2101 Io Plus

2101 I/O PLUS
Receiver
Display Unit
Part No. 81440
V01105
COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST
34-51-04
15 MARCH 2009
Publishing Number 82912
The document reference is online, please check the correspondence between the online documentation and the printed version.
2101 I/O Plus Display Components Maintenance Manual
PROPRIETARY NOTICE
This document and the information disclosed herein are proprietary data of FreeFlight Systems. Neither this document
nor the information contained herein shall be used, reproduced, or disclosed to others without the written authorization
of FreeFlight Systems, 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 FreeFlight Systems. 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, FreeFlight Systems, 3700 Interstate 35 S., Waco, Texas 76706. Telephone (254) 662-0000.
S97
Use or disclosure of information on this page is subject to the Revision B

Page TITLE-2 restrictions of the Proprietary Notice on page TITLE-2 of this document. March 15, 2009
Date Received
READER COMMENTS
Freeflight Systems welcomes all comments and recommendations to improve future editions of this
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Manual Title
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F O L D F O L D
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FreeFlight Systems
Manager, Technical Publications
Aerospace Division
3700 Interstate 35 S.
Waco, TX 76706
F O L D F O L D
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Manager, Technical Publications
Aerospace Division
3700 Interstate 35 S.
Waco, TX 76706
F O L D F O L D
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 93.4 0C
2 Hazardous - Prevent continued exposure, to burn
inhalation, and contact 2 Must increase the temperature above 37.8 0C
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
Revision B Use or disclosure of information on this page is subject to the

March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page H-1
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 22.8 0C. 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 22.8 0C
but below 37.8 0C. 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 37.8 0C but below 94.3 0C. 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 81.5 0C for 5 minutes or less. Liquids and solids
have a flash point at or above 93.4 0C.
0 Will not burn Any material that will not burn in air in an area open to a temperature
of 81.5 0C for 5 minutes.

Page H-2 restrictions of the Proprietary Notice on page TITLE-2 of this document. March 15, 2009
RECORD OF REVISIONS
Assigned To (Job Title) Location
Rev
Revision Insertion Rev
By Revision Insertion
By
No. Date Date No. Date Date

March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page RR-1
RECORD OF TEMPORARY REVISIONS

Assigned To (Job Title) Location
Temporary Date Date Date

Revision No. Revised Inserted By Removed By

March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page RTR-1
SERVICE BULLETIN LIST

FOR PART NO. 81440
Service Identified Date Included

Bulletin MOD in this Manual Description

March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page SBL-1
Service Bulletin
SB 81440-XX-00-21
2101 I/O Approach Plus GPS Navigation Systems, Part Numbers 81440-02-XXXX, 81440-
03-XXXX, 81440-12-XXXX, 81440-32-XXXX, 81440-33-XXXX, and 81440-42-XXXX.
Release of operating system –241L.
SUMMARY: FreeFlight Systems has released software system –241L for the 2101 I/O Plus.
I. PLANNING INFORMATION
A. Effectivity
This Service Bulletin applies to the 2101 I/O Approach Plus GPS Navigators, Part
Numbers 81440-02-XXXX, 81440-03-XXXX, 81440-12-XXXX, 81440-32-XXXX,
81440-33-XXXX, and 81440-42-XXXX, where XXXX equals the system operating
software.
Installation of software version -241L will become mandatory. Continued IFR
operations after June/2009 will require software version -241L and its support of 4 MB
Nav data bases.
Installation of software version -241L also requires implementation of hardware

service bulletin 81440-XX-34-14 to support 4 MB Nav data base operation.
B. Reason
This Service Bulletin advises all users of 2101 I/O Approach Plus Navigators, Part
81440-33-XXXX, and 81440-42-XXXX, of the availability of a revised operating
system, -241L.
The following changes have been incorporated into software version –241L:
• Update software to accept 4 MB Nav database.

• Modify radar waypoint input function to display confirmation prompt to pilot and
to correct digital/serial output of rdrwp identifier.
• Remove FLY DME arc option from direct-to function
• Prevent expansion of active flight plan beyond 40 waypoint maximum
C. Description
Operating system –241L is loaded using a FLASH EDGE card.
September 26, 2008 SB 81440-XX-00-21 PAGE 1 of 14
3700 Interstate 35 S., WACO, TX 76706 Telephone: 254-662-0000 Fax: 254-662-9451
D. Approval
Operating software version –241L is a minor modification to version –241K, which
was previously approved under TSO C129 (A1). 2101 I/O installations that have been
FAA approved with software programs other than –241x must be re-evaluated when
software version –241L is installed.
E. Manpower
The following man-hour estimates are based on incorporation concurrent with an
unscheduled repair or during routine maintenance:
Units Compliance Man Hours

All RDUs During Routine Maintenance 0.5
All RDUs During Repair 0.5
F. Weight and Balance

None
G. Electrical Load Data
Not Affected
H. Reference
ECN S08012
I. Other Publications Affected

84923, Rev A FreeFlight 2101 I/O Approach Plus Pilot Guide Supplement
84929, Rev A FreeFlight 2101 I/O Approach Plus GPS Receiver Installation and
Checkout Manual Supplement
J. Interchangeability and Identification

