 1 of 3)

Garmin AT Rev --

Garmin AT Rev --

Garmin AT Rev --
Figure 10-2. GX 50/60/65 NAV PCB Component Layout (Reference Only) (Sheet
1 of 2)

Garmin AT Rev --
Figure 10-2. GX 50/60/65 NAV PCB Component Layout (Reference Only)

(Sheet 2 of 2)

Garmin AT Rev --
Figure 10-3. Comm PCB Component Layout (Reference Only) (Sheet 1 of 3)

Garmin AT Rev --

Garmin AT Rev --

Garmin AT Rev --
Block Diagrams
Figure 10-4. NAV Block Diagram

Garmin AT Rev --
Figure 10-5. Comm Board Block Diagram

Garmin AT
+27.5 volts Display Output

(1.8432MHz clock)
Power Input Power Supply +12 volts microController
Control Input
+5 volts (153.6KHz clock)
© 2004 Garmin AT
+3.3 volts RS-232 I/O
(9600 baud)
Power Supply Sync

(307KHz)
(131.7KHz clock)
microwire interface
Lock Detect
Synthesizer
IF AGC Voltage
Speaker Enable
RX/TX
Mic Select
AGC Disable
Headphone Enable
Receiver Select
Noise Detect Voltage

Audio AGC Voltage
RX LO Ref Dac
(139.4 to 158.375MHz)
Mic Input
Receiver Audio Circuits
Figure 10-6. VHF Comm Main PCA Block Diagram

Detected Audio Headphone
RF Signal Output
(118.000 to 136.975MHz, TX LO
162.40 to 162.55MHz) (118.000 to 136.975MHz)
RX RF Sidetone Audio
RF AGC
GX Service Manual
Antenna
Speaker
Transmitter Audio Audio Amp Output
Modulation
Rev --
10-11
10-12
Garmin AT
System D0:D7 Display Display Data

Reset Interface
Display Clock
(921.6KHz)
Display Blanking
11.0592MHz Control signals
CPU (/WR, ALE, clock gate)
TxKey
Lock Detect Front Panel
Control Input
RX/TX
Receiver Select
Mic Select
RS-232 TxD
GX Service Manual
Speaker Enable (9600 baud)
Headphone Enable
AGC Disable RS-232 RxD
(9600 baud)
Figure 10-7. Microcontroller Block Diagram

microwire interface microwire
(data out: 131.7KHz clock; data in: 153.6KHz clock) interface
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)
Power Supply Binary

Sync (307KHz) Counter Or
Phase Charge
Comarator Pump
Lock Detect Lock Detect LD Op
microwire (25KHz)
Interface (131.7KHz clock)
Dual Mod Variable

Prescaler Divider
Figure 10-8. VHF Comm Synthesizer Block Diagram

RX LO
GX Service Manual
Voltage Loop
TX LO (118.000 to 158.375MHz)
Controlled Filter
Oscillator
RF Amp
Rev --
10-13
10-14
Garmin AT
Receiver Preselector IF and AGC
2-Pole BPF 2-Pole BPF 21.4 MHz 21.4 MHz Audio

RF 1st IF 2nd IF 3rd IF Detected
Varactor Varactor 6-Pole 2-Pole Detector
Amp Amp Amp Amp Audio
Tuned Tuned Xtal Filter Xtal Filter
GX Service Manual
Varactor AM/FM
Figure 10-9. Receiver Block Diagram

Scaling Control
Amplifier Switch
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
Figure 10-10. Audio Circuits Block Diagram

Audio Out
Audio Select +1.25v
Aud Sig In
Aud Sig Out D to A
Ground Headphone
Amplifier
RX/TX
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
Pre- 7th Order Antenna

Driver Driver Power
Tx LO Elyptic Function Switch, A
Amp Amp Amp
RF AGC
GX Service Manual
(118.00 to LPF
136.975 MHz)
R
S
Audio R
Modulation
Figure 10-11. VHF Comm Transmitter Block Diagram
© 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
12 VDC +12 Volt

10.8 VDC
Supply
Startup
Pre-Regulator
Audio
Audio Amp/ Modula
Audio In Modulator Speaker
Output
Speaker
Enable
GX Service Manual
Figure 10-12. VHF Comm Power Supply/Audio Amp Block Diagram
Rev --
10-17
Garmin AT Rev --
Assembly Drawings
Figure 10-13. GX55 Assembly (Reference Only) (Sheet 1 of 2)

Garmin AT Rev --
Figure 10–13. GX55 Assembly (Reference Only) (Sheet 2 of 2)

Garmin AT Rev --
Figure 10-14. GX50, 60, 65 Assembly (Reference Only) (Sheet 1 of 2)

Garmin AT Rev --
DETAIL A POLYUR. CELL. LABEL ASS’Y.

