T

COMPONENT MAINTENANCE MANUAL

WITH
ILLUSTRATED PARTS LIST
34-51-01
TITLE PAGE T-1
Publishing Number 82183 7 JUNE 1996
Revision A Revised 3 NOVEMBER 1997
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

PROPRIETARY NOTICE

This document and the information disclosed herein are proprietary data of Trimble. Neither this document nor
the information contained herein shall be used, reproduced, or disclosed to others without the written authoriza-
tion of Trimble, except to the extent required for installation or maintenance of recipient's equipment.

NOTICE - FREEDOM OF INFORMATION ACT (5 USC 552) AND

DISCLOSURE OF CONFIDENTIAL INFORMATION GENERALLY (18 USC 1905)

This document is being furnished in confidence by Trimble. The information disclosed here falls within exemption
(b) (4) of 5 USC 552 and the prohibitions of 18 USC 1905. For further information contact, Manager, Technical
Publications, TRIMBLE, Avionics Division, 2105 Donley Drive, Austin, Texas 78758. Telephone (512) 432-0400.

S96

34-51-01
TITLE PAGE T-2
Copyright 1996 Trimble Navigation Limited
All Rights Reserved 7 JUNE 1996
 MATERIALS HAZARD RATING CODE
This manual uses the National Fire Protection Association system to identify the different levels of hazards
caused by the use of a given material. A Hazard Code identifies three effects of a material on a person: health
(eat, drink, touch, and breathe), fire (when and how it burns), and reactivity (chemical explosions). Also, each
material is given a storage group for safety.

Each code has three numbers and one letter (for example, 130D) as shown in the Hazard Code symbol below.
The three numbers show the hazard levels for health, fire, and reactivity, in that sequence. The range of each
number is 0 to 4. The higher the number, the more dangerous the hazard. You must be careful with any
material that has a Hazard Code with a 2, 3, or 4. The letter (A thru E) in the code identifies a specific storage
group that is applicable for the material.

If applicable, materials used for the procedures in this manual are given a Hazard Code. More data on the
health and fire levels is shown on page H-2. Get specific data on a material from the data sheet supplied by the
manufacturer of the material.

POSITION 1: HEALTH HAZARD POSITION 2: FIRE HAZARD

0 No important hazard 0 Will not burn
1 Irritant - Use with caution 1 Must increase the temperature above 93.40C
2 Hazardous - Prevent continued exposure, to burn
inhalation, and contact 2 Must increase the temperature above 37.80C
3 Dangerous hazard - Use protective clothing to burn
together with protection to breathe 3 Fire and explosion hazard at ambient
4 Very bad hazard - Do not breathe vapor or temperature
come in contact with liquid without approved 4 Highly dangerous fire and explosion hazard
special protection

POSITION 3: REACTIVITY HAZARD POSITION 4: STORAGE GROUP

0 Usually stable A Acids
1 Unstable if heated B Alkalis, cyanides
2 Violent chemical change is possible C Oxidizing agents
3 Dangerous explosion is possible D Chlorinated hydrocarbons, flammable liquids,
4 Very bad explosion hazard - quickly go out of materials that are not flammable
the area if materials area exposed to fire E Neutral salts and others

HAZARD RATING PAGE H-1

Jun 7/96
 HEALTH HAZARD RATING IN POSITION 1

Rating Description Effect of Exposure

4 Very bad health Very short exposures could cause DEATH or CRITICAL
hazard REMAINING INJURY even after fast medical treatment. Do
not breathe the vapor or come in contact with the liquid
without approved protection.

3 Dangerous health Short exposures could cause DANGEROUS TEMPORARY OR

hazard REMAINING INJURY even with fast medical aid. Use
approved clothing.

2 Hazardous Intense or continued exposure could cause TEMPORARY

DISABILITY OR POSSIBLE REMAINING INJURY unless
medical aid is given immediately.

1 Irritant May cause IRRITATION on exposure. Only SMALL REMAINING

INJURY would be the result without medical treatment.
Safety glasses must be worn.

0 No important Not hazardous for usual conditions. Special personal

health hazard protection is not necessary.

FIRE HAZARD RATING IN POSITION 2

Rating Description Effect of Exposure

4 Very flammable Any liquid or gaseous material that is a liquid under pressure with a
flash point below 22.80C. Also materials that can form explosive
mixtures with air, such as dusts or combustible solids, and
pressurized small drops of flammable or combustible liquid.
PREVENT ALL SOURCES OF IGNITION.
NO SMOKING PERMITTED!

3 Highly flammable Liquids and solids that can start to burn in almost all conditions of
ambient temperature. Liquids with a flash point at or above 22.80C
but below 37.80C. Control all sources of ignition. NO SMOKING!

2 Moderately Material that must be warm or in an area open to high temperatures

combustible before ignition can occur. This rating is applicable to liquids having
a flash point above 37.80C but below 94.30C. Be very careful when
near a source of heat.

1 Lightly Materials that must be hot before ignition can occur. This rating
combustible includes materials that will burn in air in an area open to a
temperature of 81.50C for 5 minutes or less. Liquids and solids
have a flash point at or above 93.40C.

0 Will not burn Any material that will not burn in air in an area open to a temperature
of 81.50C for 5 minutes.

HAZARD RATING PAGE H-2

Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

FOLD FOLD
———————————————————————————————————————
——————————————————————————————————————--

From:
Place Stamp Here

Trimble Navigation Limited

2105 Donley Drive
Austin, TX 78758

———————————————————————————————————————
——————————————————————————————————————
FOLD FOLD
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Date Received

READER COMMENTS

Trimble welcomes all comments and recommendations to improve future editions of this publication.

Your Name Company Airline

Address

State Country Zip

Telephone No. FAX Date

Trimble Pub. No. ATA No.

Manual Title

COMMENTS/RECOMMENDATIONS:

LOCAL REPRODUCTION ENCOURAGED

(If returning by mail, please tape closed; Postal regulations prohibit use of staples.)
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Date Received

REPORT OF POSSIBLE DATA ERROR

Your Name Company Airline

Address

State Country Zip

Telephone No. FAX Date

Trimble Pub. No. ATA No.

Manual
Title

PAGE NO. PARAGRAPH FIGURE NO. TABLE NO. PROBLEM

TRIMBLE REPLY:

APPROVAL:

LOCAL REPRODUCTION ENCOURAGED

(If returning by mail, please tape closed; Postal regulations prohibit use of staples.)
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

RECORD OF REVISIONS
Assigned To (Job Title) Location

Rev Revision Insertion Rev Revision Insertion

No. Date Date By No. Date Date By

34-51-01 Pages RR-1/RR-2

Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

RECORD OF TEMPORARY REVISIONS

Assigned To (Job Title) Location

Temporary Date Date Date

Revision No. Revised Inserted By Removed By

34-51-01 Pages RTR-1/RTR-2

Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

SERVICE BULLETIN LIST

FOR PART NO. 81440

Service Identified Date Included

Bulletin MOD in this Manual Description

34-51-01 Pages SBL-1/SBL-12

Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

LIST OF EFFECTIVE PAGES

Subheading and Page Date Subheading and Page Date

Title 22 June 7/96

T-1 June 7/96 23 June 7/96
T-2 June 7/96 24 June 7/96
Hazard Rating Code June 7/96 25 June 7/96
H-1 June 7/96 26 June 7/96
H-2 June 7/96 27 June 7/96
28 June 7/96
Record of Revisions
29/30 June 7/96
RR-1/RR-2 June 7/96
F 31/32 June 7/96
Record of Temporary Revision 33 June 7/96
RTR-1/RTR-2 June 7/96 34 June 7/96
Service Bulletin List 35 June 7/96
SBL-1/SBL-2 June 7/96 36 June 7/96
37/38 June 7/96
List of Effective Pages
Testing and Fault Isolation
LEP-1 Nov 3/97
101 June 7/96
LEP-2 June 7/96
102 June 7/96
Table of Contents 103 June 7/96
TC-1 June 7/96 104 June 7/96
TC-2 June 7/96 105 June 7/96
TC-3 June 7/96 106 June 7/96
TC-4 June 7/96 107 Nov 3/97
TC-5/TC-6 June 7/96 108 June 7/96
109 June 7/96
Introduction 110 June 7/96
INTRO-1 June 7/96 111 June 7/96
INTRO-2 June 7/96 112 June 7/96
INTRO-3 June 7/96 113 June 7/96
INTRO-4 June 7/96 114 June 7/96
115 June 7/96
Description and Operation
116 June 7/96
1 June 7/96
117 June 7/96
2 June 7/96
118 June 7/96
3 June 7/96
119 June 7/96
4 June 7/96
120 June 7/96
5 June 7/96
121 June 7/96
6 June 7/96
122 June 7/96
7 June 7/96
123 June 7/96
8 June 7/96
124 June 7/96
9 June 7/96
125 June 7/96
10 June 7/96
126 June 7/96
11 June 7/96
127 June 7/96
12 June 7/96
128 June 7/96
13 June 7/96
129 June 7/96
14 June 7/96
130 June 7/96
15 June 7/96
131 June 7/96
16 June 7/96
17 June 7/96
18 June 7/96
19 June 7/96
20 June 7/96
21 June 7/96

34-51-01 Page LEP-1

Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Nov 3/97
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

LIST OF EFFECTIVE PAGES (Con't)

Subheading and Page Date Subheading and Page Date

132 June 7/96 Repair

133 June 7/96 601 June 7/96
134 June 7/96 602 June 7/96
135 June 7/96 603 June 7/96
136 June 7/96 604 June 7/96
137 June 7/96 Assembly (Including Storage)
138 June 7/96 701 June 7/96
139 June 7/96 702 June 7/96
140 June 7/96 703 June 7/96
141 June 7/96 704 June 7/96
142 June 7/96 705 June 7/96
143 June 7/96 706 June 7/96
144 June 7/96 707/708 June 7/96
145 June 7/96
146 June 7/96 Fits and Clearances
147 June 7/96 801/802 June 7/96
148 June 7/96 Special Tools, Fixtures, and Equipment
149 June 7/96 901/902 June 7/96
150 June 7/96 Illustrated Parts List
151 June 7/96 1001 June 7/96
152 June 7/96 1002 June 7/96
153 June 7/96 1003 June 7/96
154 June 7/96 1004 June 7/96
155 June 7/96 1005 June 7/96
156 June 7/96 1006 June 7/96
157 June 7/96 1007 June 7/96
158 June 7/96 1008 June 7/96
159 June 7/96 LF 1009/1010 June 7/96
160 June 7/96 1011/1012 June 7/96
161 June 7/96 1013 June 7/96
162 June 7/96 1014 June 7/96
163 June 7/96 1015 June 7/96
164 June 7/96 1016 June 7/96

Disassembly
301 June 7/96
302 June 7/96
303 June 7/96 F indicates right foldout page with blank back.
304 June 7/96 LF indicates left foldout page with blank front.
305/306 June 7/96
Cleaning
401 June 7/96
402 June 7/96
403/404 June 7/96
Check
501 June 7/96
502 June 7/96

34-51-01 Page LEP-2

Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

TABLE OF CONTENTS

INTRODUCTION .................................................................................................................. Intro-1

DESCRIPTION AND OPERATION .............................................................................................. 1

1. Physical Description ........................................................................................................ 1
2. System Description ......................................................................................................... 3
3. Functional Description .................................................................................................... 5
A. RDU Operation ..................................................................................................... 7
B. Front Panel Layout and Description ..................................................................... 8
(1) Power Switch ............................................................................................. 8
(2) LED Display ............................................................................................... 8
(3) Annunciators ........................................................................................... 10
(4) Mode Keys .............................................................................................. 11
(5) Function Keys .......................................................................................... 13
(6) Selector Knobs ........................................................................................ 14
(7) Built-In-Test ............................................................................................. 14
C. RDU Circuit Card Assemblies ............................................................................ 15
(1) Power Supply CCA (A1) .......................................................................... 15
(2) Synchro Power/Filter CCA (A3/A2) ......................................................... 18
(3) Filter CCA (A2) ........................................................................................ 19
(4) Driver CCA (A3) ...................................................................................... 20
(5) Interface CCA (A4) .................................................................................. 21
(6) GPS Sensor CCA (A5) ............................................................................ 29
(7) Processor CCA (A6) ................................................................................ 33
(8) Display CCA (A7) .................................................................................... 36

TESTING AND FAULT ISOLATION ......................................................................................... 101

1. Task ........................................................................................................................... 101
2. Equipment and Materials ............................................................................................ 101
3. Test Procedure ........................................................................................................... 101
4. Fault Isolation Procedure ............................................................................................ 102

AUTOMATIC TEST REQUIREMENTS (ATLAS)*

*Not applicable

Page TC-1
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440
DISASSEMBLY ......................................................................................................................... 301
1. Task ........................................................................................................................... 301
2. Equipment and Materials ............................................................................................ 301
A. Equipment ......................................................................................................... 301
B. Materials ............................................................................................................ 301
3. Procedure.................................................................................................................... 302
A. Upper Case Removal ....................................................................................... 302
B. Lower Case Removal ....................................................................................... 302
C. Display Assembly Removal ............................................................................. 303
D. Front Panel Key Cap Removal ........................................................................ 303
E. Circuit Card Assembly Stack............................................................................ 303

CLEANING ............................................................................................................................... 401

1. Task ........................................................................................................................... 401
2. Equipment and Materials ............................................................................................ 401
3. Procedure.................................................................................................................... 402
A. Clean External Parts ........................................................................................ 403
B. Clean Electrical Parts ....................................................................................... 403
C. Clean Glass Parts ............................................................................................ 403

CHECK .................................................................................................................................... 501

1. Task ........................................................................................................................... 501
2. Equipment and Materials ............................................................................................ 501
3. Procedures .................................................................................................................. 501
A. Examine ........................................................................................................... 501
B. Make Sure ........................................................................................................ 502

REPAIR .................................................................................................................................... 601

1. Task ........................................................................................................................... 601
2. Equipment and Materials ............................................................................................ 601
A. Equipment ........................................................................................................ 601
B. Materials ........................................................................................................... 602
3. Procedure.................................................................................................................... 602
A. Special Repair Procedures .................................................................................... 602
(1) General Comments .......................................................................................... 602
(2) Replace Battery ................................................................................................ 603
(3) Replace On/Off Switch ..................................................................................... 603
(4) Replace Rotary Encoder Switch ...................................................................... 604
B. Paint Touch-up ...................................................................................................... 604

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page TC-2
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440
ASSEMBLY (Including Storage) ............................................................................................... 701
1. Task ........................................................................................................................... 701
2. Equipment and Materials ............................................................................................ 701
A. Equipment ........................................................................................................ 701
B. Materials ........................................................................................................... 701
3. Assembly Procedure ................................................................................................... 701
A. Circuit Card Assembly Stack ................................................................................. 701
(1) CCA A5 ........................................................................................................... 701
(2) CCA A4 ........................................................................................................... 702
(3) CCA A3/A2 (Preferred Configuration) ............................................................. 703
(4) CCA A2 and CCA A3 (Alternate Configuration) .............................................. 703
(5) CCA A1 ........................................................................................................... 703
B. Display Assembly Installation ................................................................................ 704
C. Lower Case Installation ......................................................................................... 704
D. Upper Case Installation ......................................................................................... 705
4. Storage........................................................................................................................ 706
A. Task ...................................................................................................................... 706
B. Equipment and Material ........................................................................................ 706
C. Procedure for CCA ............................................................................................... 707