Modified and unmodified units are not interchangeable.
2101 I/O Approach Plus GPS Navigation Systems having operating system
–241L shall be identifiable by the identification label on the top of the unit, bearing part
number 81440-XX-241L.
II. MATERIAL INFORMATION
A. Price and Availability
Call FreeFlight Systems for price and availability at time of purchase.
All operators will be charged a $300 media/handling fee for each PCMCIA card
shipped. Operators who return a serviceable card within 90 days will receive credit.
Observe handling precautions with each card to ensure reasonable protection of the
card (normal wear and tear is acceptable). The fee will be due and payable for cards
that are not returned and for cards returned in unserviceable condition. Return cards
to FreeFlight Systems, Attention Sales Department (see address below), to receive
credit.
Customers have two choices. They may elect to send Navigators to the FreeFlight
Factory Service Center; or they may send units to an authorized Level II Service
Center for installation of this software upgrade.
Modifications accomplished at the Factory Service Center will be completed within
fifteen (15) working days after receipt of the unit, depending upon parts availability.
Level II Service Centers wishing to incorporate Service Bulletin 81440-XX-00-21
should issue a purchase order to FreeFlight for the number of Service Bulletin kits
required.
B. Parts List
Service Bulletin Kit 81440-XX-00-21 contains:
FreeFlight PN Qty Nomenclature Notes
82998-241L 1 Flash Card loaded with 2101 I/O Plus operating 1
system v. –241L
81461-XX 1 4 meg database 2
81941 1 Part Number Identification Label
SB 81440-XX-00-21 1 Service Bulletin Document
84923, Rev A 1 FreeFlight 2101 I/O Approach Plus Pilot Guide
Supplement
84929, Rev A 1 FreeFlight 2101 I/O Approach Plus GPS
Receiver Installation and Checkout Manual
Supplement
Note 1: An invoice for $300 for the flash card will accompany the Service Bulletin kit.
Operators who return an undamaged flash card within 90 days to FreeFlight Systems,
Attention Sales Department (see address below), will receive credit.
Note 2: Please state which database is required, North America (81461-10), Eurasia
(81461-12), or Pacific South America (81461-13).
C. Ordering Information
Operators of the 2101 I/O Approach Plus wishing to upgrade their system may send
the unit(s) to an approved Level II Service Center or the FreeFlight Factory Service
Center.
To upgrade the operating system at a Level II Service Center, send a purchase order
requesting Service Bulletin kit P/N 81440-XX-00-21 to:
FreeFlight Systems Attn.: Sales Dept.
3700 Interstate 35 S. Telephone 1 (254) 662-0000
Waco, TX 76706 USA Fax 1 (254) 662-9451
For FreeFlight Factory Service Center modification, send the Navigator and a
purchase order requesting incorporation of Service Bulletin 81440-XX-00-21 to:
FreeFlight Systems Attn.: Repair Dept.
Waco, TX 76706 USA Fax 1 (254) 662-9452
D. Warranty
This Service Bulletin does not affect the standard warranty of the unit from date of
purchase. For units out of warranty, this modification will be covered for ninety (90)
days.
III. ACCOMPLISHMENT INSTRUCTIONS
A. Record Configuration Settings
Software loading will erase the installation settings and the user settings. Therefore, it
is important to record these settings before installing the revised software. For
information about installation settings, refer to the 2101 I/O Approach Plus GPS
Navigation System Installation and Checkout Manual, PN 82882 (Section III -
Checkout). Following the instructions, access the Installation Set Up submenu.
1. Record the configuration settings on the Configuration Record Sheet found in
Section III of the manual.
2. Turn unit off.
Two sets of loading instructions follow. The instructions in Section III.B are for loading
version –241L over version -241B, 241C, -241D, -241E, 241F, 241G, 241H, 241J or 241K.
The instructions in Section III.C are for loading version –241L over versions -0241 or -
241A.
B. Instructions for Updating the 2101 I/O Approach Plus Operating System from
Version -241B, -241C, -241D, -241E, -241F, -241G, -241H, -241J or 241K.
1. Inspect the provided flash card, P/N 82998-241L, and verify that it contains the
following text on the label:
FreeFlight Systems
PN 82998-241L
SYSTEM: 241L
NIOP: 2.830
CRC: 3DA0-43D4
AIO: 0121
CRC: EEF4-E834
GPS: 5.05-1208
CRC: B72A-A2D5
Not A Jeppesen
Database Card
2. Insert the flash card into the memory card slot on the front of the unit.
3. Turn power ON to the 2101 I/O Plus. The unit will begin its startup procedure.
4. Verify that the following message is displayed:
FLASH CARD DETECTED
AVAILABLE VERSIONS:
It will be followed by:
NAV: 2.830 3DA043D4
PUSH NAV TO CONTINUE
5. Verify that the software version and CRC on the top line of the display match the
above text. If not, then terminate the programming procedure immediately and
contact FreeFlight.
6. Press NAV. The following message will appear.
GPS: 5.05B B72AA2D5
7. Verify that the Software Version and CRC on the top line of the display match the
contact FreeFlight.
AIO: 1.21 EEF4E834
contact FreeFlight.
10. Press NAV.
11. Verify that the following messages are displayed. A pattern will scroll across the
bottom line of the display to indicate that the image verification process is taking
place.
VERIFYING IOP IMAGE
VERIFYING GPS IMAGE
VERIFYING AIO IMAGE
After successful image verification, the following message will appear:
FLASHCARD IOP, AIO
AND GPS IMAGES OK
A message quickly flashes by and then the following appears.
UPDATE GPS CARD NOW?
NAV = YES AUX = NO
UPDATING GPS FLASH
It is followed by:
GPS FLASH UPDATE OK
PRESS NAV TO CONT
UPDATE AIO UNIT NOW?
NAV = YES AUX = NO
UPDATING AIO FLASH
It is followed by:
AIO FLASH UPDATE OK
PUSH NAV TO CONT
UPDATE NAV IOP NOW?
NAV=YES AUX=NO
UPDATING IOP FLASH
After the image verification is complete, the unit will reset. Then it will display this
message:
PERFORMING BUILT IN
TEST
CLEAR BATTERY BACKED
MEMORY SUCCESSFUL
FreeFlight
2101 I/O SAR
SYSTEM CODE: 241L
c2008
It is followed by:
IOP ROM UPDATED OK
PWR OFF, REMOVE CARD
17. Turn the unit OFF. Remove the flash card from the memory card slot and insert
a 4 MB database card.
18. Turn the power ON.
19. Verify the following message on the display:
SYSTEM CODE: 241L
c2008
After the database validation is complete, observe the following scroll up the
screen.
NAV Computer --OK
GPS Computer --OK
Aux IO Computer --OK
Database --OK
or
Database Expired
Ready for Navigation
Select any mode
20. Press AUX until the SYSTEM STATUS screen is displayed.
21. Rotate the small knob clockwise until the following screen is displayed:
REVISION: NAV 2.830
GPS 5.05-1208 AIO0121
22. Verify that the NAV IOP software version matches the line above.
23. Rotate the small knob clockwise one click and verify that the following line is
displayed:
SYSTEM CODE: 241L
c2008
24. Press the MSG key and check for any of the following error messages.
GPS CONFIG INVALID
IFR NOT ALLOWED
AIO CONFIG INVALID
IFR NOT ALLOWED
S/W CONFIG INVALID
IFR NOT ALLOWED
25. If any of the above messages appear, perform the software loading again. If
there are still error messages after the second attempt, call FreeFlight.
26. Updating the 2101 I/O Approach Plus to operating system version –241L from
version -241B, -241C, -241D, -241E, -241F, -241G, 241H, 241J or 241K is
complete. Go to Section D, Identification.
C. Instructions for Upgrading the 2101 I/O Approach Plus Operating System to
Version –241L from Version -0241 or -241A
IMPORTANT NOTES
PLEASE READ AND FOLLOW CAREFULLY
The software MUST be loaded in the correct order, as described in the instructions
immediately following this box. The loading options on the 2101 I/O Plus display will
not be presented in that order. Therefore, take care to follow the loading directions
in this Service Bulletin EXACTLY IN SEQUENCE AS WRITTEN.
DO NOT cycle power during the loading process except where noted in the
instructions. Cycling power during software loading will damage the unit. If this
occurs, the unit must be returned to FreeFlight for repair.
1. Inspect the provided flash card, P/N 82998-241L, and verify that it contains the
following text:
FreeFlight Systems
PN 82998-241L
SYSTEM: 241L
NIOP: 2.830
CRC: 3DA0-43D4
AIO: 0121
CRC: EEF4-E834
GPS: 5.05-1208
CRC: B72A-A2D5
Not A Jeppesen
Database Card
3. Turn power ON to the 2101 IO Plus. The unit will begin its startup procedure.
FLASH CARD DETECTED
AVAILABLE VERSIONS:
It is followed by:
NAV: 2.830 3DA043D4
contact FreeFlight.
GPS: 5.05B B72AA2D5
contact FreeFlight.
AIO: 1.21 EEF4E834
contact FreeFlight.
10. Press NAV.
place.
VERIFYING IOP IMAGE
VERIFYING GPS IMAGE
VERIFYING AIO IMAGE
FLASHCARD IOP, AIO
AND GPS IMAGES OK
NAV = YES AUX = NO
12. Press AUX. (If you make a mistake and press NAV, cycle power and start over.)
13. Then the following message is displayed.
NAV = YES AUX = NO
14. Press NAV. The following message appears:
UPDATING AIO FLASH
It is followed by:
AIO IMAGE VERIFICATION OK
PRESS NAV TO CONT
UPDATE NAV IOP NOW?
NAV = YES AUX = NO
UPDATING IOP FLASH
After the image verification is complete, the unit will reset and then display this
message:
PERFORMING BUILT IN TEST
MEMORY SUCCESSFUL
The unit will go through the startup sequence. (The following display will appear
if version –241L is being loaded over -241A, but not if it is being loaded over
-0241. DO NOT REMOVE THE CARD!)
IOP ROM UPDATED OK
17. Turn OFF power to the 2101 I/O Plus. Wait 30 seconds. Turn ON power to the
unit.
Then the unit will reset. Afterward it will display:
FreeFlight
2101 I/O SAR
SYSTEM CODE: 241L
c2008
FLASH CARD DETECTED
AVAILABLE VERSIONS:
This is followed by:
NAV: 2.830 3DA043D4
contact FreeFlight.
GPS: 5.05B B72AA2D5
contact FreeFlight.
AIO: 1.21 EEF4E834
contact FreeFlight.
24. Press NAV.
25. Verify that the following messages are displayed:
VERIFYING IOP IMAGE
VERIFYING GPS IMAGE
VERIFYING AIO IMAGE
FLASHCARD IOP, AIO
AND GPS IMAGES OK
A message quickly flashes by and then the following appears:
NAV = YES AUX = NO
26. Press NAV. The following message will be displayed:
UPDATING GPS FLASH
It is followed by:
GPS IMAGE VERIFICATION OK
PUSH NAV TO CONT
NAV = YES AUX = NO
UPDATING AIO FLASH
It is followed by:
PUSH NAV TO CONT
UPDATE NAV IOP NOW?
NAV = YES AUX = NO
UPDATING IOP FLASH
After the flash update is complete, the unit will reset. Then it will display this
message:
MEMORY SUCCESSFUL
The unit will reset. Then the following message will be displayed:
IOP ROM UPDATED OK
32. Turn the power ON. The unit will display this message:
Then the unit will reset.
SYSTEM CODE: 241L
c2008
34. After the Database validation is complete, observe the following scroll up the
screen.
NAV Computer --OK
GPS Computer --OK
Database --OK
or
Database Expired

Select any mode
REVISION: NAV 2.830
GPS 5.05-1208 AIO0121
displayed:
SYSTEM CODE: 241L
c2006
GPS CONFIG INVALID
IFR NOT ALLOWED
AIO CONFIG INVALID
IFR NOT ALLOWED
S/W CONFIG INVALID
IFR NOT ALLOWED
If any of the above messages appear, perform the software loading again. If there are
still error messages after the second attempt, call FreeFlight.
D. Identification
When the software has been successfully loaded with no errors reported, the flash
update procedure is complete and the operating software is version
–241L. Remove the old identification label on the top of the unit and replace it with
the Part Number Identification Tag (PN 81941) that was provided in the Service
Bulletin kit.
E. Perform System Reset
NAVIGATOR RESET
Upon completion of this procedure, the unit will be in "cold start" mode.
Please allow up to 15 minutes for GPS acquisition.
Memory Reset –
1. With UUT turned OFF, simultaneously press and hold the following keys:
NAV, NRST and –D-

2. Turn UUT power ON and continue holding the keys above until the following
message appears:
MEMORY SUCCESSFUL
3. Release the keys.
1. Turn the UUT power OFF.
2. Turn the UUT power ON. Monitor the display and verify message from
Step 2 above.
End of Reset Procedure
F. Restore Configuration Settings

Restore the configuration settings that were recorded prior to loading software. For
installation settings, refer to the 2101 I/O Approach Plus GPS Navigation System
Installation and Checkout Manual, PN 82882 (Section III - Checkout). Instructions for
accessing the user setup mode and configuring the settings are in the 2101 I/O
Approach Plus GPS Navigator Pilot Guide, PN 82881, Appendix C.
Service Bulletin
SB 81440-XX-00-23
Release of operating system –241M.
SUMMARY: FreeFlight Systems has released software system –241M for the 2101 I/O Plus.
A. Effectivity
software.
Installation of software version -241M will become mandatory. Continued IFR
operations after June/2009 will require software version -241M and its support of 4
MB Nav data bases.
Installation of software version -241M also requires implementation of hardware

service bulletin 81440-XX-34-14.
B. Reason
This Service Bulletin includes the corrections previously incorporated in SB 81440-
XX-00-19, software version 241J, and therefore, meets the terminating requirements
of AD 2009-05-08.
system, -241M.
The following changes have been incorporated into software version –241M:
• Fixed display of the estimated GPS accuracy, required for oceanic/remote

operations.
C. Description
Operating system –241M is loaded using a FLASH EDGE card.
March 23, 2009 SB 81440-XX-00-23 Rev. A PAGE 1 of 14
D. Approval
Operating software version –241M is a minor modification to version –241L, which
software version –241M is installed.
E. Manpower

None
Not Affected
H. Reference
ECN S08013
84923, Rev B FreeFlight 2101 I/O Approach Plus Pilot Guide Supplement
84929, Rev B FreeFlight 2101 I/O Approach Plus GPS Receiver Installation and
–241M shall be identifiable by the identification label on the top of the unit, bearing
part number 81440-XX-241M.

credit.
March 23, 2009 SB 81440-XX-00-23 Rev A PAGE 2 of 14
Level II Service Centers wishing to incorporate Service Bulletin 81440-XX-00-23
should issue a purchase order to FreeFlight for the number of Service Bulletin kits
required.
B. Parts List
Flash Card loaded with 2101 I/O Plus

82998-241M 1 1
operating system v. –241M
81461-XX 1 4 megabyte database 2
SB 81440-XX-00-23 1 Service Bulletin Document (this document)
FreeFlight 2101 I/O Approach Plus Pilot Guide

84923, Rev B 1
Supplement
FreeFlight 2101 I/O Approach Plus GPS

84929, Rev B 1 Receiver Installation and Checkout Manual
Supplement
Center.
Waco, TX 76706 USA Fax 1 (254) 662-9451
Waco, TX 76706 USA Fax 1 (254) 662-9452
D. Warranty
days.