FLEX CIRCUIT & DISPLAY BD. ASS’Y.
GPS ENGINE ASS’Y.

FOR -40X (GX50) ONLY LABEL ASS’Y. - BOTTOM VIEW OF UNIT
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.
Figure 10–14. GX50, 60, 65 Assembly (Reference Only) (Sheet 2 of 2)

Garmin AT Rev --

Chapter 11. Parts Lists
Notes for the following tables are as follows:
*1
Flex Circuit must be ordered when EL display is ordered.
*2, *3, *4, *5
Cell pieces must be ordered when chassis cover is ordered.
Common Parts
Part Num Qty Description
148-1702 1 BATTERY (CF), N/LI, 3V 1200mAH
308-5503-00 5 BUTTON ACTUATOR, GX, SOFT KEY
500-3124-20 1 CABLE, 2mm IDC RCPT-RCPT, 2 X 17, 4”
500-0247-02 1 CABLE, GPS BOARD/ REAR BNC CONNECTOR
*1
145-2341-01 1 EL DISPLAY, PLANAR, 80X160 PIXEL
162-1059 1 FILTER, NOTCH, GPS, BNC IN-LINE, 1575MHz
*1
418-5107-00 1 FLEX CIRCUIT ASSEMBLY, SOFT KEY, GX96
172-0004-012 1 FUSE 125V, 3A, SLOW BLOW, SMD
315-4110-00 1 KEYPAD
262-0052-00 1 KNOB, INNER CONCENTRIC
262-0053-00 1 KNOB, OUTER CONCENTRIC
262-0049 1 KNOB, POWER DZUS RAIL NMC
565-1089-00 1 LABEL, HIGH VOLTAGE WARNING
565-0569-00 1 LABEL, WARRANTY WARNING
664-0042 A/R LOCTITE, 242.
220-0003 1 NUT, RND, SLOTTED, 4-40 X 3/16” X 3/16”
428-3014-01 1 PRINTED CIRCUIT ASSEMBLY, 8 CHANNEL GPS SENSOR C129A
224-0414 4 SCREW UNDERCUT, FLAT HEAD PHILIPS, 4-40 X 3/16,
STAINLESS STEEL BLACK OXIDE.
221-0212 5 SCREW PAN HEAD PHILIPS, 2-56 X 3/16, STAINLESS STEEL,
SEWS, INT
221-0401 6 SCREW PAN HEAD PHILIPS, 4-40 X ¼” WITH SPLIT LOCK
WASHER, STAINLESS STEEL
230-0402 5 SCREW SET, 4-40 X 1/8"
252-0209 4 STANDOFF, MF, 3/16 HEX, 2-56 x ¼ STAINLESS STEEL
665-0003 A/R TAPE POLY FILE 1 MIL x 3/16”
240-0073 1 WASHER

Garmin AT Rev --
GX50 Parts
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
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
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

Garmin AT Rev --

serial numbers, and rev levels available.
310-6072-00 1 PLATE, FILLER, GX55
251-9407 1 SPACER, 3/16” X ½” LG., RND, ALUM.
252-0414 3 STANDOFF, MF, 3/16” HEX, 4-40 X ½ AL.
220-0010 1 WIRE SADDLE, MICRO SIDE ENTRY
GX60 Parts
*4
*4
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
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
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

Garmin AT Rev --

240-1202 1 WASHER, LOCK, BNC, 0.509” ID, 0.623” OD, INT.
GX65 Parts
*5
*5
310-5182-00 1 CHASSIS, GX50/60/65
*5
310-5183-00 1 COVER, CHASSIS, GX50/60
664-0009 A/R HEAT SINK COMPOUND
415-7004-xx 1 NAV COMPUTER BOARD, GX50/60/65, 6013 For board
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
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
240-1202 1 WASHER, LOCK, BNC, 0.509” ID, 0.623” OD, INT

Garmin AT Rev --
Data Cards
138-0424 1 DATA CARD, WORLDWIDE
138-0425 1 DATA CARD, AMERICAS
138-0426 1 DATA CARD, INTERNATIONAL
Maintenance Supplies
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