FITS AND CLEARANCES ........................................................................................................ 801

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT ................................................................. 901

1. Task ............................................................................................................................ 901
2. Special Tools, Fixtures, and Equipment ..................................................................... 901

ILLUSTRATED PARTS LIST .................................................................................................. 1001

Equipment Designator Index .......................................................................................... 1006
Numerical Index ............................................................................................................. 1007
Parts List ........................................................................................................................ 1013

Page TC-3
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

List of Figures

Figure 1 2101 I/O Receiver Display Unit ................................................. 1

Figure 2 2101 I/O System ........................................................................ 4
Figure 3 2101 I/O to Aircraft Interface ..................................................... 6
Figure 4 Front Panel Functionality Grouping ........................................... 9
Figure 5 Power Supply CCA (A1) .......................................................... 17
Figure 6 Synchro Power/Filter CCA (A3/A2) (Preferred) ....................... 18
Figure 7 Filter CCA (A2) ........................................................................ 19
Figure 8 Driver CCA (A3) ....................................................................... 20
Figure 9 Interface CCA (A4) .................................................................. 28
Figure 10 GPS Sensor CCA (A5) ............................................................ 31
Figure 11 Processor CCA (A6) ................................................................ 35
Figure 12 Display CCA (A7) ..................................................................... 37
Figure 101 Setup...................................................................................... 123
Figure 102 Key Test ................................................................................. 124
Figure 103 Power Up ............................................................................... 125
Figure 104 Software Configuration .......................................................... 126
Figure 105 System Configuration ............................................................ 127
Figure 106 Power Interrupt Test .............................................................. 130
Figure 107 Button Lights Tests ................................................................ 131
Figure 108 Display Tests ......................................................................... 133
Figure 109 Display Intensity Tests ........................................................... 134
Figure 110 Knob Input Tests .................................................................... 135
Figure 111 No. 1 CDI Test ....................................................................... 137
Figure 112 No. 2 CDI Test ....................................................................... 138
Figure 113 Audio Output Tests ................................................................ 139
Figure 114 Data Card Tests ..................................................................... 140
Figure 115 Analog Converter Tests ......................................................... 141
Figure 116 Real Time Clock Tests ........................................................... 143
Figure 117 User Waypoint Entry .............................................................. 144
Figure 118 Auxiliary Input Tests............................................................... 145
Figure 119 Auxiliary Output Tests ............................................................ 152
Figure 120 External Lamps and Flags Tests ........................................... 155
Figure 121 Miscellaneous Output Tests .................................................. 156
Figure 122 GPS Receiver Tests .............................................................. 157
Figure 123 Serial Port 2 Tests ................................................................. 158
Figure 124 Serial Port 1 Tests ................................................................. 162
Figure 701 Control Cable Connection ...................................................... 702
Figure 702 Filter/Power Cable Connection .............................................. 705

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page TC-4
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

List of Tables

Table 1 Leading Particulars ................................................................... 2

Table 2 ARINC 429 Input Devices ....................................................... 22
Table 3 DADS Digital Input .................................................................. 23
Table 4 AHRS Digital Inputs ................................................................ 24
Table 5 Serial Inputs ............................................................................ 24
Table 6 ARINC 429 Output Parameters .............................................. 25
Table 101 2101 I/O Final Test Procedure .............................................. 103
Table 102 Test to Fault Isolation Cross Reference ............................... 122
Table 801 Fits and Clearances .............................................................. 801
Table 1001 List of Suppliers .................................................................. 1005

Page Page TC-5

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
TC-5/TC-6
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

INTRODUCTION

How to Use this Manual

The instructions in this manual give the recommended maintenance functions to put the Trimble 2101
I/O Receiver Display Unit in serviceable condition. Standard maintenance procedures are not given
in this manual.

Refer to the table of contents to see which sections are included in this manual. The table of
contents identifies those sections that are not applicable, require no special instructions, or are
scheduled for a subsequent revision.

We recommend the tests in TESTING AND FAULT ISOLATION be done before the unit is
disassembled. These tests will analyze the performance of the Receiver Display Unit and indicate
the most probable cause of any malfunction. Should any malfunction occur, repair as necessary.

To decrease the length of sentences and titles, complete part numbers are not always shown in this
manual. A piece of the part number can show applicability to a specific assembly or component on
illustrations as well as in text and tables. Complete part numbers are always given in the
ILLUSTRATED PARTS LIST.

Related publications to use with this manual are identified in the following list:

Document Publication No.

Abbreviations for Use on Drawings and in Text* ASME Y1.1
(1989)
Standard Letter Symbols for Units of Measurement* ANSI/IEEE Std. 260
(1978)
Graphic Symbols for Electrical and Electronics Diagrams* ANSI Y32.2
(1975)
Graphic Symbols for Logic Functions* ANSI/IEEE Std. 91
(1984)

*Available from the American National Standard Institute, New York, NY

34-51-01 Page INTRO-1

Use or disclosure of information on this page is subject to the restrictions on the title page of this document. Jun 7/96
 COMPONENT

T
MAINTENANCE
MANUAL
P/N 81440

Verification of these technical instructions is done by performance or by simulation of the necessary

procedures. Checks of the manual by the engineering staff make sure the instructions and
description data agree with the applicable engineering specifications and drawings and are accurate
and sufficient. The level of verification for this manual is as shown:

Subheading Level of Verification

Testing and Fault Isolation By performance, 07 June, 1996
Disassembly By performance, 07 June, 1996
Assembly By performance, 07 June, 1996
Trimble will revise this manual as necessary to provide current data. The sources for data supplied
in this manual include engineering drawings and change orders released as of 07 June 1996.

Abbreviations
Weights and measurements in this manual are in U.S. values. The letter symbols for units of
measurement and the abbreviations are the same as shown in ANSI/IEEE Std 260 and ASME Y1.1,
except as identified below.

Abbreviations Definitions
A/C Aircraft
ADC Air Data Computer
AHRS Altitude and Heading Reference System
ANT Antenna
APR/APPR Approach
ARINC Aeronautical Radio Incorporated
AS Address Strobe

BCD Binary Coded Decimal

CCA Circuit Card Assembly

ComStat Communication Status
CCW Counter Clockwise
CDI Course Deviation Indicator
CPU Central Processing Unit
CW Clockwise

DADS Digital Air Data System

DTK Desired Track

ENT Enter
ETE Estimated Time Enroute

Page INTRO-2
34-51-01 Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Abbreviations Definitions
FC BUS Function Code Bus
FMS Flight Management System
FPL Flight Plan

GPS Global Positioning System

GS Glideslope
GMT Greenwich Mean Time

HDG Heading
HLD Hold
HSI Horizontal Situation Indicator

IF Intermediate Frequency
IFR Instrument Flight Rules
ILS Instrument Landing System
I/O Input/Output
LDS Lower Data String
LED Light Emitting Diode
LORAN Long Range Navigation

MHZ Megahertz
MSG Message

NAV Navigation
NMI Nonmaskable Interrupt

PTK Parallel Track

PWR Power

RAIM Receiver Autonomous Integrity Monitoring

RAM Random Access Memory
RDU Receiver Display Unit
RF Radio Frequency
ROM Read Only Memory
RX Receive

SAT Status Air Temperature

SATCOM Satellite Communication
SID Standard Instrument Departure
STR String
STAR Standard Terminal Arrival Route
SYN Sync

34-51-01 Page INTRO-3

Use or disclosure of information on this page is subject to the restrictions on the title page of this document. Jun 7/96
 COMPONENT

T
MAINTENANCE
MANUAL
P/N 81440

Abbreviations Definitions

TAS True Air Speed

TAT Total Air Temperature
TTL Transistor to Transistor Logic

UART Universal Asynchronous Receiver Transmitter

UDS Upper Data String
UUT Unit Under Test

VOR VHF Omnidirectional Ranging

WPT Waypoint

XT Transmit
XTK Crosstalk

Special Precautions

CAUTION
THIS EQUIPMENT IS SENSITIVE
TO DAMAGE BY ELECTROSTATIC
DISCHARGE. USE PROTECTIVE
PROCEDURES.

The 2101 I/O Receiver Display Unit contains parts that are electrostatic sensitive. If you do not obey
the necessary controls, a failure or degraded operation of the unit can occur because of static
electrical voltages. Use approved industry precautions to keep the risk of damage to a minimum
when you touch, remove, or insert static-sensitive devices. These devices are identified in the
ILLUSTRATED PARTS LIST of this manual as ESDS.

Page INTRO-4
34-51-01 Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

DESCRIPTION AND OPERATION

1. Physical Description

The Trimble 2101 I/O Receiver Display Unit (RDU) is a cockpit Dzus-mounted assembly that
consists of the following parts:

• Top Case
• Circuit Card Assemblies A1 through A6
• Bottom Case
• Display Panel (Circuit Card Assembly A7) with either black or gray bezel:

- A bank of fully independent momentary action pushbutton switches

- ON/OFF and Encoder switches

• Connectors for interface to the aircraft

See Figure 1 for a typical Receiver Display Unit. Refer to Table 1 for leading particulars.

2101 I/O Receiver Display Unit

Figure 1

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 1
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Dimensions (maximum)
Height ............................................................. 3.0 in. ( 762mm)
Width ............................................................. 5.7 in. (1449mm)
Depth ........................................................... 7.68 in. (1950mm)
Weight ....................................................................... 3.25 lb. (1.48kg)
Temperature:
Navigation Unit .................................................... -20 to +70 C
Database Card ....................................................... 0 to +55 C
RDU Mounting Dzus Rail
Power Requirements .................................................... 28 V dc @ 1.5A
Connectors:
RDU #1 .................................................................. TNL 80251
(MS27508E14B35A)
RDU #2 .................................................................. TNL 80253
(MS27508E18B35P)
Antenna Cable Assembly ....................................... TNL 20692

Leading Particulars
Table 1

The RDU circuit card assemblies are configuration specific. Depending on the
configuration selected, the following circuit card assemblies (CCAs) are used in the RDU:

CCA A1 - POWER SUPPLY

CCA A3/A2 - SYNCHO POWER/FILTER
CCA A2 - FILTER
CCA A3 - DRIVER
CCA A4 - INTERFACE
CCA A5 - GPS SENSOR
CCA A6 - PROCESSOR BOARD
CCA A7 - DISPLAY

NOTE: CCA A3/A2 Synchro Power/Filter is the preferred configuration and is installed in
place of separate A2 and A3 CCAs.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 2
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

2. System Description

The RDU is a Dzus-mounted navigation management system designed to fulfill the navigation
requirements of business and general aviation aircraft. The RDU uses Global Positioning
System (GPS) signals to:

• Track aircraft position and velocity

• Provide flight planning and waypoint (great circle) navigation features

The RDU uses a Jeppesen data base contained on a credit-card sized ROM card. The card
plugs into the RDU front panel and contains waypoints and terminal area procedures. The
North American and International data bases are maintained on a 28-day update cycle.

The 2101 I/O line replaceable units (LRUs) are:

• GPS Antenna/Preamplifier Unit

• Receiver Display Unit (RDU) (Figure 2)

The GPS antenna contains an omnidirectional flat micro-strip antenna with an integral
preamplifier.

The RDU contains all of the system processing power and uses three different software units:

• GPS Processor for GPS signal processing and navigation

• Host Processor for managing GPS sensors, flight planning, and waypoint navigation
• Aux I/O Processor to handle the input/output processing

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 3
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

2101 I/O System

Figure 2

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 4
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. Functional Description

The RDU interfaces (Figure 3) with the aircraft systems listed below:

• Heading
• True Airspeed
• Altitude
• Fuel Flow
• Course Deviation Indicator (CDI)
• Horizontal Situation Indicator (HSI)
• Autopilot
• Annunciators

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 5
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

2101 I/O to Aircraft Interface

Figure 3

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 6
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. A. RDU Operation

The RDU is controlled by mode keys, function keys, and selector knobs. Annunciator lights
provide for system messages, current navigation mode, and parallel track selection.

A mode may have one or more functions and is a logical grouping of one or more functional
categories. The mode keys are:

• NAV for access to navigation information

• WPT for access to waypoint data base

• FPL for flight planning

• CALC for performing E6B calculations

• AUX for auxiliary functions

• APT/VOR for nearest airports and VORs

A function may have one or more data pages. Data pages display status information about
the RDU, or contain data fields that allow for variable selections. A data page may also
have additional information. The information is displayed on a secondary data page or on
the upper or lower line of the current page. For example, the GPS STATUS page has
secondary status pages that display information on individual satellites.

Modes are selected by pressing one of the mode keys. When pressed, a mode key
illuminates to indicate an active mode. One of the functions of the mode is then displayed.
Pressing the mode key again displays the next function, and so on. When the last function
is reached, pressing the mode key again will reselect the first function.

If the displayed function contains data pages, rotating the small inner selector knob
sequences through the data pages. Turning the large outer selector knob allows additional
information related to the current data page to be displayed. Rotating the small inner
selector knob in the opposite direction sequences back through the data pages. The small
knob is also used to access another line of data on the current data page.

Some data pages contain fields that are changeable. The selector knobs and the ENT
function key are used to enter or change information on a data page.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 7
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. B. Front Panel Layout and Description

The RDU front panel features a two line high-intensity alphanumeric LED dot-matrix display.
Each line is capable of displaying 20 characters. Nine illuminated buttons and two
concentric knobs are used to enter data.

The RDU includes a front panel data base card reader. The card reader is used to access
the navigation data base, provided by Jeppesen. The card reader will also interface with a
RAM data card for programming flight plans and other flight data.

The functional description of the RDU can be separated into the following areas:

• Power Switch
• LED Display
• Annunciators
• Mode Keys
• Function Keys
• Selector Knobs

Each functional area is discussed below. Figure 4 shows the functionality grouping on the
front panel.

(1) Power Switch

The RDU has one power switch located at the top of the unit. When the power is
turned ON, the system goes through a series of self-diagnostic tests. When these
tests are successfully completed a “Ready for Navigation” or "Fuel on Board"
message appears.

(2) LED Display

The RDU displays information on a two line LED screen. The information displayed on
these two lines changes depending upon the mode selected. Different sets of
information are displayed for each mode. The LED screen intensity is automatically
adjusted based on ambient light.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 8
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Front Panel Functionality Grouping

Figure 4

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 9
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. B. (3) Annunciators

The annunciators (Figure 4) are located below the LED display. They are not visible
unless lit. The following paragraphs provide a description of each annunciator.

(a) MSG Annunciator

When flashing, the message (MSG) annunciator indicates a message is waiting in

the message queue. The MSG annunciator will flash until all new messages are
read. After the advisory messages are read the MSG annunciator will extinguish.
If the message is for a warning, the MSG annunciator will remain illuminated.

(b) GPS Annunciator

The GPS annunciator confirms the RDU is operating in the GPS mode. A steady
GPS annunciator indicates normal operation. A flashing GPS annunciator
indicates the RDU has changed mode due to limited availability of satellites. In
-238 software, an off GPS annunciator indicates normal operation.