2. Turn unit off.
version –241M over version -241B, 241C, -241D, -241E, 241F, 241G, 241H, 241J, 241K or
241L. The instructions in Section III.C are for loading version –241M over versions -0241
or -241A.
Version -241B, -241C, -241D, -241E, -241F, -241G, -241H, -241J or 241K.
1. Inspect the provided flash card, P/N 82998-241M, and verify that it contains the
FreeFlight Systems
PN 82998-241M
SYSTEM: 241M
NIOP: 2.831
CRC: 5966-8B71
AIO: 0121
CRC: EEF4-E834
GPS: 5.05-1208
CRC: B72A-A2D5
Not A Jeppesen
Database Card
FLASH CARD DETECTED
AVAILABLE VERSIONS:
NAV: 2.831 59668B71
contact FreeFlight.
GPS: 5.05B B72AA2D5
contact FreeFlight.
AIO: 1.21 EEF4E834
contact FreeFlight.
10. Press NAV.
place.
VERIFYING IOP IMAGE
VERIFYING GPS IMAGE
VERIFYING AIO IMAGE
FLASHCARD IOP, AIO
AND GPS IMAGES OK
NAV = YES AUX = NO
UPDATING GPS FLASH
It is followed by:
GPS FLASH UPDATE OK
PRESS NAV TO CONT
NAV = YES AUX = NO
UPDATING AIO FLASH
It is followed by:
AIO FLASH UPDATE OK
PUSH NAV TO CONT
UPDATE NAV IOP NOW?
NAV=YES AUX=NO
UPDATING IOP FLASH
message:
PERFORMING BUILT IN
TEST
MEMORY SUCCESSFUL
FreeFlight
2101 I/O SAR
SYSTEM CODE: 241M
c2008
It is followed by:
IOP ROM UPDATED OK
SYSTEM CODE: 241M
c2008
screen.
NAV Computer --OK
GPS Computer --OK
Database --OK
or
Database Expired

Select any mode
REVISION: NAV 2.831
GPS 5.05-1208 AIO0121
displayed:
SYSTEM CODE: 241M
c2008
GPS CONFIG INVALID
IFR NOT ALLOWED
AIO CONFIG INVALID
IFR NOT ALLOWED
S/W CONFIG INVALID
IFR NOT ALLOWED
26. Updating the 2101 I/O Approach Plus to operating system version –241M from
version -241B, -241C, -241D, -241E, -241F, -241G, 241H, 241J, 241K or 241L is
complete. Go to Section D, Identification.
C. Instructions for Upgrading the 2101 I/O Approach Plus Operating System
to Version –241M from Version -0241 or -241A
IMPORTANT NOTES
following text:
FreeFlight Systems
PN 82998-241M
SYSTEM: 241M
NIOP: 2.831
CRC: 5966-8B71
AIO: 0121
CRC: EEF4-E834
GPS: 5.05-1208
CRC: B72A-A2D5
Not A Jeppesen
Database Card
FLASH CARD DETECTED
AVAILABLE VERSIONS:
It is followed by:
NAV: 2.831 59668B71
contact FreeFlight.
GPS: 5.05B B72AA2D5
contact FreeFlight.
AIO: 1.21 EEF4E834
contact FreeFlight.
10. Press NAV.
place.
VERIFYING IOP IMAGE
VERIFYING GPS IMAGE
VERIFYING AIO IMAGE
FLASHCARD IOP, AIO
AND GPS IMAGES OK
NAV = YES AUX = NO
NAV = YES AUX = NO
UPDATING AIO FLASH
It is followed by:
PRESS NAV TO CONT
UPDATE NAV IOP NOW?
NAV = YES AUX = NO
UPDATING IOP FLASH
message:
MEMORY SUCCESSFUL
if version –241M is being loaded over -241A, but not if it is being loaded over
IOP ROM UPDATED OK
unit.
FreeFlight
2101 I/O SAR
SYSTEM CODE: 241M
c2008
FLASH CARD DETECTED
AVAILABLE VERSIONS:
NAV: 2.831 59668B71
contact FreeFlight.
GPS: 5.05B B72AA2D5
contact FreeFlight.
AIO: 1.21 EEF4E834
contact FreeFlight.
24. Press NAV.
VERIFYING IOP IMAGE
VERIFYING GPS IMAGE
VERIFYING AIO IMAGE
FLASHCARD IOP, AIO
AND GPS IMAGES OK
NAV = YES AUX = NO
UPDATING GPS FLASH
It is followed by:
PUSH NAV TO CONT
NAV = YES AUX = NO
UPDATING AIO FLASH
It is followed by:
PUSH NAV TO CONT
UPDATE NAV IOP NOW?
NAV = YES AUX = NO
UPDATING IOP FLASH
message:
MEMORY SUCCESSFUL
IOP ROM UPDATED OK
SYSTEM CODE: 241M
c2008
screen.
NAV Computer --OK
GPS Computer --OK
Database --OK
or
Database Expired

Select any mode
REVISION: NAV 2.831
GPS 5.05-1208 AIO0121
displayed:
SYSTEM CODE: 241M
c2008
GPS CONFIG INVALID
IFR NOT ALLOWED
AIO CONFIG INVALID
IFR NOT ALLOWED
S/W CONFIG INVALID
IFR NOT ALLOWED
D. Identification
–241M. Remove the old identification label on the top of the unit and replace it with
Bulletin kit.
NAVIGATOR RESET
Memory Reset –
NAV, NRST and –D>
message appears:
MEMORY SUCCESSFUL
5. Turn the UUT power ON. Monitor the display and verify message from Step 2
above.

Digitally signed
by Rob Ward
Rob DN: cn=Rob

Ward,
o=FreeFlight
Systems, c=US
Validité
inconnue
Ward Date:
2010.11.05
13:00:08 -05'00'
Service Bulletin
SB 81440-XX-00-25
Rev. B
Release of operating system –241N.
SUMMARY: FreeFlight Systems has released software system –241N for the 2101 I/O Plus.
A. Effectivity
software.
Installation of software version –241N is optional, however FFS strongly encourages
operators to incorporate the change, especially those using the larger North American
data base. Without the “N” update, long computational delays in processing flight
planning operations (such as direct-to) may be observed.
Continued IFR operations after June/2009 will require software version -241M or later
approved, in order to support the 4 MB Nav data bases.
Installation of software version –241N also requires implementation of hardware

service bulletin 81440-XX-34-14, if not previously performed.
B. Reason
This Service Bulletin includes the corrections previously incorporated in SB 81440-
XX-00-19, software version 241J, and therefore, meets the terminating requirements
of AD 2009-05-08.
system, -241N.
The following changes have been incorporated into software version –241N:
x Improved overall system response time

x Re-enabled fuel flow input on the ARINC input
October 4, 2010 SB 81440-XX-00-25 Rev. B PAGE 1 of 14
x Improved presentation of DME arcs on serial and ARINC outputs and
corrected a problem with joining DME arcs
x Fixed representation of PTURN waypoints in serial and ARINC outputs
x Fixed problem with system restarts when a DME arc is preceded by the DME
arc center waypoint
x Changed representation of direct-to waypoint to avoid compatibility issues
with some MFDs
x Fixed navigator restart problem when accessing airspaces with long airspace
names
x Disallowed editing of SIDs and STARs, since doing so resulted in terminal
waypoints not being found in the procedures
x Removed option for serial baro altitude input, since this option had not been
implemented
x Fixed problems with flight plan distance display after modification to a flight
plan
x Improved annunciation of external altitude input messages
x Implemented the NAV bit (bit 25) in ARINC 429 label 271 and the APR bit (bit
16) in ARINC 429 label 275
C. Description
Operating system –241N is loaded using a FLASH EDGE card.
D. Approval
Operating software version –241N is a minor modification to version –241M, which
software version –241N is installed.
E. Manpower

None
Not Affected
H. Reference
ECN S10001
October 4, 2010 SB 81440-XX-00-25 Rev B PAGE 2 of 14
84923, Rev B FreeFlight 2101 I/O Approach Plus Pilot Guide Supplement
84929, Rev B FreeFlight 2101 I/O Approach Plus GPS Receiver Installation and
–241N shall be identifiable by the identification label on the top of the unit, bearing
part number 81440-XX-241N.

Note: Upgrading to 241N from 241M is a no-cost upgrade, as the 4MB card,
manual supplements and hardware modification are not needed.
credit.
Level II Service Centers wishing to incorporate Service Bulletin 81440-XX-0025should
issue a purchase order to FreeFlight for the number of Service Bulletin kits required.
B. Parts List
Flash Card loaded with 2101 I/O Plus

82998-241N 1 1
operating system v. –241N Rev. A
81461-XX 1 4 megabyte database 2&3
SB 81440-XX-00-25
1 Service Bulletin Document (this document)
Rev. B
FreeFlight 2101 I/O Approach Plus Pilot Guide
84923, Rev B 1 3
Supplement
FreeFlight 2101 I/O Approach Plus GPS

84929, Rev B 1 Receiver Installation and Checkout Manual 3
Supplement
Note 3: This item is not needed for units previously running 241M software
Center.
Waco, TX 76706 USA Fax 1 (254) 662-9451
Waco, TX 76706 USA Fax 1 (254) 662-9452
D. Warranty
days.