Garmin AT Rev --

Chapter 12. Regulatory Documents
560-0925-00 GX55 STC Document
560-0926-00 GX50/60/65 STC Document

Garmin AT Rev. --

Chapter 13. Service Data Sheet
561-6001-500 GX Series Service Data Sheet

Garmin AT Rev. --

GX Service Data Sheet (Manual P/N 560-7001-5XX)
NOTE: GX Service Data Sheet procedures provide step by step EEPROM BYTE Info
instruction for filling out this form.
Address Description Data Value
PRELIMINARY INSPECTION 0219 Equipment Run Time _______________
Technician Date 0224 Turn On Cycle Count _______________
RMA#____________________ Serial # 0229 EEPROM Failures _______________
P/N_________________ Model 0230 NVRAM Failures _______________
Mod 0231 Minor Math Errors _______________
VISUAL DAMAGE 0232 Major Math Errors _______________
Visual Damage Initials: _____________Date: ___________________ 0233 Exception Interruption _______________
____None ___Hardware Damage ____Other
Visual Damage Details: _____________________________________
TEST MODE COMM Info (Comm V 2.X only)
________________________________________________________ RX Squelch Level________________
________________________________________________________ MIC 1 Level________________
HIDDEN DAMAGE
MIC 2 Level________________
Hidden Damage Initials_____________Date____________________
____No Damage Found ___Minor Damage ____Major Damage FINAL ACCEPTANCE TEST
Hidden Damage Details: ___________________________________ Technician: __________________ Date: ___________________
_______________________________________________________
______Return to Service Procedures Completed (Chapter 11)
_______________________________________________________
______RS232 Load Test per MET 154
NORMAL MODE NAV INFO
______3D Pos, SNRs, Elev, & AZM Match Standard Unit
Last Valid Pos: ____________________/___________________
CDI Scaling ____Automatic ____Manual ______Verify Lat/Long matches the standard unit.
Direct-To Entry ____Never Clears ____May Clear ______Verify Time and Date
Date & UTC ____Correct Not Correct______________________
______Verify Software Versions for:
Software Version: NAV________ GPS_________ COMM________
Nav Application: ________ GPS _______ Display
Database Expiration Date ______ / ______ / ____________
Database Part Number 138- ______Emergency Search (nearest airport)
NORMAL MODE COM INFO(GX60/65) ______Verify Board Rev Stickers
COM SW V2.X COM SW V1.X ______Bump Test (Raise front of unit 3” and drop it. Observe
Intercom SQLCH:______MIC1 Intercom SQLCH display for changes/blinking.)
_____MIC2 Intercom Level______________ ______Check messages for return to service messages
Transmit using: _______MIC1 Sidetone Level _____________
and MIC2 Headphone Level ___________ FINAL INSPECTION
_____MIC1 only Inspector:________________________ Date: _______________
_____MIC2 only
______Final Acceptance Test Checklist completed above
Intercom Level: ___________________________
______Scan area of replaced components
Sidetone Level: ___________________________
Headphone Level: _________________________ ______Backlighting (display and buttons)
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.
NORMAL MODE 32. Turn the large knob CW to Synthszr page.