(c) RAIM Annunciator

The Receiver Autonomous Integrity Monitoring (RAIM) annunciator confirms RAIM

is available. A steady RAIM annunciator indicates normal operation. In -238
software, an off RAIM annunciator indicates normal operation.

(d) WPT Annunciator

The Waypoint (WPT) annunciator provides notice of a waypoint arrival. When

approaching the active waypoint, the WPT annunciator will illuminate at the preset
lead time. The lead time is set by the AUX CONFIGURE ADVISORY MESSAGES
function.

(e) PTK Annunciator

The Parallel Track Annunciator (PTK) indicates a track parallel to the direct course
has been selected. The selected offset, is displayed when the MSG Key is pressed.

(f) HLD Annunciator

The Hold (HLD) annunciator provides notice that the active flight plan or approach
profile is currently in hold mode, i.e., plan suspended at the current active waypoint.
The hold mode may be manually selected or automatically set by the RDU at
predefined hold waypoints. These predefined hold waypoints are programmed into
the navigation database.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 10
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. B. (3) (g) APR Annunciator

The Approach (APR) annunciator provides notice that the approach mode is active
and the aircraft is on the final approach.

(4) Mode Keys

The front panel contains six mode keys (Figure 4), located in two rows at the bottom of
the front panel. The keys are used to select an RDU mode of operation. When a key is
pressed, it illuminates to confirm selection of that mode. Pressing a key for 1 to 1½
seconds returns the display to the primary page of the mode. The following is a brief
description of each mode key and its function:

(a) NAV Mode

The Navigation (NAV) mode is the primary RDU mode and is used to access
navigation information.

(b) WPT Mode

The Waypoint (WPT) mode provides access to the navigation data base.

(c) FPL Mode

The Flight Plan (FPL) mode is used to create, activate, revise, and erase flight
plans. The RDU can store up to 400 flight plan waypoints with a maximum of 40
waypoints in any one flight plan.

(d) CALC Mode

The Calculator (CALC) mode performs common E6B computer functions. This
mode is used to save present position. It is also used to calculate navigation
profiles, wind speed and direction, fuel ranges, flight plan summaries, etc.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 11
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. B. (4) (e) AUX Mode

The Auxiliary mode (AUX) provides access to less commonly used functions. The
mode is divided into five functional areas:

• Checklists User entered Checklists, Custom Data, Commonly used

Frequencies, etc.

• System Status Date, Time, Present Position, System operating conditions,

Data base and Software revisions

• Sensor Status GPS Status and Accuracy, Satellite Data, GPS Availability,
Approach RAIM Availability

• Configuration Parallel Offset, Search Regions, Airwatch, Advisory

Messages,CDI Sensitivity, Mag Var, DR Mode, Save/Load
Configuration

• Installation Audio Level, Display Intensity, Personal Message, User

Units, Install and Test Setup, Serial I/O Setup, AUX I/O
Setup

For detailed operational data refer to the 2101 I/O Pilot’s Guide.

(f) APT/VOR Mode

The Airport/VOR (APT/VOR) mode provides the following information:

• The 20 nearest airports

• Approaches
• VOR
• Agencies
• NDBs
• Intersections
• User waypoints

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 12
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. B. (5) Function Keys

The three function keys (Figure 4) are located to the right of the LED display. Each
function key has a unique set of applications. The following paragraphs provide a brief
description of each function key:

→) Key
(a) Direct (D

The function of the Direct (D→) key is to select a new active waypoint or a specific
course inbound or outbound; to or from the current active waypoint. The key is also
used to activate a flight plan, approach, SID, or STAR autonomously. Other
→) key are:
functions of the Direct (D

• Selection of a specific track from present position to the active waypoint

• Selection of a user defined DME arc about any active waypoint

Direct key functions are:

(1st Press) - Selects displayed waypoint, procedure, or flight plan for activation

(2nd Press) - Activates course steering as selected

(Escape) - Select any other key

(b) MSG Key

The Message (MSG) key is used to view messages on the display that do not
automatically pop-up. A flashing MSG annunciator indicates a new message is in
the queue. A steady MSG annunciator indicates an old message remains in the
queue. New and old messages located in the queue are accessed and displayed by
pressing the MSG Key.

(c) ENT Key

The Enter (ENT) key is used to enter, select, or change the information currently
displayed on the LED Screen. This key is most often used in conjunction with the
selector knobs. Enter key functions are:

(1st Press) - Opens a changeable field on the displayed page

(2nd Press) - Accepts data

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 13
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. B. (6) Selector Knobs

Two selector knobs are used (Figure 4) to control the display of information on the LED
screen. The small inner selector knob changes the information in the top line of the LED
display. The large outer selector knob changes the information in the bottom line of the
LED display.

Several lines of information are usually available in each mode of operation. A clockwise
turn of either knob sequences the display through the information. A counterclockwise
turn sequences the display backward.

The selector knobs also control the change of information on the LED lines and are used
for selecting variable data. When data is being entered, the small inner selector knob is
used to select data. The large outer selector knob is used to move from one field to the
next.

Angle brackets “< >” indicate that the field between the brackets may be changed by
rotation of the small inner selector knob. To select new data:

• Rotate the SMALL INNER SELECTOR KNOB to the desired data page.

• Press the ENT key.

• Rotate the LARGE OUTER SELECTOR KNOB to move to the data field to be
changed.

• Rotate the SMALL INNER SELECTOR KNOB to change information in the data field.

• Press the ENT key to complete the data entry.

(7) Built-In-Test

The RDU performs built-in-test (BIT) to isolate system failures to the LRU level. BIT
identified failures are:

• Oscillator out of adjustment

• Host I/O Processor Failure
• GPS Signal Processor Failure
• GPS Antenna Failure
• Data base Failure
• Data base out of date

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 14
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. RDU Circuit Card Assemblies

To assist in the troubleshooting process, a block diagram and an explanation of the block
diagram for each of the following circuit card assemblies is provided:

• Power Supply CCA (A1)

• Filter CCA (A2)
• Driver CCA (A3)
• Interface CCA (A4)
• GPS Sensor CCA (A5)
• Processor CCA (A6)
• Display CCA (A7)

(1) Power Supply CCA (A1)

The power supply CCA (A1) develops ±15 Vdc, +5 Vdc, and +3 Vdc (Figure 5). The
output voltages are used to supply Vcc and to bias circuitry on the other RDU CCAs.
There are no user replaceable components on this CCA.

(a) ±15 Vdc Voltage

The ±15 Vdc is developed by full-wave bridge rectifier circuit. The output is filtered
and distributed to the other RDU CCAs.

(b) +5 Vdc Voltage

The +5 Vdc is developed by its own rectifier circuit. The output is filtered and
distributed to the other RDU CCAs.

(c) +3 Vdc Voltage

The +3 Vdc is developed by its own rectifier circuit. The output is filtered and
distributed to the other RDU CCAs.

(d) Audio Output Driver

The power supply assembly provides a 600 ohm audio output signal and an
audio output monitor signal.

(e) Annunciator Driver

Driver for APR, HLD, MSG, and WPT.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 15
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (1) (f) Power Switch

The power switch on the front of the display panel supplies aircraft power to the A1
CCA. Aircraft power failures will result in a power failure signal being generated by
this CCA. Since aircraft power is applied to the CCA, an aircraft power failure will
cause a Non-Maskable Interrupt (NMI) to be generated. The NMI will shut down the
RDU to prevent damage to its circuity. The RDU must be turned OFF and then ON
following any NMI.

(g) Reset Control

The Power Supply CCA contains the system reset and power monitor circuitry.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 16
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Power Supply CCA (A1)

Figure 5

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 17
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (2) Synchro Power/Filter CCA (A3/A2)

The Synchro Power/Filter CCA (A3/A2) is an integral unit. The CCA uses Rigid/Flex
construction to interface the A3 and A2 portions of this CCA. An alternate configuration
uses separate A3 and A2 CCAs. However, the integral A3/A2 configuration is the
preferred.

The Synchro Power/Filter CCA (A3/A2) circuits are used to eliminate electromagnetic
and electrostatic interference from the synchro drive signals (Figure 6). The CCA has
its own ±21Vdc power supply. This power supply provides isolation of the supply
voltages used to operate the operational amplifiers, buffers and ancillary circuits on
this CCA. Isolation of the synchro drive circuitry is necessary to ensure “clean”
synchro drive voltages are output to the aircraft systems.

Six synchro signals are applied to operational amplifiers where they are processed
with their reference signals. These signals are buffered to provide for signal isolation
and routed through lowpass pi filters. Electromagnetic and electrostatic interference
is filtered out by the lowpass pi filters. The synchro signals are then supplied to the
appropriate aircraft sensor.

The other RDU signals bypass the operational amplifier and buffer stages. However,
they are routed through the low pass pi filters to eliminate interference.

There are no user replaceable components on this CCA.

Synchro Power/Filter CCA (A3/A2) (Preferred)

Figure 6

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 18
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (3) Filter CCA (A2)

The Filter CCA (A2) circuits are used to eliminate electromagnetic and electrostatic
interference from the RDU signals (Figure 7). RDU signals, except for the synchro
signals, are filtered by lowpass pi filters. The signals are then distributed throughout
the RDU and to the appropriate aircraft sensor.

This CCA is used with CCA A3 when the preferred CCA A3/A2 configuration is not
used. CCA A2 performs the same function as the filter portion of CCA A3/A2.

There are no user replaceable components on this CCA.

Filter CCA (A2)

Figure 7

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 19
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (4) Driver CCA (A3)

The Driver CCA (A3) circuits are used to eliminate electromagnetic and electrostatic
interference from the synchro drive signals (Figure 8). The CCA has its own ±21Vdc
power supply. This power supply provides isolation of the supply voltages used to
operate the operational amplifiers, buffers and ancillary circuits on this CCA. Isolation
of the synchro drive circuitry is necessary to ensure “clean” synchro drive voltages are
output to the aircraft systems.

Six synchro signals are applied to operational amplifiers where they are processed
with their reference signals. These signals are buffered to provide for signal isolation
and routed through lowpass pi filters. Electromagnetic and electrostatic interference is
filtered out by the lowpass pi filters. The synchro signals are then supplied to the
appropriate aircraft sensor.

All other RDU signals bypass the operational amplifier and buffer stages and are not
filtered on this CCA. This CCA is used with CCA A2 when the preferred CCA A3/A2
configuration is not used. CCA A3 performs the same function as the synchro drive
portion of CCA A3/A2.

There are no user replaceable components on this CCA.

Driver CCA (A3)

Figure 8

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 20
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (5) Interface CCA (A4)

The Interface CCA (A4) (Figure 9) consists of the following circuits:

• Interface Processor
• Analog Inputs
• Analog Outputs
• ARINC 429 Inputs
• ARINC 429 Outputs
• Discrete I/O Inputs
• Discrete I/O Outputs

(a) Interface Processor

The interface processor is a Motorola 68332. It controls the external input/

output (I/O) device interfaces, data transfers between the external I/O
interfaces and the host processor. The RDU I/O communicates to external
systems by the use of CDI, Annunciator, and Serial Inputs/Outputs.

1 CDI Output

The RDU provides standard Course Deviation Indicator (CDI) output

signals.

2 Additional Annunciator Output

The annunciator lights are:

• Dead Reckoning (DR)

• Approach enable (APR EN)
• Approach mode (APR MDE)

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 21
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (5) (b) Analog Inputs

The following analog inputs are processed by the A4 CCA:

• Two analog Altimeter input (X, Y, Z)

• One analog True Air Speed input (X, Y, Z)
• One analog Heading input (X, Y, Z)
• TAS and HDG Ref inputs
• HSI Ref Hi signal
• STR Ref Hi signal
• REF_COM.

(c) Analog Outputs

The RDU provides analog outputs from the analog output circuits to the Discrete I/O
for interface with aircraft systems. SYN 1X, SYN 2X, SYN 3X, SYN 1Y, SYN 2Y,
SYN 3Y are analog outputs routed to the interface connector. The STR signal, the
left/right signal and the REF 1, 2, 3, and 4 signals are routed to the interface
connector as analog outputs.

(d) ARINC 429 Inputs

The ARINC 429 ports transmit data at high or low speed and are user
programmable. The input ports are listed in Table 2.

Name Function

DADS Digital Air Data System

AHRS Attitude and Heading Reference System

RADAR Color Weather Radar

FUEL Digital Fuel Flow Indicator

ARINC 429 Input Devices

Table 2

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 22
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (5) (d) 1 DADS Input

The RDU accepts inputs of True Airspeed (TAS), Pressure Altitude, and
Barometrically Corrected Altitude, Total Air Temperature (TAT), and Static Air
Temperature (SAT). The system accepts these inputs as ARINC 419/575 or
429 data (Table 3).

Label
(Octal) Parameter Format
203 Altitude (Press) 419/575 BNR
204 Altitude (Baro) 419/575 BNR
210 TAS 419/575 BNR
211 Total Air Temperature 419/575 BNR
213 Static Air Temperature 419/575 BNR
230 TAS 419/575 BCD

OR

Label
(Octal) Parameter Format
203 Altitude (Press) 429 BNR
204 Altitude (Baro) 429 BNR
210 TAS 429 BNR
211 Total Air Temperature 429 BNR
213 Static Air Temperature 429 BNR

DADS Digital Inputs

Table 3

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 23
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (5) (d) 2 AHRS Input

The RDU accepts heading inputs on the AHRS port (Table 4).

Label
(Octal) Parameter Format
314 True HDG 429 BNR
320 Mag HDG 429 BNR

AHRS Digital Inputs

Table 4

3 RADAR Input

The RDU accepts inputs of waypoint coordinates on the RADAR port.

On receipt of valid waypoint latitude and longitude the RDU will assign an
identifier of “rdrwp” to the coordinates. The input may be the ARINC 419 or
ARINC 429 format.

4 Fuel Input

The Fuel input port accepts inputs of Total Fuel and Fuel Flow (Table 5).

Label
(Octal) Parameter Format
244 Fuel Flow Rate 429 BNR
247 Total Fuel 429 BNR

Serial Inputs
Table 5

5 Serial Input

The RDU supports two programmable serial input channels. Each channel is
capable of interfacing to air data and altitude computers.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 24
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (5) (e) ARINC 429 Outputs

The RDU provides outputs for three synchros, a Horizontal Deviation Indicator and
a Vertical Deviation Indicator for driving a Horizontal Situation Indicator (HSI).

The standard ARINC 429 labels supported by the RDU are listed in Table 6.