2. Turn unit off.
version –241N over version -241B, 241C, -241D, -241E, 241F, 241G, 241H, 241J, 241K,
241L or 241M. The instructions in Section III.C are for loading version –241N over
versions -0241 or -241A.
Version -241B, -241C, -241D, -241E, -241F, -241G, -241H, -241J, 241K, 241L or
241M.
1. Inspect the provided flash card, P/N 82998-241N, and verify that it contains the
FreeFlight Systems
PN 82998-241N
SYSTEM: 241N Rev. A
NIOP: 2.832
CRC: 4FD3-2889
AIO: 0122
CRC: A46E-2325
GPS: 5.05-1208
CRC: B72A-A2D5
Not A Jeppesen
Database Card
FLASH CARD DETECTED
AVAILABLE VERSIONS:
NAV: 2.832 4FD32889
contact FreeFlight.
GPS: 5.05B B72AA2D5
contact FreeFlight.
AIO: 1.22 A46E2325
contact FreeFlight.
10. Press NAV.
place.
VERIFYING IOP IMAGE
VERIFYING GPS IMAGE
VERIFYING AIO IMAGE
FLASHCARD IOP, AIO
AND GPS IMAGES OK
NAV = YES AUX = NO
UPDATING GPS FLASH
It is followed by:
GPS FLASH UPDATE OK
PRESS NAV TO CONT
NAV = YES AUX = NO
UPDATING AIO FLASH
It is followed by:
AIO FLASH UPDATE OK
PUSH NAV TO CONT
UPDATE NAV IOP NOW?
NAV=YES AUX=NO
UPDATING IOP FLASH
message:
PERFORMING BUILT IN
TEST
MEMORY SUCCESSFUL
FreeFlight
2101 I/O SAR
SYSTEM CODE: 241N
c2010
It is followed by:
IOP ROM UPDATED OK
SYSTEM CODE: 241N
c2010
screen.
NAV Computer --OK
GPS Computer --OK
Database --OK
or
Database Expired

Select any mode
REVISION: NAV 2.832
GPS 5.05-1208 AIO0122
displayed:
SYSTEM CODE: 241N
c2010
GPS CONFIG INVALID
IFR NOT ALLOWED
AIO CONFIG INVALID
IFR NOT ALLOWED
S/W CONFIG INVALID
IFR NOT ALLOWED
26. Updating the 2101 I/O Approach Plus to operating system version –241N from
version -241B, -241C, -241D, -241E, -241F, -241G, 241H, 241J, 241K, 241L or
241M is complete. Go to Section D, Identification.
C. Instructions for Upgrading the 2101 I/O Approach Plus Operating System
to Version –241N from Version -0241 or -241A
IMPORTANT NOTES
following text:
FreeFlight Systems
PN 82998-241N
SYSTEM: 241N Rev. A
NIOP: 2.832
CRC: 4FD3-2889
AIO: 0122
CRC: A46E-2325
GPS: 5.05-1208
CRC: B72A-A2D5
Not A Jeppesen
Database Card
FLASH CARD DETECTED
AVAILABLE VERSIONS:
It is followed by:
NAV: 2.832 4FD32889
contact FreeFlight.
GPS: 5.05B B72AA2D5
contact FreeFlight.
AIO: 1.22 A46E2325
contact FreeFlight.
10. Press NAV.
place.
VERIFYING IOP IMAGE
VERIFYING GPS IMAGE
VERIFYING AIO IMAGE
FLASHCARD IOP, AIO
AND GPS IMAGES OK
NAV = YES AUX = NO
NAV = YES AUX = NO
UPDATING AIO FLASH
It is followed by:
PRESS NAV TO CONT
UPDATE NAV IOP NOW?
NAV = YES AUX = NO
UPDATING IOP FLASH
message:
MEMORY SUCCESSFUL
if version –241N is being loaded over -241A, but not if it is being loaded over
IOP ROM UPDATED OK
unit.
FreeFlight
2101 I/O SAR
SYSTEM CODE: 241N
c2010
FLASH CARD DETECTED
AVAILABLE VERSIONS:
NAV: 2.832 4FD32889
contact FreeFlight.
GPS: 5.05B B72AA2D5
contact FreeFlight.
AIO: 1.22 A46E2325
contact FreeFlight.
24. Press NAV.
VERIFYING IOP IMAGE
VERIFYING GPS IMAGE
VERIFYING AIO IMAGE
FLASHCARD IOP, AIO
AND GPS IMAGES OK
NAV = YES AUX = NO
UPDATING GPS FLASH
It is followed by:
PUSH NAV TO CONT
NAV = YES AUX = NO
UPDATING AIO FLASH
It is followed by:
PUSH NAV TO CONT
UPDATE NAV IOP NOW?
NAV = YES AUX = NO
UPDATING IOP FLASH
message:
MEMORY SUCCESSFUL
IOP ROM UPDATED OK
SYSTEM CODE: 241N
c2010
screen.
NAV Computer --OK
GPS Computer --OK
Database --OK
or
Database Expired

Select any mode
REVISION: NAV 2.832
GPS 5.05-1208 AIO0122
displayed:
SYSTEM CODE: 241N
c2010
GPS CONFIG INVALID
IFR NOT ALLOWED
AIO CONFIG INVALID
IFR NOT ALLOWED
S/W CONFIG INVALID
IFR NOT ALLOWED
D. Identification
–241N. Remove the old identification label on the top of the unit and replace it with
Bulletin kit.
NAVIGATOR RESET
Memory Reset –
NAV, NRST and –D>
message appears:
MEMORY SUCCESSFUL
5. Turn the UUT power ON. Monitor the display and verify message from Step 2
above.

LIST OF EFFECTIVE PAGES Insert latest change pages and destroy superseded pages.
Dates of Original and Change pages are:

Original................... 1 November 1997
Rev. A .......... 20 January 2004
Rev. B .......... 15 March 2007
Page Description Page No. Date

Front Cover Mar 15/09
Title Page TITLE-1 - TITLE-2 Mar 15/09
Hazard Rating Code H-1 - H-2 Mar 15/09
Record of Revisions RR-1 Mar 15/09
Record of Temporary Revisions RTR-1 Mar 15/09
Service Bulletin List SBL-1 Mar 15/09
List of Effective Pages LEP-1 Mar 15/09
Table of Contents TC-1 - TC-4 Mar 15/09
Introduction INTRO-1 - INTRO-3 Mar 15/09
Description and Operation 1 - 26 Mar 15/09
Test and Fault Isolation 101 - 163 Mar 15/09
Disassembly 301 - 302 Mar 15/09
Cleaning 401 - 402 Mar 15/09
Check 501 - 502 Mar 15/09
Repair 601 - 603 Mar 15/09
Assembly 701 - 704 Mar 15/09
Special Tools, Fixtures, and Equipment 901 - 902 Mar 15/09
Illustrated Parts List 1001 - 1014 Mar 15/09


March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page LEP-1
TABLE OF CONTENTS
INTRODUCTION.............................................................................................................................................. INTRO-1
DESCRIPTION AND OPERATION............................................................................................................................... 1

1. Physical Description....................................................................................................................................... 1
2. System Description........................................................................................................................................ 2
3. Functional Description.................................................................................................................................... 3
A. RDU Operation......................................................................................................................................... 3
B. Front Panel Layout and Description......................................................................................................... 5
(1) Power Switch.................................................................................................................................... 6
(2) LED Display...................................................................................................................................... 6
(3) Internal Annunciators........................................................................................................................ 6
(4) Mode Keys......................................................................................................................................... 7
(5) Function Keys.................................................................................................................................... 8
(6) Selector Knobs................................................................................................................................... 9
(7) Built-In-Test........................................................................................................................................ 9
C. RDU Circuit Card Assemblies................................................................................................................ 10
(1) Power Supply CCA (A1)................................................................................................................... 10
(2) Synchro Power/Filter CCA (A3/A2).................................................................................................. 10
(3) Interface CCA (A4)........................................................................................................................... 12
(4) GPS Sensor CCA (A5)..................................................................................................................... 20
(5) Processor Board CCA (A6).............................................................................................................. 23
(6) Display Assembly CCA (A7)............................................................................................................. 24
TESTING AND FAULT ISOLATION.......................................................................................................................... 101

1. Task .......................................................................................................................................................... 101
2. Equipment and Materials........................................................................................................................... 101
3. Test Procedure.......................................................................................................................................... 101
4. Fault Isolation Procedure........................................................................................................................... 101
AUTOMATIC TEST REQUIREMENTS (ATLAS)*
DISASSEMBLY......................................................................................................................................................... 301
1. Task .......................................................................................................................................................... 301
2. Equipment and Materials.......................................................................................................................... 301
A. Equipment ....................................................................................................................................... 301
B. Materials........................................................................................................................................... 301
3. Procedures................................................................................................................................................ 301
A. Upper Case Removal......................................................................................................................... 301
B. Lower Case Removal......................................................................................................................... 301
C. Circuit Card Assembly Stack Removal............................................................................................... 302
CLEANING............................................................................................................................................................... 401
1. Task........................................................................................................................................................... 401
A. Equipment.......................................................................................................................................... 401
B. Materials............................................................................................................................................. 401
3. Procedures................................................................................................................................................ 401
A. Clean External Parts........................................................................................................................... 402
B. Clean Electrical Parts......................................................................................................................... 402
C. Clean Glass Parts.............................................................................................................................. 402
D. Clean Mechanical Parts..................................................................................................................... 402
CHECK..................................................................................................................................................................... 501
1. Task........................................................................................................................................................... 501
*Not applicable