33. Turn the large knob CW to Ref Osc Cal page.
1. Inspect for hidden damage. Circle Hidden Damage condition.
Initial and date. Record hidden damage details at the end of this 34. Turn the large knob CW to Front End Cal page.
procedure. 35. Turn the large knob CW to Rcvr Squelch page.
2. Record the Part Number, Mod Level and Model Number. 36. Turn the large knob CW to Mic 1 Level page.
3. Connect the cables from the test station to the unit. Power it on. 37. Turn the large knob CW to Mic 2 Level page.
4. After normal startup, Press ENTER to Nav Flagged (or Nav Info) 38. Turn the unit off and back on in normal mode.
page.
MONITOR MODE
5. Turn the large knob any direction to Last Valid Position page.
Record it in the space provided. 39. Press and hold the NAV button to enter Monitor Mode.
6. Press the SYS smart key to reach Navigation Info page. 40. Turn the large knob CW to RF Level page.
7. Press ENTER. 41. Turn the large knob CW to Noise Level page.
8. Turn large knob CCW to CDI Scaling. 42. Turn the large knob CW to Hdphon Lvl page.
9. Turn the large knob CCW to Direct To. 43. Turn the large knob CW to Icm Sq page.
10. Press the SYS smart key. 44. Turn the large knob CW to Mic1 Sqlch page.
11. Turn the large knob CW to System Info. Press ENTER. 45. Turn the large knob CW to Mic2 Sqlch page.
12. Record the Date & Time. 46. Turn the large knob to the Transmit Mic page. Circle the Mic
13. Turn the large knob CW to Current Software Version. Record it Configuration.
and serial number. Check that the serial number matches the 47. Turn the large knob CW to the Intcom Lvl page.
chassis. 48. Turn the large knob CW to SidTon Lvl page.
14. Turn the small knob CCW to VHF COMM SW Version.
49. Turn the large knob CW to Lo Dsp Lvl page.
15. Turn the small knob CCW to GPS Sensor SW Version.
50. Turn the large knob CW to Hi Dsp Lvl page. Record it in the
16. Turn the small knob CCW to Database page. Record database space provided.
expiration date, part number and database type.
51. Turn the large knob CW to Locks. It is factory set to 0.
17. Turn the large knob CW to Fuel Measure page. Record type fuel.
52. Perform the final acceptance test and record the results.
18. Press the SYS smart key twice. Sign and date.
19. Turn the large knob CCW to Comm Info page. 53. Perform Final Inspection and record the results. Sign and
20. Press ENTER to RF Signal Level page. Record value. date.
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

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Service Manual

October 2004 560-7001-501 Rev. --

ii GX Service Manual © 2004 Garmin AT

Navigating Our Phone System

© 2004 Garmin AT GX Service Manual iii

CHAPTER 4. ANTENNA INSTALLATION GUIDES ................................................................................................ 4-1

CHAPTER 5. AIRCRAFT INSTALLATION TROUBLESHOOTING .......................................................................... 5-1

iv GX Service Manual © 2004 Garmin AT

BATTERY REPLACEMENT .................................................................................................................................8-5

CHAPTER 13. SERVICE DATA SHEET .............................................................................................................. 13-1

© 2004 Garmin AT GX Service Manual v

vi GX Service Manual © 2004 Garmin AT

January 2001 ........................................................................................................................... Revision A

October 2004 ...........................................................................................................................Revision --

© 2004 Garmin AT GX Service Manual vii

This Page Intentionally Left Blank

viii GX Service Manual © 2004 Garmin AT

Service Authorization and Audits

Updating Service Manuals

© 2004 Garmin AT GX Service Manual 1-1

Sources for Soldering Standards

GPS Signal Source

Guide for using hand tools

1-2 GX Service Manual © 2004 Garmin AT

Guide for Using Fasteners

© 2004 Garmin AT GX Service Manual 1-3

1-4 GX Service Manual © 2004 Garmin AT

© 2004 Garmin AT GX Service Manual 2-1

Power/Volume/Squelch Knob (GX60/65)

Small and Large Knobs

2-2 GX Service Manual © 2004 Garmin AT

NRST (Nearest Waypoint)

MAP (Graphic Moving Map)

© 2004 Garmin AT GX Service Manual 2-3

FPL (Flight Plan)

SYS (System Mode)

SKIP (Start-Up Option)

Map Function Smart Keys

Map Waypoint Keys

APT, VOR, INT, NDB, & USR

Waypoint LIST Key

Waypoint SCAN Key

2-4 GX Service Manual © 2004 Garmin AT

Map Setup Keys

Communications Radio Mode Smart Keys - GX60/65

RCL (Recall) (GX60/65)

MON (Monitor) (GX60/65)

MEM (Memorize) (GX60/65)

XIT (Exit) (GX60/65)

© 2004 Garmin AT GX Service Manual 2-5

2-6 GX Service Manual © 2004 Garmin AT

• Automatic waypoint sequencing

GPS Receiver Performance Specifications

© 2004 Garmin AT GX Service Manual 2-7

GX50 and GX60/65 Avionics Outputs

2-8 GX Service Manual © 2004 Garmin AT

GX55 Avionics Outputs

© 2004 Garmin AT GX Service Manual 2-9

VHF Comm Features (GX60/65)

VHF Comm Receiver Performance Specifications (GX60/65)

2-10 GX Service Manual © 2004 Garmin AT

VHF Comm Transceiver Performance Specifications (GX60/65)

© 2004 Garmin AT GX Service Manual 2-11