Label
(Octal) Parameter Format
001 Distance 429 BCD
002 ETE 429 BCD
012 Groundspeed 429 BCD
015 Wind Speed 429 BCD
016 Wind Direction 429 BCD
075 To/From Waypoint 429 BNR
076 Altitude (MSL) 429 BNR
114 DTK 429 BNR
115 Bearing 429 BNR
116 Crosstrack 429 BNR
121 Steering 429 BNR
125 GMT 429 BCD
147 Magnetic Var 429 BNR
174 Glideslope Deviation 429 BNR
251 Distance 429 BNR
252 ETE 429 BNR
260 Date 429 BCD
270, 271,
275 Status 429 DISC
310 Latitude 429 BNR
311 Longitude 429 BNR
312 GS 429 BNR

ARINC 429 Output Parameters

Table 6 (page 1 of 2)

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 25
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Label
(Octal) Parameter Format
313 Track 429 BNR
314 Heading 429 BNR
315 Wind Speed 429 BNR
316 Wind Direction 429 BNR
321 Drift Angle 429 BNR
351 Distance to Dest 429 BNR
352 Time to Dest 429 BNR
366 N/S Velocity 429 BNR
367 E/W Velocity 429 BNR
NOTE: The following GAMMA data is only sent when GAMMA
is selected.
074 No. of Waypoints GAMMA
303 Waypoint Rec. Start GAMMA
304 WPT ID (1-3) GAMMA
305 WPT ID (4-6) GAMMA
306 WPT Latitude GAMMA
307 WPT Longitude GAMMA
113 Checksum GAMMA
NOTE: In place of the GAMMA Waypoint data, channel 2
supports the output of Waypoint data in ARINC 429
format as a user programmable option.
324-347 Waypoint Lat/Long 429 BNR

ARINC 429 Output Parameters

Table 6 (page 2 of 2)

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 26
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (5) (f) Discrete I/O Inputs

The RDU supports seven discrete input signals. The inputs are:

• OLEO (Air/Ground) State

• Heading Valid
• Speed Valid
• Altitude Synchro Valid
• 3 Spares

(g) Discrete I/O Outputs

The RDU outputs 14 discrete signals to define the current system status. The
outputs are:

• Track Change
• Steering Valid
• Nav Super Flag
• Warn (MSG)
• Waypoint Alert
• Dead Reckoning (DR)
• TO/FROM
• NAV Flag
• Synchro Valid
• Hold (HLD)
• Approach (APR)
• Approach Enable
• 2 Spares

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 27
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Interface (A4) CCA

Figure 9

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 28
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (6) GPS Sensor CCA (A5)

The GPS Sensor CCA (see Figure 10) contains a Motorola Computer operating at
25 MHz. It also contains two flash EEPROMs 128Kx8 each, and two SCRAM devices,
128Kx8 each.

Down Converter
The NPU current source transmits the 5 Vdc and 40 mA current to the antenna. The
same coax sends an RF signal of 1.575 GHz to the NPU. The RF is then filtered,
amplified, and filtered again.

Despreader
The down converter sends the IF to three sets of 3-channel despreaders where it is
translated into microprocessor-usable code.

The code is processed by the computer to yield position and velocity and stored in a
data buffer. When the Host CCA requests position and velocity, the data buffer sends
this information. The almanac part of the code is stored in battery-backed RAM.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page
Page 29
29/30
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

GPS Sensor CCA (A5)

Figure 10

Pages 31/32
34-51-01 Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (7) Processor CCA (A6)

The Processor CCA (A6) (Figure 11) board contains the following circuits:

• Memory
• Main Processor
• UART + ADC
• Sensors
• Display/keyboard Interface
• System Clocks
• External Interface

(a) Memory

Memory receives read and write enable signals from the Main Processor for both
the Lower Data String (LDS) and Upper Data String (UDS).

Memory select is accomplished by use of the first four (4) address lines (0 - 3).
U405 and U406 are both volatile RAM. However, a 3.6 Vdc battery provides
constant voltage, making them battery backed non-volatile RAM.

(b) Main Processor

The main processor accesses memory locations and implements data transfer to
or from memory. There are 24 address lines and 16 data transfer lines utilized.

(c) UART + ADC

The UART + ADC receives data in a serial form and transforms it into a parallel
format. It also accepts parallel formatted data and transforms it to a serial format.
The purpose of the two way data transfer is to connect a parallel bus to serial
data circuits.

(d) Sensors

Sensor data is input to the data bus and used for navigation solutions. The main
processor controls the use of sensor data. The sensor circuits use system clock
inputs to control the timing and flow of sensor data to the data bus.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 33
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (7) (e) Display Keyboard Interface

The display keyboard interface circuits allow interfacing of the display board and
data signals. Keyboard inputs to and from the display are buffered.

(f) System Clocks

System clocks control the timing for the use and display of all RDU data. The
master oscillator develops a frequency of 16.368 MHz. This frequency is divided
by two to provide 8.186 MHz for the display data shift register. The 8.186 MHz is
also used as a clock input.

(g) External Interface

A digital to analog chip converts the localizer left/right signals from digital to
analog. These analog signals are sent to the aircraft systems and the course
deviation indicator.

The battery on this CCA is user replaceable.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 34
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Processor CCA (A6)

Figure 11

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 35
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. (8) Display CCA (A7)

The Display CCA (A7) (Figure 12) provides the user interface for monitoring, changing,
and accessing data. The display is also the user interface for performing
troubleshooting and checking the health status of the RDU. Functionally, the display
consists of:

• Power Switch
• Mode Keys
• Function Keys
• Selector Knobs
• Display Modules

(a) Power Switch

The Receiver Display Unit has one power switch (S10) located at the top of the
display panel. The power switch provides aircraft power to CCA A1.

(b) Mode Keys

The Mode keys are located in two rows at the bottom of the front panel. They are
used to select the RDU’s mode of operation. When a key is pressed, it
illuminates to confirm selection of that mode.

(c) Function Keys

The function keys are located to the right of the LED display. Each function key
has a unique set of applications.

(d) Selector Knobs

The RDU uses an encoder (S11) to control the display of information on the LED
screen. The encoder uses a small (inner) and a large (outer) knob for function
selection.

User replaceable components on this CCA are the power switch (S10), encoder
(S11), and the mode and function key caps.

(e) Display Modules

The ten dot matrix displays are driven serially by Control CCA circuitry. Each
display contains four characters made up of 5 columns by 7 rows of dots for
each character. Five FETs on the Display/Keyboard drive the columns. To create
a display, the Control CCA turns off all column drivers, sends data serially to fill all
ten display ICs, then strobes each column driver. The width of the column
strobes is determined by the photo sensor.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 36
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Display CCA (A7)

Figure 12

34-51-01 PagePage
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
37
37/38
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

TESTING AND FAULT ISOLATION

1. Task
Use the test procedures in this section to test the 2101 I/O Receiver Display Unit. The test
procedures include fault detection and isolation (diagnostics) for Level II repair. Isolation is to
the CCA or other Level II subassembly. Wiring, connectors, pins and solder joints are assumed
to be performing at an acceptable level of operation.

Use the test procedures in Table 101 to make an analysis of the performance of the Receiver
Display Unit. To isolate any malfunction that may occur, note the failed test step and refer to
Table 102. Table 102 cross-references failed test steps to the Figure number for the
appropriate troubleshooting flow diagram.

TEST NOTICE
The source of Table 101 is Trimble Navigation Final
Test Procedure, 2101 I/O, 81440-XXTP.

2. Equipment and Materials

NOTE: Equivalent alternatives are permitted for the equipment and materials in this list.

Refer to Table 101 for a list of the necessary equipment for testing and fault isolation.

3. Test Procedure

CAUTION
THIS EQUIPMENT IS SENSITIVE
TO DAMAGE BY ELECTROSTATIC
DISCHARGE. USE PROTECTIVE
PROCEDURES.

Use the instructions in Table 101 to connect the Receiver Display Unit to the test equipment
(refer to Figure 101). Perform the tests as given and look for the specified results.

Page 101
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4. Fault Isolation Procedure

When there is a test failure:

- Use Table 101 to get the number of the failed test.

- Use the failed test step number in Table 102 to identify the fault isolation procedure for
isolating the malfunction to a CCA. When more than one CCA is identified for possible
failure, the CCA given first is the most probable.

- Refer to Figure 1 of the ILLUSTRATED PARTS LIST for a description and location of the
defective CCA.

- Refer to the instructions in DISASSEMBLY and ASSEMBLY to replace a defective CCA.

Page 102
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

2101 I/O GPS NAVIGATOR ASSEMBLY, DWG NO. 81440-XXTP

RECEIVER DISPLAY UNIT

1.0 INTRODUCTION

This document contains procedures for final testing of the Model 2101 I/O GPS RDU, 81440-XX.

2.0 TEST EQUIPMENT

The following test equipment is required:

Description Part Number

CDI/AIO Test Set (ET-2000) 82074
Cable, AIO Test Set, 66 pin
Cable, CDI Test Set, 37 pin
Cable, Test Set Serial to PC
Cable, NPU to GPS Ant.
Oscilloscope Tek 2236 or equiv.
Digital Multimeter HP 3466 or equiv.
GPS Antenna 16248 or 81194
PC, 386 with VGA monitor and 1 comm port, 1 printer port
Printer
Database Card 81461-XX
Counter PM-6666 or Equiv.
28 Vdc Power Supply
115 Vac 40 Hz Future Development

2101 I/O Final Test Procedure

Table 101(page 1 of 18)
Page 103
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3.0 SOFTWARE REQUIREMENTS

The following software is required on the PC.

IOMON21.EXE ........... Displays Auxiliary Input Data

SPECS.DAT ............... Contains acceptance bounds for Analog tests
NAVFT.EXE................ Tests GPS sensor version 2.36 or later
NAVFT.REF................ Position reference file used by NAVFT.EXE
ex: 30 23.22 N 97 42.79 W 200 M
SPDRIVE.COM .......... Serial I/O driver
READNAV.EXE .......... ASCII Serial test

4.0 TEST PROCEDURE

4.1 Equipment Set-Up and Test Initialization

4.1.1 Set Up

Set the AIO test set switches as follows:

ALTVLD down
GOAROUND down
SPDVLD down
HDGREF down
HDGVLD down
ALT/HDG/ TAS Ref down
GEARUP down
STRNGREF down
OLEO down

NOTE: UUT is NOT connected at this time.

Connect the CDI/AIO test set to the power supply 28 Vdc, turn it on, and verify a
voltage of 28 V _
+ 2 V. Then turn it off.

2101 I/O Final Test Procedure (page 2 of 18)

Table 101
Page 104
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Figure 1 ATP Test Equipment Interconnect

2101 I/O Final Test Procedure (page 3 of 18)

Table 101

Page 105
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.1.2 UUT Configuration

Record the UUT Part Number, Serial Number, and Date on the Test Data Record
sheet.
Record installed Service Bulletins on the Test Data record.
Connect UUT and test sets in accordance with Figure 1. Insert the data base
card into the front of the UUT.

4.1.3 Key Test

Press each of the nine keys several times each. Verify smooth operation of
each key.

4.1.4 Power Up

Turn on the CDI/AIO test set.

Turn on the UUT.

Verify the following messages on the display:

TRIMBLE
2101 I/O
NAV Computer —OK
GPS Computer —OK
Aux IO Computer —OK
Data base —OK
or
Data base —Expired

4.1.5 Software Configuration

On the UUT, press AUX repeatedly until SYSTEM STATUS is briefly displayed.
Rotate the small knob clockwise until REVISION numbers are displayed.

Use the software dash number (last characters of the part number on the ID
tag) as an index into Table 1.

2101 I/O Final Test Procedure (page 4 of 18)

Table 101
Page 106
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Verify that the software versions are in accordance with Table 1.

UUT P/N NAV GPS AIO

81440-XX-0229 2.580 4.02-1214 0110
81440-XX-0233 2.580 4.02-1214 0110
81440-XX-0238 2.600 4.02-1214 0110
81440-XX-238A 2.601 4.02-1214 0110
81440-XX-0239 2.581 4.02-1214 0010

Table 1

4.1.6 System Configuration

Press AUX repeatedly until INSTALL is briefly displayed.

Rotate the small knob until SERIAL I/O SETUP is displayed.
Rotate the large knob until SERIAL 1 I/O is displayed.
Press →
D ,→D ,→D , rotate the small knob one click right, press ENT.
Rotate the small knob until AIO1 is displayed. Press ENT.

Turn small knob right until AUX I/O SETUP is displayed.

Rotate the large knob until SYNCHRO OUTPUT #1 is displayed. Press ENT,
rotate the small knob right to select HDG. Press ENT.

Rotate the large knob until SYNCHRO OUTPUT #2 is displayed. Press ENT,
rotate the small knob right to select HDG. Press ENT.

Rotate the large knob until SYNCHRO OUTPUT #3 is displayed. Press ENT,
rotate the small knob right to select HDG. Press ENT.

Rotate the large knob until AUTOPILOT ROLL STEER is displayed.

Press ENT, rotate the small knob right to select NORMAL. Press ENT.

2101 I/O Final Test Procedure (page 5 of 18)

Table 101
Page 107
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Nov 3/97
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.1.7 Save Waypoint

Press CALC until PRESS (ENT) TO SAVE POSITION TO alpha is displayed.

Press ENT.

Press WPT until the upper display briefly reads “USER”.

Rotate the small knob until waypoint alpha is displayed.

Record the name and coordinates of this waypoint in the 2101 I/O Final Test
Record comments section.

4.1.8 Power Interrupt Test

Press the “pulse” button and verify that the UUT does not reset.

If UUT restarts its initialization sequence, the unit failed the test.

Record results of 4.1 on 2101 I/O Final Test Record.

4.2 User Interface Tests

4.2.1 Button Light Tests

Note the display of the UUT. If MSG is flashing, press the MSG key
repeatedly, until the annunciator stops flashing, and the screen noted above is
displayed again.

Press the following keys, in sequence, and verify the results on the UUT
display:

Key Result

NAV NAV Key is On, all others dim.

→
D NAV Key is On, → D is Blinking,
all others dim.
WPT WPT Key is On, all others dim.
ENT ENT Key is blinking, WPT is On, all others dim.
FPL FPL Key is On, all others dim.
CALC CALC Key is On, all others dim.
AUX AUX Key is On, all others dim.
APT/VOR APT/VOR Key is On, all others dim.
MSG MSG and APT/VOR are On, all others dim.

2101 I/O Final Test Procedure (page 6 of 18)

Table 101
Page 108
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.2.2 Display Tests

Press the AUX repeatedly until INSTALL is briefly displayed.

Rotate the small knob until INSTALL & TEST SETUP is displayed. Rotate the large
knob right until DISPLAY DIAGNOSTICS is briefly displayed.

NOTE: AUX is always on. MSG, GPS and RAIM may be on.

Observe the annunciator LEDs. They should light in a sequential manner in the
following order and in the color indicated:

-00, -01 -10, -11

MSG Amber Green
GPS Amber Green
RAIM Amber Green
WPT Amber Green
PTK Amber Green
HLD Amber Green
APR Green Green

Observe both lines of the display for any unlit, always lit, or dimly lit pixels as
the dashed horizontal line scrolls.

Observe the key LEDs. They should light in a sequential manner in the
following order:

NAV, WPT, FPL, CALC, AUX, →

D , MSG, ENT, APT/VOR

2101 I/O Final Test Procedure (page 7 of 18)

Table 101
Page 109
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.2.3 Display Intensity Tests

Rotate the small knob counterclockwise until the display reads SET DISPLAY
INTENSITY. Press ENT.

Rotate both knobs several revolutions clockwise and verify that the display and
keys increase in intensity.

Rotate both knobs several revolutions counterclockwise and verify that the display
and keys decrease in intensity.

Press ENT.

4.2.4 Knob Input Tests

Press the NAV key.

Note the Upper Display Line text on the UUT. Turn the small knob clockwise 24
times. Verify that changing text is displayed for each knob click, and that after the
24th screen, the Upper Display line indicates the same text as noted.