March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page TC-1

3. Procedures................................................................................................................................................ 501
A. Examine............................................................................................................................................. 501
B. Make Sure.......................................................................................................................................... 501
C. Check Lithium Battery........................................................................................................................ 502
REPAIR.................................................................................................................................................................... 601
1. Task........................................................................................................................................................... 601
A. Equipment.......................................................................................................................................... 601
B. Materials............................................................................................................................................. 601
3. Precautions for Lithium Batteries............................................................................................................. 602
A. How to Prepare for Maintenance...................................................................................................... 602
B. Warning Label on the Battery Container........................................................................................... 602
C. Replacement Procedure................................................................................................................... 602
D. Discard Procedure............................................................................................................................ 602
4. Procedures.............................................................................................................................................. 602
A. Special Repair Procedures............................................................................................................... 602
B. Paint Touch-up Procedures............................................................................................................... 603
ASSEMBLY (Including Storage)............................................................................................................................... 701

1. Task .......................................................................................................................................................... 701
A. Equipment.......................................................................................................................................... 701
B. Materials............................................................................................................................................ 701
3. Procedures.............................................................................................................................................. 701
A. Circuit Card Assembly Stack.............................................................................................................. 701
(1) CCA A5........................................................................................................................................ 701
(2) CCA A4........................................................................................................................................ 701
(3) CCA A3/A2 ................................................................................................................................. 701
(4) CCA A1........................................................................................................................................ 702
B. Lower Case Installation...................................................................................................................... 702
C. Upper Case Installation...................................................................................................................... 702
4. Storage..................................................................................................................................................... 703
A. Task................................................................................................................................................... 703
B. Equipment and Materials.................................................................................................................... 703
C. Procedures......................................................................................................................................... 704
FITS AND CLEARANCES*

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT................................................................................................... 901
1. Task .......................................................................................................................................................... 901
2. Special Tools, Fixtures, and Equipment.................................................................................................... 901
ILLUSTRATED PARTS LIST................................................................................................................................... 1001

1. Introduction............................................................................................................................................. 1001
2. How to Find a Part.................................................................................................................................. 1001
3. Contents of Illustrated Parts List............................................................................................................. 1001
A. List of Supplies................................................................................................................................ 1001
B. Equipment Designator Index........................................................................................................... 1001
C. Numerical Index............................................................................................................................... 1001
D. Parts List.......................................................................................................................................... 1001
4. Supplier Codes...................................................................................................................................... 1002
5. Abbreviations and Symbols................................................................................................................... 1003
A. Abbreviations................................................................................................................................. 1003
B. Symbols......................................................................................................................................... 1003
*Not applicable

Page TC-2 restrictions of the Proprietary Notice on page TITLE-2 of this document. March 15, 2009
List of Figures
Figure Intro-1 Hazardous Material Warning.....................................................................................................INTRO-3

Figure Intro-2 Caution Label............................................................................................................................INTRO-3
Figure 1 2101 I/O Plus Receiver Display Unit................................................................................................... 1
Figure 2 2101 I/O Plus System......................................................................................................................... 4
Figure 3 2101 I/O Plus to Aircraft Interface....................................................................................................... 5
Figure 4 Front Panel Functionality.................................................................................................................... 8
Figure 5 Power Supply CCA (A1).................................................................................................................... 11
Figure 6 Synchro Power/Filter CCA (A3/A2) (Preferred)................................................................................. 12
Figure 7 Interface CCA (A4)............................................................................................................................ 14
Figure 8 GPS Sensor CCA (A5)...................................................................................................................... 21
Figure 9 Processor Board CCA (A6)............................................................................................................... 25
Figure 10 Display Assembly CCA (A7).............................................................................................................. 26
Figure 101-A ATP Test Equipment Interconnect................................................................................................... 104
Figure 101 Set Up . .......................................................................................................................................... 121
Figure 102 Key Test ......................................................................................................................................... 122
Figure 103 Power Up ....................................................................................................................................... 123
Figure 104 Software Configuration ................................................................................................................. 124
Figure 105 System Configuration .................................................................................................................... 125
Figure 106 Save Waypoint . ............................................................................................................................. 128
Figure 107 Power Interrupt Test . ..................................................................................................................... 129
Figure 108 Button Light Tests .......................................................................................................................... 130
Figure 109 Knob Input Tests ............................................................................................................................ 132
Figure 110 Display Tests . ................................................................................................................................ 134
Figure 111 Display Intensity Tests ................................................................................................................... 135
Figure 112 Audio Output Tests ........................................................................................................................ 136
Figure 113 No. 1 CDI Test ............................................................................................................................... 137
Figure 114 No. 2 CDI Test .............................................................................................................................. 138
Figure 115 External Lamps and Flags Test....................................................................................................... 139
Figure 116 Auxiliary Input Tests ...................................................................................................................... 140
Figure 117 Miscellaneous Output Tests ........................................................................................................... 143
Figure 118 Auxiliary Output Tests ................................................................................................................... 144
Figure 119 GPS Receiver Tests . .................................................................................................................... 151
Figure 120 Serial Port 2 Tests . ........................................................................................................................ 152
Figure 121 Serial Port 1 Tests . ........................................................................................................................ 156
Figure 122 Data Card Tests ............................................................................................................................. 159
Figure 123 Analog Converter Tests ................................................................................................................. 160
Figure 124 Real-Time Clock Tests ................................................................................................................... 162
Figure 125 User Waypoint Entry ...................................................................................................................... 163
Figure 701 Control Cable Connection............................................................................................................... 702
Figure 702 Filter/Power Cable Connection....................................................................................................... 703
Figure 1001 Receiver Display Unit................................................................................................................... 1007
Figure 1002 Display Assembly (P/N 8340 and 82550)...................................................................................... 1013

List of Tables
Table Intro-1 Related Publications...............................................................................................................INTRO-1

Table Intro-2 Level of Verification.................................................................................................................INTRO-1
Table Intro-3 Abbreviations..........................................................................................................................INTRO-3
Table 1 Leading Particulars............................................................................................................................. 2
Table 2 ARINC 429 Input Devices................................................................................................................. 13
*Not applicable

March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page TC-3
Table 3 DADS Digital Input............................................................................................................................ 15

Table 4 AHRS Digital Inputs.......................................................................................................................... 15
Table 5 Radar / Digital Inputs........................................................................................................................ 15
Table 6 Fuel Digital Inputs............................................................................................................................. 16
Table 7 GNS Digital Inputs ........................................................................................................................... 16
Table 8 ARINC 429 Output Parameters ....................................................................................................... 16
Table 9 ARINC 429 VDL Output Parameters................................................................................................. 18
Table 10 ARINC 743 TAWS Output Parameters.............................................................................................. 19
Table 11 30212 Hardware Configuration......................................................................................................... 20
Table 12 84588 Hardware Configuration......................................................................................................... 20
Table 101 Final Test Procedure....................................................................................................................... 102
Table 101-A Essential Test Equipment................................................................................................................ 102
Table 101-B Option 1 Test Equipment................................................................................................................. 102
Table 101-C Option 2 Test Equipment................................................................................................................. 102
Table 101-D Required Software.......................................................................................................................... 103
Table 101-E Software Configuration................................................................................................................... 103
Table 101-F UUT Display.................................................................................................................................... 108
Table 101-G AIO Test Points................................................................................................................................111
Table 101-H Test Points...................................................................................................................................... 112
Table 101-I Discrete Field Display..................................................................................................................... 112
Table 101-J Reference Field Display.................................................................................................................. 113
Table 101-K Channel Display.............................................................................................................................. 113
Table 101-L Specs.dat File List.......................................................................................................................... 118
Table 102 Test to Fault Isolation Cross Reference
Software Version 0241 and Above.................................................................................................. 120
Table 301 CCA/IPL Cross Reference.............................................................................................................. 302
Table 601 Paint Touch-up................................................................................................................................ 603
Table 901 Software by Release Date.............................................................................................................. 901
Table 1001 List of Suppliers............................................................................................................................ 1004
Table 1002 Equipment Designator Index......................................................................................................... 1005
Table 1003 Part Number/Drawings (Figures) Cross Reference...................................................................... 1006
Table 1004 Parts............................................................................................................................................. 1010
Table 1005 83480 and 82550 Faceplate Parts................................................................................................ 1014
*Not applicable

Page TC-4 restrictions of the Proprietary Notice on page TITLE-2 of this document. March 15, 2009
INTRODUCTION
How to Use this Manual

The instructions in this manual give the recommended maintenance functions to put the FreeFlight 2101 I/O Plus
Receiver Display Unit in serviceable condition. Standard maintenance procedures and standard equipment 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
Table Intro-1: Related Publications
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, 16 April, 1997
Disassembly By performance, 16 April, 1997
Assembly By performance, 16 April, 1997
Table Intro-2: Level of Verification
FreeFlight 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 25 April 1997.

March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page INTRO-1
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 in Table Intro-3.

Abbreviations Definitions
A/C Aircraft
ADC Air Data Computer
AHRS Attitude and Heading Reference System
ANT Antenna
APR Approach
ARINC Aeronautical Radio Incorporated
AS Address Strobe
BCD Binary Coded Decimal
CCA Circuit Card Assembly

ComStat Communication Status
CDI Course Deviation Indicator
CPU Central Processing Unit
DADS Digital Air Data System

DTK Desired Track
ENT Enter
ETE Estimated Time Enroute

FC BUS Function Code Bus
FET Field Effect Transistor
FFS FreeFlight Systems
FMS Flight Management System
FPL Flight Plan
GPS Global Positioning System

GS Glideslope
GMT Greenwich Mean Time
HDG Heading
HDI Horizontal Deviation Indicator
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
LORAN Long Range Navigation
LRU Line Replacement
NAV Navigation
NMI Nonmaskable Interrupt
PTK Parallel Track
RAIM Receiver Autonomous Integrity Monitoring

Page INTRO-2 restrictions of the Proprietary Notice on page TITLE-2 of this document. March 15, 2009
Abbreviations Definitions
RDU Receiver Display Unit

RF Radio Frequency
RX Receive
SAT Status Air Temperature

SATCOM Satellite Communication
SID Standard Instrument Departure
STR String
STAR Standard Terminal Arrival Route
SYN Sync
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
VDI Vertical Deviation Indicator

VOR VHF Omnidirectional Ranging
WPT Waypoint
XT Transmit
XTK Crosstalk
Table Intro-3: Abbreviations
Special Precautions

Figure Intro-1: Hazardous Material Warning
The 2101 I/O Plus Receiver Display Unit contains lithium batteries. Before you do any maintenance procedures, refer to
REPAIR and read the instructions on these batteries for your protection. A battery container that breaks open can cause
a sudden fire if moisture gets to the lithium. Fumes from the lithium and thionyl chloride electrolyte are poisonous and
caustic. Parts that contain hazardous material are identified in the ILLUSTRATED PARTS LIST (or CATALOG).