Turn the small knob counterclockwise eight times.

Verify that changing text is displayed for each knob click, and that after the eighth
screen, the Upper Display line indicates the same text as noted.

Note the Lower Display Line text on the UUT.

Turn the large knob clockwise 24 times.

Verify that changing text is displayed for each knob click, and that after the 24th
screen, the Upper Display line indicates the same text as noted.

Turn the large knob counterclockwise eight times.

Verify that changing text is displayed for each knob click, and that after the eighth
screen, the Lower Display line indicates the same text as noted.

Record results of 4.2 on 2101 I/O Final Test Record.

2101 I/O Final Test Procedure (page 8 of 18)

Table 101
Page 110
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.3 External IOP I/O Tests

4.3.1 External CDI Output Test

4.3.1.1 #1 CDI TEST

Press the AUX key repeatedly until INSTALL is briefly displayed.

Rotate the small knob left until the INSTALL & TEST SETUP is displayed.
Rotate the large knob one click right I/O INTERFACE CHECK. Press ENT.
Rotate the small knob until the CDI needle is centered on the CDI test set.
Press ENT.

Rotate the small knob until the CDI needle is aligned with the furthest left dot
on the CDI test set. Press ENT.

Verify that the display indicates 5L, and the Cross Track needle on the CDI
test set indicates full left deflection.

Rotate the small knob clockwise ten times. After each click, verify that the
display and the Cross Track needle on the CDI test set indicate the deflection
listed below (+
_ 0.25 divisions):

4L (left), 3L, 2L, 1L, 0, 1R, 2R, 3R, 4R, 5R (right)

Press ENT.

4.3.1.2 #2 CDI TEST

Connect the DC volt meter positive lead to the A/P +RT test point on the CDI/
AIO test set. Connect the negative lead to the GRD test point.

Rotate the small knob until the meter reads zero.

Press ENT.

Verify that the voltmeter reads -150 mV, +

_ 3 mV.

Press ENT.

Rotate the small knob right until the 5R is displayed.

Verify that the voltmeter reads +150 mV, +

_ 3 mV.

2101 I/O Final Test Procedure (page 9 of 18)

Table 101
Page 111
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.3.1.2 #2 CDI TEST

Press ENT until FLAG: FROM is displayed.

Verify that the From Flag is visible on the CDI.

Rotate the small knob right one click at a time and verify that the flags
and lamps match the UUT screen.

On the CDI/AIO test set, set the HSIEF and STRNGREF switches to the
Up position.

Pess ENT until TEST SYNCHRO #1 is displayed. Rotate knob right

so 030° is displayed.

With an oscilloscope, verify that the following test points on the CDI/AIO test
set contain an approximately 450 Hz sine wave of the amplitutde
shown, within 10%. Also verify that the sine wave is in phase or out of
phase withSYN1X, as indicated. Use the ENT key to move from
synchro #1 to #2 to #3 to roll steering.

Test Point Setting V(pp) Phase

SYN1X Synchro #1 030° 18.0 In Phase
SYN1Y Synchro #1 030° 9.0 In Phase
SYN2X Synchro #2 030° 18.0 In Phase
SYN 2Y Synchro #2 030° 9.0 In Phase
SYN3X Synchro #3 030° 18.0 In Phase
SYN3Y Synchro #3 030° 9.0 In Phase
STEERING Roll 15° right 9.0 Out of Phase

Press ENT.

2101 I/O Final Test Procedure (page 10 of 18)

Table 101
Page 112
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.3.2 Audio Output Tests

Press AUX until INSTALL is briefly displayed. Rotate the small knob left until SET
AUDIO LEVEL is displayed.

Press ENT.

Rotate the small knob clockwise repeatedly until a tone is heard. Rotate the large
knob counterclockwise repeatedly and verify that the tone decreases in pitch.

Rotate the small knob counterclockwise repeatedly until the tone is no longer
audible. Rotate large knob clockwise at least one revolution. Press ENT.

4.3.3 Data Card Tests

Press APT/VOR and observe data for nearest location. (Data may vary
between data card cycles).

Repeat the above step for APPROACH, VOR, NDB and INT.

4.3.4 Analog Converter Tests

Press AUX repeatedly until SYSTEM STATUS is briefly displayed.

If necessary, rotate the small knob until Date and Time are displayed.

Rotate the small knob clockwise until INPUT VOLTAGE is displayed.

Verify INPUT VOLTAGE is 25 to 30 volts.

Verify INTERNAL TEMP is 20O to 70O C.

Rotate the large knob clockwise once.

Verify CRYSTAL OFFSET is less than 24 Hz.

Verify MEMORY BATTERY is greater than 3.4 V.

Rotate the large knob clockwise once.

2101 I/O Final Test Procedure (page 11 of 18)

Table 101
Page 113
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.3.4 Analog Converter Tests (Con't)

Verify GPS ANTENNA voltage is between 3 and 5 V.

Verify GPS ANTENNA CURRENT is greater than 20 mA.

Disconnect GPS Antenna Cable.

Verify that the antenna voltage is 4.8 to 5.3 V and the current is less than 10 mA.

4.3.5 Real Time Clock Tests

Turn the UUT off and wait three minutes.

Turn the UUT on.

After the initial messages scroll past, Press the AUX key repeatedly until
SYSTEM STATUS is briefly displayed.

NOTE: The unit will report a GPS antenna failure.

Verify that Date and Time are within 2 minutes of GMT.

Reconnect GPS Antenna cable.

4.3.6 User Waypoint Entry

Press WPT repeatedly until the upper display reads “USER”.

Rotate the small knob, if required, to view the waypoint recorded in step 4.1.7 in
the comments section of the 2101 I/O Final Test Record.

Verify the coordinates are the same as recorded.

Record results of 4.3 on 2101 I/O Final Test Record.

2101 I/O Final Test Procedure (page 12 or 18)

Table 101
Page 114
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.4 Auxiliary I/O Tests

4.4.1 Auxiliary Input Tests

Press the AUX key repeatedly until INSTALL is briefly displayed.

Rotate the small knob clockwise until PERSONAL MESSAGE.

Rotate the large knob until NEW PERSONAL MESSAGE is displayed.
Press →D , AUX, →D . Next rotate the small knob clockwise until
AUX IO CARD MODE is displayed.
Press ENT.
Rotate the small knob clockwise until TEST is displayed.
Press ENT.

Set the Serial Selector Switch on the CDI/AIO test set to 1BIP.

On the PC, type IOMON21 <Enter>

Verify that the right portion of the Discrete field on the PC display
reads 01af.

Set each switch in the following list to the UP position, verify that the
Discrete field shown on PC changes as indicated, then return the
switch to the DOWN position.

Switch Discrete Field

ALTVLD 01ab
SPDVLD 01ad
HDGVLD 01ae
OLEO 01a7
GEARUP 01bf
GOAROUND 018f

Verify that the Reference field on the PC display reads 0 0 0 0 0.

2101 I/O Final Test Procedure (page 13 of 18)

Table 101
Page 115
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Set each switch in the following list to the UP position, verify that the
Reference field shown on PC changes as indicated, then return the
switch to the DOWN position.

Switch Reference Field

HDGREF 11100
HSIREF 00010
STRNGREF 00001

In the LOOPBACK field of the PC screen, verify that all four of the error
counts are less than 4.

In the A/D Channel field of the PC screen, verify the following readings
(+
_ 40 counts) are all displayed in BLACK. Readings displayed in RED
are out of tolerance.

Channel Analog Reading Channel Analog Reading

0 fd16 8 fe41
1 fac2 9 066a
2 f998 10 05d9
3 fa2c 11 0548
4 fc80 12 04b7
5 fdab 13 0426
6 (not tested) 14 (not tested)
7 (not tested) 15 0000

Press X followed by Y on the PC to terminate the program.

2101 I/O Final Test Procedure (page 14 of 18)

Table 101
Page 116
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.4.2 Auxiliary Output Tests

Press ENT, turn the small knob counterclockwise until NORMAL is displayed.
Press ENT.
Press AUX repeatedly until INSTALL is briefly displayed.

4.4.3 Miscellaneous Output Tests

Use the oscilloscope to monitor the 6WCLK, 6WDATA, and 6WSYN

test points. All three should be digital signals switching between 0V+
_1 and
12V+ _ 3. The three lines should appear qualitatively as follows:

Signal Description
6WCLK Continuous clock at 12.5 kHz, with 50%
duty cycle
6WDATA Bursts of random digital data each bit is
80µs wide
6WSYN Signal is low between bursts of data and high
during data transmission. It drops low for one bit
time approx. 8 bits into the message.

Use the oscilloscope to monitor the PPS test point on the CDI/AIO test set.
It should be a digital signal switching between 0 V+
_1 and 4 V+
_ 1.5 . The
period should be one pulse per second and the duty cycle should be
approximately 1%.

Record results of 4.4 on 2101 I/O Final Test Record.

2101 I/O Final Test Procedure (page 15 of 18)

Table 101
Page 117
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.5 GPS Receiver Tests

Set the Port Selector Switch on the CDI/AIO test set to Port 3BIP.

On the PC, type SPDRIVE <Enter> then NAVFT @ <Enter>.

Observe the PC screen for UUT data.

Observe the PC screen for the message “Doing position fixes”. If this message is not
displayed, wait 5 minutes. If the UUT is tracking no satellites after the wait, the unit
fails. Record the failure, then proceed to section 4.6. Otherwise wait until three or
more satellites are available and the UUT is “Doing position fixes” before continuing.

On the PC, press the F1 key and wait for the test to complete. If INVALID TEST
appears on the summary, press F9 then F1, to repeat the test. Once a valid test is
complete, note any faults on the Test Data Record.

NOTE: Disregard TEMP, SYNCH, and ENT ANT Fail messages.

On the PC, press the F2 key to print the results.

Sign the printout and attach it to the Test Data Record.

Set the Port Selector Switch on the CDI/AIO test set to Port 3DIF.

Observe that the position data continues to be updated.

On the PC, press <ESC> twice to terminate the program.

Record results of 4.5 on 2101 I/O Final Test Record.

4.6 Serial Port Tests

4.6.1 Serial Port 2 Tests

Press AUX until INSTALL is briefly displayed.

Rotate small knob until AUX I/O SETUP is displayed.
Rotate the large knob until PRESS ALTITUDE INPUT is displayed.
Press ENT and set to SERIAL.
Press ENT.

Set the Port Selector Switch on the CDI/AIO test set to Port 2DIF.

On the PC, type READNAV <Enter>.

2101 I/O Final Test Procedure (page 16 of 18)

Table 101
Page 118
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.6.1 Serial Port 2 Tests (Con't)

On the UUT, rotate the small knob left until SERIAL I/O SETUP is displayed.
Rotate large knob to display SERIAL-1 IN.
Press ENT.
Turn small knob to select none.
Press ENT.

Rotate the large knob to display SERIAL-1 OUT.

Press ENT.
Rotate the small knob to select NONE.
Press ENT.

Rotate the large knob to SERIAL-2 IN.

Press ENT.
Rotate small knob to display ENCODER.
Press ENT.

Rotate large knob to SERIAL-2 OUT.

Press ENT.

Rotate small knob to K0.

Press ENT.

Observe the PC screen for position and other data.

Set the Port Selector Switch on the CDI/AIO test set to Port 2BIP.

Observe the PC screen for continuing position and other data updates.

Press the AUX key until SYSTEM STATUS is briefly displayed.

Rotate the small knob until PRESENT POSITION is displayed.
Rotate the large knob to display “PRES ALT”.

Observe: PRES ALT 1250.

2101 I/O Final Test Procedure (page 17 of 18)

Table 101
Page 119
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4.6.2 Serial Port 1 Tests

Set the Port Selector Switch on the CDI/AIO test set to Port 1DIF.

On the UUT, press AUX until INSTALL is briefly displayed. Rotate the small
knob until SERIAL I/O SETUP is displayed.

Rotate large knob to display SERIAL-2 IN. Press ENT. Rotate the small knob
to select none. Press ENT.

Rotate the large knob to display SERIAL-2 OUT. Press ENT. Rotate the small
knob to select none. Press ENT.

Rotate the large knob to SERIAL-1 IN. Press ENT. Rotate small knob to
select ENCODER. Press ENT.

Rotate the large knob to SERIAL-1 out. Press ENT. Rotate small knob to
select K0. Press ENT.

Observe the PC screen for position and other data.

Set the Port Selector Switch on the CDI/AIO test set cable to Port 1BIP.

Observe the PC screen for continuing position and other data updates.

Press the AUX key until SYSTEM STATUS is briefly displayed. Rotate the
small knob until PRESENT POSITION is displayed. Rotate the large knob to
display “PRES ALT”.

Observe: PRES ALT 1250.

On the PC press X to terminate the program.

Record results of 4.6 on 2101 I/O Final Test Record.

4.7 Test Termination

Turn off the equipment and disconnect the UUT.

Record necessary information on the 2101 I/O Final Test Record.

2101 I/O Final Test Procedure (page 18 of 18)

Table 101
Page 120
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

2101 I/O FINAL TEST RECORD

TNL 2101 I/O P/N: 81440-_____-___________ Serial #:_________________________

Start Date:__________________________ SB 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17
18 19 20 21 22

[PASSED] [FAILED]
4.1 Equipment Set-up and Test Initialization [ ] [ ]
4.2. User Interface Tests [ ] [ ]
4.3. External IOP I/O Tests [ ] [ ]
4.4 Auxiliary I/O Tests [ ] [ ]
4.5 GPS Receiver Tests [ ] [ ]
4.6 Serial Port Tests [ ] [ ]

OVERALL TEST RESULT: [ ] [ ]

Comments:

TESTED BY:____________________________

Page 121
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Failed Test Step No. Fault Isolation Procedure

Figure No.