Figure Intro-2: Caution Label
The 2101 I/O Plus 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.

March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page INTRO-3
DESCRIPTION AND OPERATION

1. Physical Description
The 2101 I/O Plus Receiver Display Unit (RDU) is a cockpit Dzus-mounted assembly that consists of the following
parts:
• Top Case
• Circuit Card Assemblies (CCA) A1 through A6
• Bottom Case
• Display Panel (CCA A7) with either black or gray bezel:
- A bank of fully independent momentary action push button 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.
Figure 1: 2101 I/O Plus Receiver Display Unit

March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. Page 1
Dimensions (maximum)

Height .........................................................................................................................3.0 in. ( 762 mm)
Width .........................................................................................................................5.7 in. (1449 mm)
Depth . .....................................................................................................................7.68 in. (1950 mm)
Weight.......................................................................................................................... 3.25 lb (1.48 kg)
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................................................................................................................................. FFS 80251
(MS27508E14B35A)
RDU #2................................................................................................................................. FFS 80253
(MS27508E18B35P)
Antenna Cable Assembly..................................................................................................... FFS 20692
Table 1: Leading Particulars
The RDU CCAs are configuration specific. Depending on the configuration selected, the following CCAs are used in the
RDU:
CCA A1 - Power Supply

CCA A3/A2 - Synchro Power/Filter
CCA A4 - Interface
CCA A5 - GPS Sensor
CCA A6 - Processor Board
CCA A7 - Display Assembly
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 database 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 databases are
maintained on a 28-day update cycle.

Page 2 restrictions of the Proprietary Notice on page TITLE-2 of this document. March 15, 2009
The 2101 I/O Plus (Figure 2) line-replaceable units (LRUs) are:
• GPS Antenna/Preamplifier Unit

• Receiver Display Unit
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
3. Functional Description
The RDU interfaces (Figure 3) with the aircraft systems listed below:
• Heading (HDG)
• True Airspeed (TAS)
• Altitude
• Fuel Flow
• Course Deviation Indicator (CDI)
• Horizontal Situation Indicator (HSI)
• Autopilot
• Annunciators
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 database
• FPL for flight planning
• CALC for performing E6B calculations
• AUX for auxiliary functions
• NRST for nearest airports and VORs
A function (mode) may have one or more data pages. Data pages display status information about the RDU or
contain data fields that allow for variable selections. Information may be 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 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 backward through the
data pages. The small knob is also used to access another line of data on the current data page.

Figure 2: 2101 I/O Plus System

Figure 3: 2101 I/O Plus to Aircraft Interface
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.
B. Front Panel Layout and Description
The RDU front panel features a two line high-intensity alphanumeric Light Emitting Diode (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 database card reader. The card reader is used to access the navigation
database. The card reader also interfaces 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 of 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
performs 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 lines changes
depending upon the mode selected. Different sets of information are displayed for each mode. The LED
screen intensity is automatically adjusted to the ambient light.
(3) Internal 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 flashes until all new messages are read. After the advisory messages are read,
the MSG annunciator extinguishes. If the message is for a warning, the MSG annunciator remains
illuminated.
(b) WPT Annunciator
The Waypoint (WPT) annunciator provides notification of a waypoint arrival. When approaching the
active waypoint, the WPT annunciator illuminates at the preset lead time. The lead time is set by the
AUX CONFIGURE ADVISORY MESSAGES function.
(c) 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.
(d) HLD Annunciator
The Hold (HLD) annunciator provides notice the active flight plan or approach profile being in hold
mode, i.e., the flight plan is 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.
(e) APR Annunciator
The Approach (APR) annunciator provides notification the approach mode is active and aircraft is on the
final approach.

NOTE: The RAIM and GPS Internal Annunciator lights have no function in
software versions -241A and higher.
(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 database.
(c) FPL Mode
The Flight Plan (FPL) mode is used to create, activate, revise, and erase flight plans. The RDU stores 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.
(e) AUX Mode
The Auxiliary (AUX) mode 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, database and software
versions
• Sensor Status GPS status and accuracy, satellite data, GPS availability, approach RAIM
availability

• Configuration Parallel offset, I/O interface check, DR mode, display diagnostic

• User Setup Search regions, airwatch, personal message, save/load configuration

• Install Setup Serial I/O setup, audio level, CDI sensitivity, select user unit, advisory messages,
GPS antenna height, OAT "K" factor, track error graphic, display intensity, magnetic
variation
For detailed operational data refer to the 2101 I/O Plus Pilot’s Guide (P/N 82881).
(f) NRST Mode
The Nearest (NRST) mode provides the following information:
• Airports

• Approaches
• VOR
• Agencies
• NDBs
• Intersections
• User waypoints
(5) Function Keys
Three function keys (Figure 4) are located on the front panel. Each function key has a unique set of
applications. The following paragraphs provide a brief description of each function key:
(a) Direct (D ) Key
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 functions of the Direct (D ) key are:
• Selection of a specific track from present position to the active waypoint

• Selection of a user defined DME arc about any active waypoint
Figure 4: Front Panel Functionality

Direct (D ) key operations 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
(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

• Database Failure
• Database Out-of-Date
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)

• Synchro Power/Filter CCA (A3/A2)
• Interface CCA (A4)
• GPS Sensor CCA (A5)
• Processor Board CCA (A6)
• Display Assembly CCA (A7)
(1) Power Supply CCA (A1)
The power supply CCA (A1) develops ±15 V dc, +5 V dc, and +3 V dc (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 V dc Voltage
The ±15 V dc is developed by full-wave bridge rectifier circuit. The output is filtered and distributed to
the other RDU CCAs.
(b) +5 V dc Voltage
The +5 V dc is developed by its own rectifier circuit. The output is filtered and distributed to the other
RDU CCAs.
(c) +3 V dc Voltage
The +3 V dc is developed by its own rectifier circuit. The output is filtered and distributed to the
Display CCA.
(d) Audio Output Driver
The power supply assembly provides an audio output signal and an audio output monitor signal
(e) Annunciator Driver
Driver for APR, HLD, MSG, and WPT.
(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.
(g) Reset Control
The Power Supply CCA contains the system reset and power monitor circuitry.
(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.

Figure 5: Power Supply CCA (A1)

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 ±21 V dc 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.
Figure 6: Synchro Power/Filter CCA (A3/A2)
(3) Interface CCA (A4)
The Interface CCA (A4) (Figure 7) 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 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)
(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 and 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
GNS Reserved for Honeywell Satellite Landing System
Table 2: ARINC 429 Input Devices

Figure 7: Interface CCA (A4)

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
230 TAS 419/575 BCD
OR
Label
203 Altitude (Press) 429 BNR
204 Altitude (Baro) 429 BNR
210 TAS 429 BNR
211 Total Air Temperature 429 BNR
Table 3: DADS Digital Inputs
2 AHRS Input
The RDU accepts heading inputs on the AHRS port (Table 4).
Label
314 True HDG 429 BNR
320 Mag HDG 429 BNR
Table 4: AHRS Digital Inputs
3 RADAR Input
The RDU accepts inputs of waypoint coordinates on the RADAR port.
Label
324-347 WPT LAT/LON 429 BNR
Table 5: Radar Inputs
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.

Label
244 Fuel Flow Rate 429 BNR

Table 6: Fuel Digital Inputs
5 GNS (Reserved for Honeywell SLS)

Label
033 TDS Label-SLS Tuning 429
101 GNS HDOP 429
102 GNS VDOP 429
110 GNS Latitude 429
111 GNS Longitude 429
232 TDS Label - Airport Identifier 429
242 TDS Label - Airport/station Identifier 429
243 TDS Label - Procedure Selection 429
244 TDS Label - Station 429
270 VDL Status 429
273 GNS Status 429
355 GNS Maintenance 429
Table 7: GNS Inputs
6 Serial Input
The RDU supports two programmable serial-input channels. Each channel is capable of
interfacing to air data and altitude computers.
(e) ARINC 429 Outputs
The RDU provides outputs for three synchros, a Horizontal Deviation Indicator (HDI) and a Vertical
Deviation Indicator (VDI) for driving a Horizontal Situation Indicator (HSI).
The standard ARINC 429 labels supported by the RDU are listed in Table 8.
Label
001 Distance 429 BCD
002 ETE 429 BCD
012 Groundspeed 429 BCD
015 Wind Speed 429 BCD
016 Wind Direction 429 BCD

Table 8: ARINC 429 Output Parameters

Label
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
233-236 Flight ID 241H or later 429 BNR/BCD
251 Distance 429 BNR
252 ETE 429 BNR
260 Date 429 BCD
270, 271 Status 429 DISC
275 Status Gama 429 DISC
310 Latitude 429 BNR
311 Longitude 429 BNR
312 GS 429 BNR
313 Track 429 BNR
314 Heading 429 BNR
315 Wind Speed 429 BNR
316 Wind Direction 429 BNR
321 Drift Angle 429 BNR
324-347 Waypoint Lat/Long 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
Table 8: ARINC 429 Output Parameters (cont)

Label
NOTE: The following GAMA data is only sent when GAMA is selected.
074 No. of Waypoints GAMA
261 GPS Discrete Word 1 GAMA
303 Waypoint Rec. Start GAMA
304 WPT ID (1-3) GAMA
305 WPT ID (4-6) GAMA
306 WPT Latitude GAMA
307 WPT Longitude GAMA
326 Latitude Deviation Scale Factor 429 BNR
327 Vertical Deviation Scale Factor 429 BNR
113 Checksum GAMA
Table 8: ARINC 429 Output Parameters (cont)
Software version 241C, D, H, J, K and M
NOTE: The following ARINC 429 labels are transmitted in a Burst at a minimum rate of 10 times/
second for a minimum of one second for ARINC 429 VDL LO selection.

Label
033 TDS - SLS Tune 429 BNR
242 TDS - Airport/Station Id. 429 BNR
244 TDS - Station Id. 429 BNR
243 TDS - Procedure Selection 429 BNR
232 TDS - Airport Id. 429 BNR
Table 9: ARINC 429 VDL Output Parameters

Port 1 (J2-16 and 23) - Software version 241H or later

Port 2 (J2-58 and 57) - Software version 241H or later

Label
076 Altitude (MSL) 743
101 HDOP 743
102 VDOP 743
103 True Track 743
110 Latitude 743
111 Longitude 743
112 Ground Speed 743
125 UTC 743
130 Horizontal Integrity 743
136 Vertical FOM 743
147 Mag. Variation 743
165 Vertical Speed 743
166 N/S Velocity 743
174 E/W Velocity 743
247 Horizontal FOM 743
260 Date 743
273 Sensor Status 743
Table 10: ARINC 743 TAWS Output Parameters
(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
• Three Spares
(g) Discrete I/O Outputs
The RDU outputs 13 discrete signals to define the current system status. The outputs are:
• Leg Change
• Steering Valid
• Nav Super Flag
• Warn (MSG)
• (WPT Alert)
• Dead Reckoning (DR)
• TO/FROM
• NAV Flag
• Synchro Valid
• Hold (HLD)
• Approach (APR)
• (APR EN)
• Two Spares

(4) GPS Sensor CCA (A5)
The GPS Sensor CCA (Figure 8) contains the following circuits:
• Memory
• Processor
• External Interface
• Down Converter
• Galileo
The basic function of the GPS12 channel is to provide accurate navigation data (position and velocity) to the
Processor Board CCA (A6) of a navigation system by acquiring and tracking GPS satellite signals. It shall
identify the position within 0.056 nmi and velocity of the vehicle within 5 knots or better.
Satellite acquisition and signal tracking are performed through interfaces to the GPS receiver hardware. The
GPS signals are processed and sent to navigation routines which produce position and velocity estimates
which are sent to the processor board via an 8-bit parallel interface. The GPS12 software shall communicate
with the host and a serial interface. The processor hardware (68340) shall communicate via Galileo chips,
A-to-D converter (ADC), 8-bit parallel bus (buffer) and DUART.
(a) Memory
30212 hardware maintains the battery backed RAM memory while power is turned off. In 84588
hardware, certain data variables are periodically written to flash memory, programmable RF section
attenuators and antenna power control.
Writing data to flash memory is triggered by any of three events: the receipt of new ephemeris data
for any satellite, the receipt of new almanac data for any satellite, or the elapse of 375 seconds since
data was last stored in flash. The data recorded in flash includes a version number, a checksum, and
GPS date and time so that the power-up data recovery logic can ensure that the most recently written
valid sector of data is restored. Additionally, the data saved in flash includes oscillator offset, almanacs,
ionospheric corrections, UTC corrections, current position and velocity, the most recently received GPS
text message, ephermeris, dynamics code, operational masks, reverence altitude and IO options.
(b) Processor
The processor is a 68340 Motorola computer operating at 25 MHz and accesses memory location and
provides data transfer to or from memory.
(c) External Interface
The A-to-D converter allows the GPS12 to monitor the status of the primary power supply, synthesizer
module, back-up battery, antenna power supply feed, and internal temperature. The GPS12
communicates with the host via a bi-directional, 8-bit parallel bus. The GPS12 may also communicate
with external devices via the 68340 internal DUART on a bi-directional serial data port.
The analog-to-digital converter inputs vary by hardware type.
Channel Measurement Valid Range Channel Measurement Valid Range

0 internal temperature 15C to 70C 0 internal temperature 15C to 70C
1 PLL 0.0v to 0.3v 1 PLL 0.5v to 2.5v
2 battery 1.0v to 3.8v 2 battery 1.0v to 3.8v
3 antenna voltage 3.0v to 4.9v 3 antenna voltage 3.0v to 4.9v
4 A/C power 1.15v to 3.0v 4 A/C power 1.15v to 3.0v
5 antenna current 10ma to 150ma 5 antenna current 10ma to 150ma
6 2.495v reference 2.3v to 2.7v 6 2.495v reference 2.3v to 2.6v
7 5v 4.7v to 5.3v 7 IFVCO 0.5v to 2.5v
Table 11: 30212 Hardware Configuration Table 12: 84588 Hardware Configuration

Figure 8: GPS Sensor CCA (A5)
Revision B
March 15, 2009 Use or disclosure of information on this page is subject to the restrictions of the Proprietary Notice on page TITLE-2 of this document. Page 21
(d) Down converter
After filtering and buffering, the antenna signal goes through two mixers and filters to perform a
two-stage down conversion to the final IF. The local oscillator signals for the mixers come from the
synthesizer module. In addition to providing the local oscillator signals for the mixers, the synthesizer
module also produces other frequencies used by the 12-channel GPS unit processor. The IF module
processes the IF signal, amplifying it and limiting it's bandwidth. The resulting signal is fed to the Galileo
chips.
(e) Galileo
The Galileo chip is a custom IC that contains hardware for tracking the GPS signal and extracting
carrier and code information, and also provides the millisecond timing interrupt. The GPS12 software
controls the operation of the tracking hardware in the Galileo chip. In turn, the Galileo chip provides
GPS signal information to the GPS12.
(5) Processor Board CCA (A6)
The Processor Board CCA (A6) (Figure 9) 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 using the first four (4) address lines (0 - 3). U405 and U406 are both
volatile SRAM. A 3.6 V dc battery provides a constant voltage making U407 and U408 battery-backed,
non-volatile RAM.
(b) Main Processor
The main processor is a Motorola computer operating at 16 MHz and accesses memory locations and
provides data transfer to or from memory. There are 23 address lines and 16 data transfer lines. The
main programming is contained in U401 and U402, flash memory (4 megabit) 524,288 x 8 each.
(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
GPS sensor data is input to the data bus through P502 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. Buffered input lines connect data card to main processor
data lines and address lines through P504. Power is distributed through P505. Control lines for audio
and annunciations are sent through P506.

(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 16.0 MHz. This frequency is divided by two to provide 8.0 MHz for the display
data shift register. The 8.0 MHz is also used as a clock input.
(g) External Interface
A digital to analog chip converts the localizer left/right and up/down signals from digital to analog.
These analog signals are sent to the aircraft systems and the course deviation indicator. A serial RS422
driver controls input and outputs. A super flag driver is installed through a 0.5 amp fuse. A 1 PPS driver
is available for 1 PPS output. To/From, Nav, and GS flags are available.
(6) Display Assembly CCA (A7)
The Display Assembly CCA (A7) (Figure 10) 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 RDU has one power switch (S10) located at the top of the display panel. The power switch
provides aircraft power to CCA A1 power supply.
(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 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.
(e) Display Modules
The ten-dot matrix displays are driven serially by CCA control circuitry. Each display contains four
characters made up of 5 columns by 7 rows of dots for each character. Five FETs on the display drive
the columns. To create a display, the CCA control circuitry turns OFF all column drivers, sends data
serially to fill all ten display ICs, and then strobes each column driver. The width of the column strobes
is determined by a photo sensor.

Figure 9: Processor Board CCA (A6)

Figure 10: Display Assembly CCA (A7)

TESTING AND FAULT ISOLATION
1. Task
Use the test procedures in this section to test the 2101 I/O Plus 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 for software version -241A and above.
TEST NOTICE
The source of Table 101 is FreeFlight Systems Final Test Procedure, 2101 I/O, 81440-XXTP, Rev AC.
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

Use the instructions in Table 101 to connect the Receiver Display Unit to the test equipment (refer to Figure 1).
Perform the tests as given and look for the specified results.
4. Fault Isolation Procedure
When there is a test failure:
• Use Table 101 to get the number of the failed test.

• Find 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 1001 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.

Table 101: Final Test Procedure Part 1 of 17
1.0 INTRODUCTION
This document contains procedures for final testing of Model 2101 I/O Plus RDU Assembly, 81440-XX.
2.0 TEST EQUIPMENT
The following test equipment is required:
Description Part Number

Cable, Test Set Serial to PC
Cable, RDU to GPS Antenna
Cable, DC power, 2-wire, 22 AWG minimum,
bare wire or banana plug terminations
at both ends
DC Power Supply, 28 V ± 1 V, 3 A
Oscilloscope TEK 2236 or equivalent
Digital Multimeter HP 3466 or equivalent
GPS Antenna 16248-11 or 81194
PC, 386 with VGA monitor and 1 comm port
Database Card, Approach Plus 81461- 1x
Table 101-A: Essential Test Equipment
Either of the following sets of test equipment is also required:

Navigator Test Set 82298-00
Cable Assembly, 37 pin 82991-00
Cable Assembly, 66 pin 82992-00
115 V ac, 400 Hz Power Supply
Table 101-B: Option 1 Test Equipment

OR
CDI Test Set 80167 (ET-0067)
AIO Test Set
Cable, AIO Test Set, 66 pin
Cable, CDI Test Set with Port Switch
Power Interrupt Test Fixture TNL No. ET-95-044
115 V ac, 400 Hz Power Supply
Table 101-C: Option 2 Test Equipment

The following software is required on the PC.
Software Release Date Purpose

IOMON21.EXE 08/30/94 Displays Auxiliary Input Data
SPECS.DAT 01/16/97 Contains acceptance bounds for analog tests
NAVFT.EXE 01/29/98 Tests GPS sensor. Version 3.06 or later
NAVFT.REF 06/23/05 Position reference file used by NAVFT.EXE.
Example: 30 23.22 N 97 42.79 W 200 M
READNAV.EXE 02/02/95 ASCII serial test
Table 101-D: Required Software
3.0 SOFTWARE CONFIGURATION