4.1.1 Set Up 101

4.1.3 Key Test 102

4.1.4 Power Up 103

4.1.5 Software Configuration 104

4.1.6 System Configuration 105

4.1.8 Power Interrupt Test 106

4.2.1 Button Light Tests 107

4.2.2 Display Tests 108

4.2.3 Display Intensity Tests 109

4.2.4 Knob Input Tests 110

4.3.1.1 #1 CDI Test 111

4.3.1.2 #2 CDI Test 112

4.3.2 Audio Output Tests 113

4.3.3 Data Card Tests 114

4.3.4 Analog Converter Tests 115

4.3.5 Real Time Clock Tests 116

4.3.6 User Waypoint Entry 117

4.4.1 Auxiliary Input Tests 118

4.4.2 Auxiliary Output Tests 119

4.4.3 External Lamps and Flags Tests 120

4.4.4 Miscellaneous Output Tests 121

4.5 GPS Receiver Tests 122

4.6.1 Serial Port 2 Tests 123

4.6.2 Serial Port 1 Tests 124

Test to Fault Isolation Cross Reference

Table 102

Page 122
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Set Up
Figure 101

Page 123
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Key Test
Figure 102

Page 124
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Power Up
Figure 103
Page 125
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Software Configuration
Figure 104

Page 126
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

System Configuration (Sheet 1 of 3)

Figure 105

Page 127
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

System Configuration (Sheet 2 of 3)

Figure 105

Page 128
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

System Configuration (Sheet 3 of 3)

Figure 105

Page 129
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Power Interrupt Test

Figure 106

Page 130
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Button Light Tests (Sheet 1 of 2)

Figure 107

Page 131
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Button Light Tests (Sheet 2 of 2)

Figure 107

Page 132
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Display Tests
Figure 108
Page 133
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Display Intensity Tests

Figure 109

Page 134
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Knob Input Tests (Sheet 1 of 2)

Figure 110

Page 135
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Knob Input Tests (Sheet 2 of 2)

Figure 110

Page 136
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

No. 1 CDI Test

Figure 111
Page 137
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

No. 2 CDI Test

Figure 112

Page 138
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Audio Output Tests

Figure 113
Page 139
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Data Card Tests

Figure 114

Page 140
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Analog Converter Tests (Sheet 1 of 2)

Figure 115

Page 141
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Analog Converter (Sheet 2 of 2)

Figure 115

Page 142
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Real Time Clock Tests

Figure 116

Page 143
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

User Waypoint Entry

Figure 117

Page 144
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Input Tests (Sheet 1 of 7)

Figure 118

Page 145
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Input Tests (Sheet 2 of 7)

Figure 118

Page 146
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Input Tests (Sheet 3 of 7)

Figure 118

Page 147
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Input Tests (Sheet 4 of 7)

Figure 118

Page 148
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Input Tests (Sheet 5 of 7)

Figure 118

Page 149
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Input Tests (Sheet 6 of 7)

Figure 118

Page 150
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Input Tests (Sheet 7 of 7)

Figure 118

Page 151
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Output Tests (Sheet 1 of 3)

Figure 119

Page 152
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Output Tests (Sheet 2 of 3)

Figure 119

Page 153
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Auxiliary Output Tests (Sheet 3 of 3)

Figure 119

Page 154
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

External Lamps and Flags Tests

Figure 120

Page 155
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Miscellaneous Output Tests

Figure 121

Page 156
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

GPS Receiver Tests

Figure 122

Page 157
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Serial Port 2 Tests (Sheet 1 of 4)

Figure 123

Page 158
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Serial Port 2 Tests (Sheet 2 of 4)

Figure 123

Page 159
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Serial Port 2 Tests (Sheet 3 of 4)

Figure 123

Page 160
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Serial Port 2 Tests (Sheet 4 of 4)

Figure 123

Page 161
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Serial Port 1 Tests (Sheet 1 of 3)

Figure 124

Page 162
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Serial Port 1 Tests (Sheet 2 of 3)

Figure 124

Page 163
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Serial Port 1 Tests (Sheet 3 of 3)

Figure 124

PagePage 164
164/165
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 1/96
7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

DISASSEMBLY

1. Task

Use these procedures to remove parts from the RDU to do cleaning, checks, and replacement of
parts as necessary. References to figure and item numbers in the ILLUSTRATED PARTS LIST
(IPL) show you where to find the parts to remove. The applicable figure number in the IPL is
given in each primary paragraph and does not change until specified differently.

Before you disassemble the RDU, use TESTING AND FAULT ISOLATION to examine its
condition or to find the most probable cause of its malfunction. This is to prevent disassembly
that is not necessary. Do only those procedures of disassembly necessary to remove defective
parts and to correct malfunctions.

To aid in assembly, tag all removed connections and connecting hardware to show data about
the assembly location. Identify any tie points for wire assembly to prevent damage to the wire
insulation during final assembly.

2. Equipment and Materials

NOTE: Equivalent alternatives are permitted for the equipment and materials in this list.

A. Equipment

#1 Phillips

Hex wrench: 1/16 inch and 0.050 inch

1/2 inch Open end wrench

1/16 inch Nut driver

B. Materials

None

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 301
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. Procedure

CAUTION
THIS EQUIPMENT IS SENSITIVE
TO DAMAGE BY ELECTROSTATIC
DISCHARGE. USE PROTECTIVE
PROCEDURES.

A. Upper Case Removal

(1) Remove eight screws (25, IPL Figure 1) securing sides of the upper case (40) to the
lower case (200).

(2) Remove one screw (50, IPL Figure 1) securing top of the upper case (40) to the lower
case (200).

(3) Remove two screws (25) securing the bottom flange of the upper case (40) to the
lower case (200).

(4) Remove nut and lock washer securing coax connector (105) to upper case (40).
Rotate the antenna connector slightly to align flat side of connector with flat side of
hole in the case. Separate case from connector.

(5) Remove four screws (30) securing each of the two connectors (A2J1 and A2J2) to
back of upper case(40).

(6) Remove upper case.

B. Lower Case Removal

(1) Remove four screws (45) securing lower case (200) to bezel (160).

(2) Mating connectors are all that is holding the display board assembly (175) to CCA A1
(55) and CCA A6 (135). Gently pull bezel (160), with display board assembly (175)
attached, straight forward from lower case (200).

(3) Remove eight screws (45) securing lower case (200) to circuit board assembly A6
(135).

(4) Remove two screws (50) securing CCA A1 (55) to side of lower case (200).

(5) Remove lower case.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 302
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. C. Display Assembly Removal

(1) Using a .050-inch hex wrench, loosen ON/OFF knob set screw (P/O 150) and remove
the ON/OFF knob (150).

(2) Using a .050-inch hex wrench, loosen the set screw (P/O 145) on the small center
knob. Remove the small center knob (145) by pulling outward.

(3) Using a 1/16-inch hex wrench, loosen the set screw (P/O 145) on the remaining knob
(145) and remove knob by pulling outward.

(4) Remove three screws (65) securing CCA A7 (175) to bezel (160).

(5) Separate CCA A7 from bezel (160) being careful to protect and retain display filter
(170) for assembly at a later time.

D. Front Panel Key Cap Removal

(1) Carefully pull the key cap (165) forward from the display filter (170). The key cap will
pop off exposing the switch and the LEDs.

E. Circuit Card Assembly Stack

Separation of CCAs in the card assembly stack must be performed as outlined below in
order of reference designator (A1, A2, A3, etc.). The following chart cross-references the
CCA reference designators with the applicable IPL item number.

Ref Des Nomenclature IPL Item No.

A1 Power Supply 55
A3/A2* Synchro Power/Filter 75
A2 Filter 80
A3 Driver 85,85A,85B
A4 Interface 100
A5 GPS Sensor 115
A6 Processor Board 135

* CCA A3/A2 Synchro Power/Filter is the preferred configuration and is installed

in place of separate A2 and A3 CCAs. A3/A2 is an integral assembly
connected by Rigid/Flex.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 303
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. E. (1) CCA A1

NOTE: When CCA A1 is separated from CCA A6, user data stored in
memory will be lost.

(a) Disconnect Filter/Power cable assembly (60) from CCA A1 (55).

(b) Disconnect lead assembly connecting CCA A3/A2 (75) or CCA A3 (85) to
CCA A1 (55).

(c) Carefully separate CCA A1 (55) from CCA A6 (135) by pulling straight upward.

(2) CCA A3/A2 (Preferred Configuration)

(a) Remove one screw (65) and four screws (70) securing CCA A3/A2 (75) to
standoffs (95).

CAUTION: DO NOT STRESS THE RIGID/FLEX CONNECTION

BETWEEN THE A3 AND A2 COMPONENTS OF
CCA A3/A2. DAMAGE TO THE CIRCUIT LAYERS
MAY OTHERWISE RESULT.

(b) Carefully separate CCA A3/A2 (75) from CCA A4 (100) and CCA A6 (135)
connectors.

(3) CCA A2 and CCA A3 (Alternate Configuration)

(a) Carefully separate CCA A2 (80) from CCA A6 (135) by pulling straight upward.

(b) Remove one screw (65) and four screws (70) securing CCA A3 (85) to standoffs
(95).

(c) Carefully separate CCA A3 (85) from CCA A4 (100) by pulling straight upward.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 304
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

(4) CCA A4

(a) Remove five standoffs (95) securing CCA A4 (100) to standoffs (110).

(b) Disconnect control cable (90) from CCA A4 (100).

(b) Carefully separate CCA A4 (100) from CCA A5 (115) by pulling straight upward.

(5) CCA A5

(a) Remove five standoffs (110) securing CCA A5 (115) to four standoffs (130) and
one standoff (125).

(b) Carefully separate CCA A5 (115) from CCA A6 (135) by pulling straight upward.

34-51-01 PagePage
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
305
305/306
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

CLEANING

1. Task

To clean the 2101 I/O Receiver Display Unit (RDU), remove dust, dirt, and unwanted oil and
grease. This prevents corrosion and prepares surfaces so you can apply a finish or paint. Be
careful when you clean the equipment so you do not damage it. Do all the operations in dust-
free conditions. It is recommended you use filtered, low-pressure air, or a clean, soft, natural-
bristle brush to clean the equipment. You also can use a clean cloth moistened with isopropyl
alcohol. Do not use more air pressure than is necessary for the task.

After you clean the assemblies and parts, protect them from moisture, dust, or other
contamination. Keep them protected until you do a visual check and assemble the unit.

2. Equipment and Materials

WARNING: BEFORE YOU USE A MATERIAL, YOU MUST KNOW THE

HAZARD CODE AND GET THE NECESSARY
PROTECTION. REFER TO THE PAGE ABOUT HAZARD
CODES IN THE FRONT OF THIS MANUAL.

NOTE: Equivalent alternatives are permitted for the equipment and materials in this list.

Air-ionizing nozzle or gun attachment for compressed air (20 psi) — Optional source
Crocus cloth, Grade 4/0 — Optional source
HAZARD CODE 130D
Solvent — Isopropyl alcohol (99%); Optional source
Non-vinegar based glass cleaner

34-51-01 Page 401

Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. Procedure

CAUTION
THIS EQUIPMENT IS SENSITIVE
TO DAMAGE BY ELECTROSTATIC
DISCHARGE. USE PROTECTIVE
PROCEDURES.

CAUTIONS: 1. IF YOU CLEAN ELECTROSTATIC SENSITIVE PARTS

WITH PRESSURIZED AIR, MAKE SURE THE HOSE HAS
AN AIR-IONIZING NOZZLE OR GUN. WITHOUT THE
NOZZLE OR GUN ATTACHMENT, AIR FLOW CAN CAUSE
THE PARTS TO BE DAMAGED BY AN ELECTROSTATIC
CHARGE.

2. USE A VACUUM WITH A GROUNDED METALLIC NOZZLE

TO PREVENT DAMAGE FROM AN ELECTROSTATIC
CHARGE.

3. BEFORE YOU USE ISOPROPYL ALCOHOL AS A

SOLVENT, MAKE SURE IT DOES NOT DAMAGE THE
PAINTED SURFACES. APPLY A MINIMUM QUANTITY
OF THE SOLVENT TOO MUCH SOLVENT CAN DAMAGE
PARTS THAT ARE SENSITIVE TO MOISTURE.

4. USE ISOPROPYL ALCOHOL CAREFULLY WHEN YOU

CLEAN FLUX FROM SOLDER CONNECTIONS. DO NOT
LET THE SOLVENT TOUCH THE CONNECTOR BODY.
FREON, ACRYLIC, TOLUIC, OR ETHYLENE TYPE
SOLVENTS ARE NOT PERMITTED BECAUSE THEY
DAMAGE THERMO-PLASTIC CONNECTORS.

5. WHEN YOU REMOVE UNWANTED FLUX FROM THE

CCA, MAKE SURE THE CCA IS SUFFICIENTLY DRIED
AFTER CLEANING. THE INSULATING CAPABILITIES
OF ACRYLIC INSULATING COMPOUNDS WILL
DECREASE IF ISOPROPYL ALCOHOL REMAINS ON
THE COMPOUNDS TOO LONG.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 402
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. A. Clean External Parts

(1) Use compressed air or a soft, natural-bristle brush to remove light or moderate dirt and
dust from external parts.

(2) Use a cloth moistened with non-vinegar based glass cleaner to remove oil and grease
from external parts.

(3) Clean painted surfaces that have stenciled index markings, numbers, or letters with a
clean cloth moistened with a mild detergent. If the paint is in a recessed or engraved
area, clean with a stiff-bristle brush moistened with a mild detergent.

B. Clean Electrical Parts

(1) Clean electrical parts fully with a soft, natural-bristle brush moistened with isopropyl
alcohol.

NOTE: DO not clean A7 CCA (175, IPL Figure 1) with alcohol.

(2) Clean printed wiring boards with a soft, natural-bristle brush moistened with
isopropyl alcohol.

(3) Use compressed air to remove dust and dirt from around connector pins.

C. Clean Glass Parts

CAUTIONS: 1. IF DIRT, OIL, OR GREASE IS GRITTY, BE CAREFUL

NOT TO SCRATCH THE GLASS.

2. DO NOT USE EXCESSIVE PRESSURE WHEN YOU

CLEAN THE GLASS. TOO MUCH PRESSURE CAN
CRACK OR BREAK THE GLASS.

(1) Clean dust from the LED filter with pressurized air or a natural-bristle brush.

(2) Remove fingerprints and dirt with a cotton swab moistened with a mild, non-vinegar
based glass cleaner.

34-51-01 PagesPage 403

403/404
Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document. Jun 1/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

CHECK

1. Task

Visual checks are to be performed during the testing, maintenance and repair of the 2101 I/O
RDU. These visual checks make sure the parts of the RDU are physically intact and show no
signs of wear, damage, or possible failure. Use established shop practices to perform these
checks. Replace parts that are worn or damaged.

2. Equipment and Materials

None.

3. Procedures

CAUTION
THIS EQUIPMENT IS SENSITIVE
TO DAMAGE BY ELECTROSTATIC
DISCHARGE. USE PROTECTIVE
PROCEDURES.

A. Examine:

(1) All surfaces, including covers, for twisted, bent, or damaged areas that prevent a
correct fit or prevent proper movement of a part.

(2) Painted surfaces for marred or worn finishes.

(3) Threaded parts for burred or cross-threaded areas.

(4) Electrical insulation for:

• Charred areas
• Breaks
• Brittleness

(5) Each CCA for:

• A cracked or broken printed wiring board (PWB)

• Obvious opens in the printed circuit traces
• Loose terminals
• Damaged solder connections

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 501
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. A. (6) Electrolytic Capacitors for:

• Leaking
• Bulging

(7) Composition resistors and capacitors for:

• Splits
• Cracks
• Discolored or burned areas

(8) Flex-print cables for cuts or tears that expose conductors.

B. Make Sure:

(1) The unit is clean and free of:

• Dirt
• Chips
• Solder splashes
• Other particles and substances you do not want

(2) All parts are satisfactorily attached.

(3) All hardware is installed and tight.

(4) Connector pins are not bent or damaged.

(5) Solder connections are correctly attached and the solder is applied correctly.

(6) Wires do not touch any sharp edges of the chassis, screw threads, or other
surfaces that can damage the insulation.

(7) Wires or components are not compressed when you put the cover on the unit.

(8) The identification plate can be read.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 502
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

REPAIR

1. Task

Repair of the 2101 I/O RDU is to the subassembly level. This section shows you how to perform
authorized repair of subassemblies which were found to be defective during testing.

Repair of the 2101 I/O RDU is usually:

• Replacement of defective parts and wires
• Repair or replacement of a defective subassembly
• Paint touch-up

Repair of a subassembly is usually replacement of defective parts.

Disassemble the unit only to the level necessary to make repairs.

2. Equipment and Materials

WARNING: BEFORE YOU USE A MATERIAL, KNOW THE HAZARD

CODE AND GET THE NECESSARY PROTECTION.
REFER TO THE PAGE ABOUT HAZARD CODES IN THE
FRONT OF THIS MANUAL.

NOTE: Equivalent alternatives are permitted for equipment and materials in this list.

A. Equipment

Desolder equipment — STA-TEMP Desolder System with appropriate replaceable tip

cartridges, Metcal, Inc, STA-TEMP Systems Division

Solder equipment — STA-TEMP Model STSS-002 Solder System with appropriate

replaceable tip cartridges, Metcal, Inc, STA-TEMP Systems Division

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 601
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

B. Materials

Sleeving, non-rigid, insulation, crosslinked, flexible polyolefin, heat shrinkable, electrical,

clear (flammable), 0.250-inch inside diameter (MIL-I-23043/5, Class 2) - Minnesota Mining
and MFG Co, Electronized Chemicals Co, Electrical Products Div., Wilmington, MA

HAZARD CODE 330D

Charcoal black — No. 8102-05, Cardinal Paint Co

HAZARD CODE 330D

Semi-gloss black — No. F63B12, Sherwin Williams Co, Cleveland, OH

HAZARD CODE 330D

Cadet gray — No. 331535, Pratt and Lambert Paint Co

HAZARD CODE 130D

Solvent — Isopropyl alcohol (99%), semigrade; Optional source

Sleeve, AWG 24 wire size - Optional source

Crocus cloth, grade 4/0 - Optional source

3. Procedure

CAUTION
THIS EQUIPMENT IS SENSITIVE
TO DAMAGE BY ELECTROSTATIC
DISCHARGE. USE PROTECTIVE
PROCEDURES.

A. Special Repair Procedures

(1) General comments and procedures applicable to this unit are:

• Refer to the ILLUSTRATED PARTS LIST (IPL) for:

- Figure and item numbers

- Subassembly and component locations
- Part numbers
- Quantities
- Attaching hardware.

• Refer to FITS AND CLEARANCES for component clearances.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 602
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. A. (2) Replace Battery

(a) For access to CCA A6 (135, IPL Figure 1), perform disassembly of the circuit
card assembly stack according to the procedures in DISASSEMBLY.

(b) Heatsink and desolder each battery lead.

(c) Remove and properly dispose of battery (136).

(d) Add insulation sleeve to positive side of battery lead.

(e) Place battery (136) on CCA A6 (135) observing correct polarity.

(f) Heatsink and solder each battery lead.

(g) Install CCA A6 (135) according to the procedures in ASSEMBLY.

(h) Test battery using procedures in TESTING AND FAULT ISOLATION.

(3) Replace ON/OFF Switch

(a) Remove knob (150) and CCA A7 (175) according to procedures in

DISASSEMBLY.

(b) Carefully remove heat shrinkable insulation from ON/OFF switch

(180, IPL Figure 1).

(c) Tag or record wire terminations for reference during assembly.

(d) Desolder both wires.

(e) Remove nut (P/O 180) and flat washer (185) securing switch (180) to
CCA A7 (175).

(f) Remove switch.

(g) Install new ON/OFF switch and secure with flat washer (185) and nut (P/O 180).

(h) Slide approximately 1/2 inch of heat shrinkable insulation over both
ON/OFF switch wires.

(i) Heatsink and solder previously marked wire to center of ON/OFF switch.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 603
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. A. (3) (j) Heatsink and solder previously marked wire to pin 2 of ON/OFF switch.

(k) Install knob (150) and CCA A7 (175) according to the procedures in
ASSEMBLY.

(l) Check power with procedures in TESTING AND FAULT ISOLATION.

(4) Replace Rotary Encoder Switch

(a) Remove knobs (145, IPL Figure 1) and CCA A7 (175) according to procedures
in DISASSEMBLY.

(b) Desolder rotary encoder switch (190) leads from CCA A7 (175).

(c) Carefully separate rotary encoder (190) switch from CCA A7 (175).

NOTE: Make sure rotary encoder switch CCA mounting holes are
free from solder.

(d) Install new rotary encoder switch (190) on CCA A7 (175).

(e) Heatsink rotary encoder switch leads and solder each lead to CCA A7.

(f) Install knobs (145) and CCA A7 (175) according to the procedures in
ASSEMBLY.

(g) Refer to TESTING AND FAULT ISOLATION for appropriate test procedures.

B. Paint Touch-up

(1) Sand all areas to be painted with a grade 4/0 crocus cloth.

(2) Clean the surfaces to be painted with a clean cloth moistened with isopropyl alcohol.

Description Paint IPL Figure/Item No.

Upper Case Charcoal black 1/40
Lower Case Charcoal black 1/200
Bezel Semi-gloss black 1/160A & C
Bezel Cadet gray 1/160B & D

Paint Touch-up
Table 601

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 604
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

ASSEMBLY (INCLUDING STORAGE)

1. Task

This section provides instructions to assemble the 2101 I/O RDU. Do only those procedures
applicable to the level of disassembly.

References to figure and item numbers in the ILLUSTRATED PART LIST (IPL) show you the
location of the parts as they are assembled. The applicable figure number in the IPL is given in
each primary paragraph and does not change until specified differently.
Refer to paragraph 4. for storage instructions.

2. Equipment and Materials

A. Equipment
#1 Phillips
Hex wrench: 1/16 inch and 0.050 inch
½" Open end wrench
1/16" Nut driver

B. Material
None.

3. Assembly Procedure

CAUTION
THIS EQUIPMENT IS SENSITIVE
TO DAMAGE BY ELECTROSTATIC
DISCHARGE. USE PROTECTIVE
PROCEDURES.

A. Circuit Card Assembly Stack

(1) CCA A5

(a) Install and tighten four standoffs (130) and one standoff (125) to CCA A6 (135).
Do not over tighten.

(b) Carefully mate connector A5P1 with connector A6J502.

(c) Secure CCA A5 (115) to CCA A6(135) with five standoffs (110).
Do not overtighten standoffs.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 701
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

(2) CCA A4

(a) Carefully mate connector A4P1 with connector A5P3.

(b) Secure CCA A4 (100) to CCA A5(115) with five standoffs (95).
Do not overtighten standoffs.

(c) Connect control cable (90) from CCA A4 (100) to CCA A6 (135).
See Figure 701 for correct connector positioning.

Control Cable Connection

Figure 701

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 702
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. A. (3) CCA A3/A2 (Preferred Configuration)

CAUTION: DO NOT STRESS THE RIGID/FLEX CONNECTION

BETWEEN THE A3 AND A2 COMPONENTS OF CCA A3/
A2. DAMAGE TO THE CIRCUIT LAYERS MAY
OTHERWISE RESULT.

(a) Carefully mate CCA A3/A2 (75) connector P1 and J1 to CCA A4 (100) connectors
J2A and J2B and CCA A6 (135) connector P701.

(b) Secure CCA A3/A2 (75) to standoffs (95) with one screw (65) and four screws
(70).

(4) CCA A2 and CCA A3 (Alternate Configuration)

(a) Carefully mate CCA A3 (85) connector J2 to CCA A4 (100) connectors J2A and
J2B.

(b) Secure CCA A3 (85) to standoffs (95) with one screw (65) and four screws (70).

(c) Carefully mate CCA A2 (80) connector P1 to CCA A6 (135) connector P701.

(5) CCA A1

(a) Carefully mate CCA A1 (55) connectors J505 and J506 to CCA A6 (135)
connectors P505 and P506.

(b) Connect lead assembly connecting CCA A3/A2 (75) or CCA A3 (85) to mating
connector on CCA A1 (55).

(c) Connect Filter/Power cable assembly (60) from CCA A3/A2 (75) or CCA A2 (80)
to mating connector on CCA A1 (55). See Figure 702 for correct connector
positioning.

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 703
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. B. Display Assembly Installation

(1) Install display filter (170) in bezel (160). Hold bezel and display filter up to a light
and check that display filter is properly oriented.

(2) Mate CCA A7 (175) to bezel (160) and secure in place with three screws (65).

(3) Install large knob (145) onto shaft of switch A7S11 (190). Maintain 0.020 inch
clearance between back of knob and front of bezel (160).

(4) Using a 1/16-inch hex wrench, tighten the set screw (P/O 145).

(5) Install small center knob (145) onto shaft of switch A7S11 (190). Maintain 0.020 inch
clearance between back of knob and front of large knob.

(6) Using a .050-inch hex wrench, tighten the set screw (P/O 145). Check that small and
large knobs do not interfere with each other.

(7) Install ON/OFF knob (150) onto shaft of switch A7S10 (180). Maintain 0.020 inch
clearance between back of knob and front of bezel (160).

(8) Using a .050-inch hex wrench, tighten ON/OFF knob set screw (P/O 150).

C. Lower Case Installation

(1) Carefully position Circuit Card Assembly Stack in lower case (200).

(2) Secure lower case (200) to side of CCA A1 (55) with two screws (50).

(3) Secure lower case (200) to circuit board assembly A6 (135) with eight screws (45).

(4) Secure bezel (160) to lower case (200) with four screws (185).

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 704
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

D. Upper Case Installation

(1) Install coax connector (105) through rear of upper case. Ensure that gasket is in
place on connector.

(2) Install lock washer and nut onto connector and tighten.

(3) Position upper case (40) over lower case (200) and slide forward over connectors
A2J1 and A2J2.

(4) Secure each of the two connectors (A2J1 and A2J2) to back of upper case (40) with
four screws (30).

Filter/Power Cable Connection

Figure 702

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 705
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. D. (5) Secure the bottom flange of the upper case (40) to the lower case (200) with two
screws (25).

(6) Secure sides and top of the upper case (40) to the lower case (200) with eight
screws (25).

(7) Secure upper case (40) to lower case (200) with one screw (50) in top of upper
case (200).

Assembly of the RDU is complete. Test the RDU in accordance with TESTING
AND FAULT ISOLATION.

4. Storage

A. Task

Use these instructions to store or ship the Receiver Display Unit. If you must keep the RDU
in storage for long periods, keep it in conditions with a temperature range of -30 to +55 °C
(-20 to +131 °F). For extended time in storage, you must protect the RDU from dust,
moisture, and other contamination.

When you send equipment to Trimble for warranty repair, you must use the approved ATA
container, or equivalent. Warranty responsibility is contingent upon the use of a specified
ATA container.

B. Equipment and Materials

NOTES: 1. Equivalent alternatives are permitted for the equipment and

materials in this list.

2. Whenever possible, repackage the equipment within the original

packaging material.

Plastic or steel strapping (0.375 inch wide) with required strapping tool - Optional source

Static shielding bag - Optional source

Container - ATA 300, Category II, size 014, 10 by 10 by 10 inches. The container should
provide protection from excessive levels of heat, moisture, and damage from mishandling.

Dunnage - Polyurethane, polyether, fire retardant, with a density of 1.2 to 1.3 pounds per
cubic foot

Top: 8 by 8 by 4 inches with 1.5 inch nubbins

Bottom: 10 by 10 by 7.5 inches with 1.5 inch nubbins

34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 706
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

4. C. Procedure for CCAs

CAUTIONS: 1. THIS EQUIPMENT IS ELECTROSTATIC DIS-

CHARGE SENSITIVE. DO NOT PUT IT NEAR STRONG
ELECTROSTATIC, ELECTROMAGNETIC, MAG-
NETIC, OR RADIOACTIVE FIELDS.

2. DO NOT USE CARTON TAPE. REMOVAL OF TAPE

DAMAGES THE CONTAINER AND SHORTENS THE
USABLE LIFE SPAN OF THE CONTAINER.

(1) Put the CCA into a static shielding bag that is sufficient in size to contain the unit.
Fold the mouth of the bag over to enclose the unit. Do not seal the bag.

(2) Place the CCA into the container on top of a layer of foam protection.

(3) Place top layer of foam protection over the CCA and close the container.

(4) Secure the container with two bands of strapping.

(5) Attach a FRAGILE and an ESDS label to the outside of the container. The ESDS label
indicates the bag should be opened only at an approved work station.

(6) Mark the container to identify the contents and the date the CCA was packed.

34-51-01 Pages
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Page 707
707/708
Jun
Jun 7/96
1/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

FITS AND CLEARANCES

The fits and clearances in Table 801 are necessary to assemble the 2101 I/O Receiver Display Unit
correctly. Refer to the ILLUSTRATED PARTS LIST by figure and item number to see the assembly
of the parts in Table 801. Make sure these conditions and limits are followed in the repair and
assembly of the RDU.

IPL Figure/Item No. Condition to Measure Limits

1 - 145, 150 Clearance between the 0.020 ± 0.010 inch

knob and the front panel

1 - 145 Clearance between dual knobs 0.020 ± 0.010 inch

Fits and Clearances

Table 801

34-51-01 Pages 801/802

Use or disclosure of information on this page is subject to the restrictions on the title page of this document.Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

1. Task
This section gives all the tools, fixtures, and equipment specified in the other sections. These
tools are necessary to do the maintenance on the 2101 I/O Receiver Display Unit. The
materials necessary for maintenance are not included in this section. They are identified under
the subheading where they are used.

The list of tools, fixtures, and equipment in paragraph 2 includes the source of supply. The
applicable supply code (also known as the CAGE code) from the Cataloging Handbook H4/H8,
Commercial and Government Entity (CAGE), Sections A and B is shown in parentheses after
the source of supply. Use the CAGE code to get the full identification of the supplier.

The work area where the tools, fixtures, and equipment are used must have protection from
electrostatic discharge to prevent damage to the Receiver Display Unit.

2. Special Tools, Fixtures, and Equipment

NOTE: Equivalent alternatives are permitted for the equipment in this list.

A. Available from TR Navigation, Inc., Trimble Navigation Limited, Austin, Texas (0LL70)

CDI/AIO Test Set, Trimble Part No. ET-2000

Navigation Data base Card — Jeppsen P/N 81461-xx

B. Available from STA-TEMP Systems Division, Metcal Inc., Menlo Park, CA (47882)

Solder equipment — STA-TEMP Model STSS-002, Solder System with appropriate

replaceable tip cartridges - or equivalent

Desolder equipment — STA-TEMP Desolder System with appropriate replaceable tip

cartridges - or equivalent

C. Available from Commercial Source

Oscilloscope, Tek 2236 or equivalent

Digital Multimeter
PC, 386 with VGA monitor and 1 comm port, 1 printer port
Printer
Counter PM-6666 or Equiv.

34-51-01 Pages 901/902

Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

ILLUSTRATED PARTS LIST

1. Introduction

The Illustrated Parts List gives the parts used to make the 2101 I/O Receiver Display Unit. It
also supplies the necessary data to get replacement parts for repair and fault isolation. The list
of parts is given in general disassembly sequence. The illustrations show where you can find
each part and are an important aid in disassembly and assembly procedures.

2. How to Find a Part

A. Get the location of a part as follows:

• If the part number is known, refer to the Numerical Index to find the figure and item
numbers in the Parts List.

• If the equipment designator is known, refer to the Equipment Designator Index to find
the figure and item numbers in the Parts List.

B. After you get the figure and item number, refer to the Parts List for more identification data.

3. Contents of Illustrated Parts List

A. List of Suppliers

The names and addresses of companies that supply the items included in the Parts List are
shown in Table 1001. The supplier CAGE code is given in the NOMENCLATURE column
of the Parts List to identify the supplier. Refer to paragraph 4.

B. Equipment Designator Index

(1) The Equipment Designator Index is an alphanumeric list of the equipment designators
given to the electrical/electronic parts. Equipment designators used on schematic and
wiring diagrams are shown in this index. With the designator, it is easy to identify a part
and to find the applicable data in the Parts List.

(2) Each entry in the Equipment Designator Index identifies the figure and item numbers
where the part is found in the Parts List. A hyphen between two designators shows a
continuous sequence of designators (example: A1-A5 is the same as A1 thru A5).

Page 1001
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 82183

3. C. Numerical Index

(1) The Numerical Index is an alphanumeric list of all the part numbers shown in the
PART NUMBER columns of the Parts List. Also included in the index are the Trimble
part numbers that are equivalent to the manufacturer part number. Optional
manufacturer part numbers are not included in the index.

(2) The FIG. ITEM column gives all of the locations of a part. If a part number is in
more than one FIG. ITEM location, the part number is shown only one time in the
PART NUMBER column.

(3) The TTL REQ column shows the total number of parts that are used at each FIG.
ITEM location.

(4) The column for AIRLINE STOCK NO. has space for customers to use.

D. Parts List

(1) An item number is given to each part in the Parts List and on the related figure. The
item numbers show the general disassembly sequence. Some of the parts are not
shown on a figure, such as a fully assembled item, an unprogrammed microcircuit, and
a selection of resistors. Items that are not illustrated have a dash before the item
number in the parts list.

(2) An item number with a letter suffix (A thru Z except I and O) shows any one of these
conditions has occurred:

• A modification (by a service bulletin)

• A change in configuration from the initial item

• A change to a better part (no service bulletin)

(3) The PART NUMBER column shows the part number given by the primary
source of the part, either Trimble or a commercial supplier, or the part number
of a U.S. standard part. When this column shows the part number of a commercial
supplier or a U.S. standard part, the NOMENCLATURE column shows the Trimble part
number. When this column shows the Trimble part number for ordinary commercial
hardware, the NOMENCLATURE column gives a full description of the part.

(4) The AIRLINE STOCK NUMBER column has space for customers to use.

34-51-01
Use or disclosure of information on this page is subject to the restrictins on the title page of this document.
Page 1002
June 1/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

3. D. (5) The NOMENCLATURE column gives the applicable name for each assembly,
subassembly, and part. The indention of the nomenclature data is used to show
the relation of an item to the other items in the parts list. Other data that is shown
in this column is as follows:

• Identifies the supplier of commercial parts. (Refer to paragraph 4.)

• Shows optional manufacturer part numbers (OPT MFG PN) with their supplier code
when there is more than one supplier of a part. At the first location of a part with
more than one source of supply, the applicable OPT MFG PN data is shown. Any
subsequent locations of the same part refer to the first location for the OPT MFG
PN.

• Identifies parts you can use when the recommended part is not available.
These parts, shown as (ALTERNATE PART), are interchangeable with any other
part in the same item number group. An item number group includes the initial item
number plus those with the same item number that have a letter suffix.

• Identifies parts that can have dangerous effects with the warning *HAZARDOUS
MATERIAL*. Refer to the special precautions in the INTRODUCTION of this
manual.

• Identifies parts that are electrostatic discharge sensitive with the identification
(ESDS) or **STATIC SENSITIVE DEVICE**. Refer to the special precautions
in the INTRODUCTION of this manual.

• Identifies parts that are airworthiness critical with the identification

(AIRWORTHINESS CRITICAL ITEM). Refer to the special precautions in the
INTRODUCTION of this manual.

• Identifies parts that are moisture sensitive with the identification *MOISTURE
SENSITIVE*. Refer to the special precautions in the INTRODUCTION of this
manual.

(6) The EFF (Effectivity) CODE column identifies differences in specific configurations of
the top assembly in each figure:

• If this column is empty, the part is used in all configurations of the top assembly for
that figure.

• If this column has a letter code, the part is only used in the configuration of the top
assembly that has the same letter code.

• If this column has more than one letter code, the part is used in each top
assembly with any of the same letter codes.

Page 1003
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 82183

3. D. (7) The UNITS PER ASSY column shows the quantity of each part used in the next
higher assembly. The letters AR are an indication that the quantity is not known
for sure or it changes as necessary. The letters RF identify a reference item.

4. Supplier Codes

A. The NOMENCLATURE column of the Parts List shows a supplier code with the letter V
before it. This code (from Cataloging Handbook H4/H8, Commercial and Government Entity
(CAGE), Sections A and B) identifies where to get the specified item. A list of these codes
with the applicable names and addresses is shown in Table 1001 (List of Suppliers).

B. When the supplier has no code number, the name and address of the supplier are
given in the NOMENCLATURE column of the Parts List.

5. Abbreviations and Symbols

A. Abbreviations
ASME Y1.1 is used as the standard for abbreviations. The abbreviations that are not
included in ASME Y1.1 are as follows:

ESDS Electrostatic Discharge Sensitive

MFG Manufacturer
OPT Optional
RF Reference
TTL REQ Total Required

B. Symbols
This symbol is used on illustrations:

For static sensitive or ESDS

34-51-01
Use or disclosure of information on this page is subject to the restrictins on the title page of this document.
Page 1004
June 1/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

CODE SUPPLIER CODE SUPPLIER

0LL70 TR NAVIGATION INC

DBA TRIMBLE NAVIGATION
2105 DONLEY DR
AUSTIN, TX 78758-4534

80205 NATIONAL AEROSPACE STANDARDS

COMMITTEE AEROSPACE INDUSTRIES
ASSOCIATION OF AMERICA INC
1250 EYE ST NW
WASHINGTON, DC 20005

81073 GRAYHILL INC

561 HILLGROVE AVE
P.O. BOX 10373
LA GRANGE, IL 60525-0373

82104 STANDARD GRIGSBY INC

88 N. DUGAN RD
SUGAR GROVE, IL 60554-0890

List of Suppliers
Table 1001

Page 1005
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 82183

EQUIPMENT DESIGNATOR INDEX

EQUIPMENT FIG. ITEM PART EQUIPMENT FIG. ITEM PART
DESIGNATOR NUMBER DESIGNATOR NUMBER
A1 1 55
A1 1 55A
A3/A2 1 75
A2 1 80
A3 1 85
A3 1 85A
A3 1 85B
A4 1 100
A4 1 100A
A5 1 115
A6 1 135
A6BT401 1 136
A7 1 175
A7 1 175A
A7S10 1 180
A7S11 1 180A
U401,U402 1 120

34-51-01
Use or disclosure of information on this page is subject to the restrictins on the title page of this document.
Page 1006
June 1/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

NUMERICAL INDEX

AIRLINE FIG. TTL

PART NUMBER STOCK NO. ITEM REQ

NAS620C416L 1 185 1
12047 1 136 1
12584 1 65 4
12815 1 70 4
14297 SEE 2713MMPREL24-2
14409-00 1 165 9
16572 1 145 1
16919 1 5 1
20692 1 105 1
22611-10 1 115 1
2713MMPREL24-2 1 190 1
4129-0015 SEE NAS620C416L
56A36-01-1-02N 1 180 1
80064 1 20 1
80211-01 1 -175A 1
80211-02 1 175 1
80212-10 1 135 1
80229 1 200 1
80231 1 160 1
80232 1 195 1
80235-00 1 90 1
80238-00 1 60 1
80243 1 150 1
80286 1 30 8
80298 SEE 56A36-01-1-02N
80418-XXXX 1 120 2
80420 1 35 1
80425 1 110 5
80447 1 45 12
80448 1 50 3
80714-01 1 -160B 1

Page 1007
Page 1007
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 1/96
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 82183

NUMERICAL INDEX

AIRLINE FIG. TTL

PART NUMBER STOCK NO. ITEM REQ

80833-22 1 15 1
80908-10 1 -100A 1
80909-30D 1 85B 1
80909-31D 1 - 85A 1
80909-50D 1 - 85 1
80932-00 1 - 55A 1
80932-10 1 55 1
81160 1 -160A 1
81338 1 95 5
81339 1 130 4
81340 1 125 1
81367-00 1 80 1
81373 1 40 1
81434 1 25 10
81440-00 1 - 1 RF
81440-01 1 - 1A RF
81440-10 1 - 1B RF
81440-11 1 - 1C RF
81443 1 10 1
81444 1 170 1
81467-1 1 -160C 1
81675-00-A 1 75 1
81874-00-A 1 100 1

34-51-01
Use or disclosure of information on this page is subject to the restrictins on the title page of this document.
Page 1008
June 1/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Reciever Display Unit (Sheet 1 of 2)

Figure 1

Pages 1009/1010
34-51-01 Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

Receiver Display Unit (Sheet 2 of 2)

Figure 1

PagesPage 1011
34-51-01 1011/1012
Jun
Jun 7/96
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
1/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

UNIT
FIG. PART AIRLINE NOMENCLATURE EFF PER
ITEM NUMBER STOCK NO. 1234567 CODE ASSY

USABLE ON CODES
CODE A 81440-00
CODE B 81440-01
CODE C 81440-10
CODE D 81440-11

1- 1 81440-00 DISPLAY UNIT, RECEIVER A RF

(ESDS)
- 1A 81440-01 DISPLAY UNIT, RECEIVER B RF
(ESDS)
- 1B 81440-10 DISPLAY UNIT, RECEIVER C RF
(ESDS)
- 1C 81440-11 DISPLAY UNIT, RECEIVER D RF
(ESDS)
5 16919 .LABEL, COPYRIGHT 1
SILICON SOFTWARE
10 81443 .LABEL, IDENTIFICATI0N 1
15 80833-22 .LABEL, BEZEL 1
20 80064 .LABEL, SERVICE BULLETIN 1
25 81434 .SCREW 10
PL 100 FLH 4-40X0.25
SS BLK
30 80286 .SCREW 8
PL FLH 4-40X0.25
SS BLK
35 80420 .DOME 1
40 81373 .CASE, UPPER 1
45 80447 .SCREW 12
PL 100 FLH 4-40X0.25
SS BLK
50 80448 .SCREW 3
55 80932-10 .CIRCUIT CARD ASSEMBLY- 1
POWER SUPPLY
(ESDS)
(A1)
(PREFERRED PART)

- ITEM NOT ILLUSTRATED

Page 1013
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 82183

UNIT
FIG. PART AIRLINE NOMENCLATURE EFF PER
ITEM NUMBER STOCK NO. 1234567 CODE ASSY

- 55A 80932-00 .CIRCUIT CARD ASSEMBLY- 1

POWER
(ESDS)
(A1)
(ALTERNATE PART)
60 80238-00 .CABLE ASSEMBLY-
FILTER/POWER 1
65 12584 .SCREW 4
PL PH 4-40X0.32
SS
70 12815 .SCREW 4
PL PN 4-40X0.25
SS
75 81675-00-A .CIRCUIT CARD ASSEMBLY- 1
SYNCHRO POWER/FILTER
(ESDS)
(A3/A2)
(PREFERRED PART)
80 81367-00 .CIRCUIT CARD ASSEMBLY- 1
FILTER
(A2)
(ALTERNATE PART)
(USE WITH ITEM 85,85A OR
85B)
85 80909-50 .CIRCUIT CARD ASSEMBLY- 1
DRIVER
(ESDS)
(A3)
(ALTERNATE PART)
(USE WITH ITEM 80)
- 85A 80909-31D .CIRCUIT CARD ASSEMBLY- 1
DRIVER
(ESDS)
(A3)
(ALTERNATE PART)
(USE WITH ITEM 80)

- ITEM NOT ILLUSTRATED

34-51-01
Use or disclosure of information on this page is subject to the restrictins on the title page of this document.
Page 1014
June 1/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 81440

UNIT
FIG. PART AIRLINE NOMENCLATURE EFF PER
ITEM NUMBER STOCK NO. 1234567 CODE ASSY

- 85B 80909-30D .CIRCUIT CARD ASSEMBLY- 1

DRIVER
(ESDS)
(A3)
(ALTERNATE PART)
(USE WITH ITEM 80)
90 80235-00 .CABLE, CONTROL 1
95 81338 .STANDOFF, M-F 3-16 HEX 5
4-40X0.25
100 81874-00-A .CIRCUIT CARD ASSEMBLY- 1
INTERFACE
(ESDS)
(A4)
(PREFERRED PART)
- 100A 80908-10 .CIRCUIT CARD ASSEMBLY- 1
INTERFACE
(ESDS)
(A4)
(ALTERNATE PART)
105 20692 .CABLE ASSEMBLY- 1
GPS SIGNAL
110 80425 .STANDOFF, M-F 4-40X0.563 5
115 22611-10 .CIRCUIT CARD ASSEMBLY- 1
GPS SENSOR
(ESDS)
(A5)
120 80418-XXXX .MICROCIRCUIT-EPROM 2
CMS 256K X 8
150ns UV DIP
(ESDS)
(UNPROGRAMMED)
(U401,U402)
(XXXX DENOTES SOFTWARE
VERSION-CALL TRIMBLE
CUSTOMER SERVICE AT
1-800-487-4662)

- ITEM NOT ILLUSTRATED

Page 1015
34-51-01
Use or disclosure of information on this page is subject to the restrictions on the title page of this document.
Jun 7/96
 T
COMPONENT
MAINTENANCE
MANUAL
P/N 82183

UNIT
FIG. PART AIRLINE NOMENCLATURE EFF PER
ITEM NUMBER STOCK NO. 1234567 CODE ASSY

125 81340 .STANDOFF, F-F 4-40X0.437 1

130 81339 .STANDOFF, M-F 4-40X0.437 4
135 80212-10 .CIRCUIT CARD ASSEMBLY- 1
PROCESSOR BOARD
(ESDS)
(A6)
136 12047 ..BATTERY 1
(A6BT401)
145 16572 .KNOB SET, DUAL 1
150 80243 .KNOB, ON-OFF 1
160 80231 .BEZEL A 1
- 160A 81160 .BEZEL B 1
- 160B 80714-01 .BEZEL C 1
- 160C 81467-1 .BEZEL D 1
165 14409-00 .CAP, KEY 9
170 81444 .FILTER, DISPLAY A,B 1
175 80211-02 .DISPLAY BOARD ASSEMBLY A,B 1
(A7)
- 175A 80211-01 .DISPLAY BOARD ASSEMBLY C,D 1
(A7)
180 56A36-01-1-02N ..SWITCH, ROTARY 1
SPDT 360
(V81073)
(TPN 80298)
(A7S10)
185 NAS620C416L ..WASHER, FLAT 1
(TPN 4129-0015)
190 2713MMPREL24-2 ..SWITCH, ROTARY 1
ENCODE 24 POS
(V82104)
(TPN 14297)
(A7S11)
195 80232 .GUIDE, CARD 1
200 80229 .CASE, LOWER 1

- ITEM NOT ILLUSTRATED

34-51-01
Use or disclosure of information on this page is subject to the restrictins on the title page of this document.
Page 1016
June 1/96