Use the following table to determine the test set software configuration.
SOFTWARE VERSION NAV GPS AIO

241A (-02, -03, -12) 2.631 5.02-0812 0111
241B (-02, -03, -12) 2.632 5.04-1111 0113
241C (-02, -03, -12) 2.633 5.04-1111 0115
241D (-02, -03, -12) 2.634 5.05-1114 0116
241H (ALL) 2.638 5.05-1114 0121
241J (ALL) 2.639 5.05-1208 0121
241K (ALL) 2.750 5.05-1208 0121
241M (ALL) 2.831 5.05-1208 0121
241S (-02, -03, -12) 2.735 5.05-0420 0118
Table 101-E: Software Configuration
4.0 TEST PROCEDURE
4.1 EQUIPMENT SET-UP AND TEST INITIALIZATION
4.1.1 Set Up
Set the test set switches as follows:
OLEO down
GEARUP down
GOAROUND down
ALTVLD down
SPDVLD down
HDGVLD down
HDGREF down
HSIREF down
STRNGREF down

Figure 101-A: ATP Test Equipment Interconnect
Connect the DC Power Supply to the AC line and turn it ON.
Verify a voltage of 28 V 2 V.
Turn the DC Power Supply OFF.
Record the UUT Part Number, Serial Number, Work Order Number and Date on the Test Data
Record.
Record installed Service Bulletins on the Test Data Record.

Connect UUT and test sets in accordance with Figure 1.
Insert database card P/N 81461-1X into the front of the UUT.
Connect 28 VDC and 115 VAC to test set.

4.1.2 Key Test
Press each of the nine keys several times each.

Verify smooth operation of each key.
4.1.3 Power Up
Turn ON the power supply.
On test set, set UUT 28 VDC switch to ON.
On test set (p/n 82298-00) set 26 VAC switch to ON.
Turn ON the UUT.
Verify the following messages on the display:
FREEFLIGHT (TRIMBLE)
2101 I/O
NAV Computer — OK
GPS Computer — OK
Aux IO Computer — OK
Database — OK
or
Database — Expired
4.1.4 Software Configuration
On the UUT, press AUX repeatedly until "SYSTEM STATUS" is displayed briefly.
Rotate the small knob clockwise (cw) 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.
Verify the software versions are in accordance with Table 1.
Rotate small knob cw one click.
Verify System Code is the same as software dash number.
4.1.5 System Configuration
Press AUX until "CONFIGURE" is displayed briefly.
Rotate small knob cw until "DISPLAY DIAGNOSTIC" is displayed.
Press D , D , ENT, D .
After screen changes, press ENT.

Rotate small knob cw one click to display ENABLED.
Press ENT.

Press AUX repeatedly until "INSTALL SETUP" 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.
Rotate small knob cw until "AUX I/O SETUP" is displayed.
NOTE: Record the settings before changing on the test record comment.
Rotate the large knob until "SYNCHRO OUTPUT #1" is displayed.
Press ENT.
Rotate the small knob cw to select HDG.
Press ENT.
Press ENT.
Press ENT.
Press ENT.
Press ENT.
Rotate the large knob until "AUTOPILOT ROLL STEER" is displayed.
Press ENT.
Rotate the small knob cw to select NORMAL.
Press ENT.

Perform the following steps only if using software versions 241H or above:
Turn outer know clockwise until DIGITAL OUTPUT #1 is displayed.
Press ENT.
Select ARINC 429 LO.
Press ENT.
Turn outer knob clockwise until DIGITAL OUTPUT #2 is displayed.
Press ENT.
Select ARINC 429 LO.
Press ENT.

4.1.6 Save Waypoint
Press CALC until “PRESS (ENT) TO SAVE POSITION TO alpha” is briefly 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 Test Data Record comments section.
4.1.7 Power Interrupt Test
At power interrupt test fixture, press the PULSE button.
Verify the UUT does not reset.
If using test fixture 82298-00, set toggle switch to “200 ms” prior to pressing the PULSE button.
If UUT restarts its initialization sequence, the unit failed the test.
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, key 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, ENT key is blinking.
CALC CALC key is ON, all others dim.
AUX AUX key is ON, all others dim.
NRST NRST key is ON, all others dim.
MSG MSG and NRST are ON, all others dim.
Table 101-F: UUT Display
4.2.2 Knob Input Tests
Press the NAV key.
Note the upper display line text on the UUT. Turn the inner knob clockwise 28 times (24 times if
241C or higher). Verify changing text is displayed for each knob click, and after the last click, the
upper display line indicates the same text as noted.
Turn the inner knob counterclockwise seven times (eight times if 241C or higher). Verify changing
text is displayed for each knob click, and after the last click, the upper display line indicates the
same text as noted.
Note the lower display line text on the UUT. Turn the large knob clockwise 27 times (24 times if
241C or higher). Verify changing text is displayed for each knob click, and after the last click, the
lower display line indicates the same text as noted.
Turn the large knob counterclockwise seven times (eight times if 241C or higher). Verify changing
text is displayed for each knob click, and after the last click, the lower display line indicates the
same text as noted.
4.2.3 Display Tests
Press the AUX repeatedly until "CONFIGURE" is displayed briefly.
Rotate the small knob cw until "DISPLAY DIAGNOSTIC" is displayed.
Observe both lines of the display for any unlit, always lit, or dimly lit pixels as the dashed horizontal
line scrolls.
Observe the annunciator LEDs. They should light in the following sequence.

MSG
GPS
RAIM
WPT
PTK

HLD
APR

NOTE: GPS and RAIM are used only in test mode.
Observe the key LEDs. They should light in the following sequence.
NAV, WPT, FPL, CALC, AUX, D , MSG, ENT, NRST
NOTE: AUX is always ON. MSG may be on.

4.2.4 Display Intensity Tests

Press AUX until "INSTALL SETUP" is displayed briefly.
Rotate the small knob cw until the display reads "SET DISPLAY INTENSITY."
Press ENT.
Rotate both knobs several revolutions clockwise.
Verify the display and keys increase in intensity.
Rotate both knobs several revolutions counterclockwise.
Verify the display and keys decrease in intensity.
Press ENT.
4.2.5 Audio Output Tests
Rotate the small knob cw until "SET AUDIO LEVEL" is displayed.
Press ENT.
Rotate the small knob cw repeatedly until a tone is heard.
Rotate the large knob ccw repeatedly.
Verify the tone decreases in pitch.
Rotate the large know 2 full revolutions clockwise.
Rotate the small knob ccw repeatedly until the tone is no longer audible.
Press ENT.
4.3 EXTERNAL IOP I/O TESTS
4.3.1 External CDI Output Test

4.3.1.1 No. 1 CDI TEST
Press AUX until "CONFIGURE" is displayed briefly.
Rotate the small knob cw one click until "I/O INTERFACE CHECK" is displayed.
Press ENT.
Verify the display indicates "5L", and the Cross Track needle on the CDI test set indicates full left
deflection.
Rotate the small knob cw ten times.
After each click, verify 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 No. 2 CDI TEST
Connect the DC voltmeter to the LT/RT test point on the test set.
Verify the display indicates 5L.
Verify the meter reads -187 mV, + 47 mV /- 10 mV.
Rotate the small knob cw five clicks.
Verify the meter reads between -10mV to +10 mV.
Rotate the small knob cw until the "5R" is displayed.
Verify the voltmeter reads +187mV, + 10 mV /- 47 mV.
4.4 AUXILIARY I/O TESTS
4.4.1 External Lamps and Flags Tests
Press ENT until "FLAG: FROM" is displayed.
Verify the From:Flag is visible on the CDI.
Rotate the small knob cw one click at a time.
Verify the flags and lamps match the UUT screen.

NOTE: Super Flag light on CDI tester will illuminate when the NAV flag is out of view.
4.4.2 Auxiliary Output Tests
On the AIO test set, set the HSIREF and the STRNGREF switches to the UP position.


Using the DMM, measure the AC voltages at test points VAC1 and VAC2 and record on the Test
Data Record Sheet.
Press ENT until TEST SYNCHRO #1 is displayed. Rotate a knob right so 030° is displayed.
With an oscilloscope, verify that the following test points on the AIO test set contain a 400 ±20 Hz
sine wave that is in phase or out of phase with SYN1X, as indicated below in the phase column.
Using DMM, verify the AC voltage of the following test points with the values indicated below in
the Amplitude column, to within 10%. The values in the Amplitude column depend on the voltages
VAC1 and VAC2 measured above and must be calculated by using the equation provided below.
After measuring SYN1X and SYN1Y, use the ENT key to move from synchro #1 to #2 to #3 to roll
steering.
Test Point Setting Amplitude VAC Phase

SYN1X Synchro #1 030° =0.45*VAC1 In Phase
SYN1Y Synchro #1 030° =0.23*VAC1 In Phase
STEERING Roll 15 right =0.23*VAC2 Out of Phase
Table 101-G: AIO Test Points
Rotate the knob until ROLL 30 RIGHT is displayed. Verify an out of phase sinewave of
approximately twice the amplitude. Rotate the knob to ROLL 30 LEFT and verify an in-phase sine
wave.
Press ENT.
On the AIO test set, set HSIREF and the STRNGREF switch to the down position.
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 0 V ± 1 and 12 V ± 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 80 µs wide
6WSYN Signal is low between bursts of data and high during data transmission. It
drops low for one bit time approximately eight bits into the message.
Table 101-H: Test Points


Use the oscilloscope to monitor the PPS test point on the CDI test set cable. 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%.
4.4.4 Auxiliary Input Tests
Press the AUX key repeatedly until "USER SETUP" is displayed.
Rotate the small knob cw until "PERSONAL MESSAGE" is displayed.
Rotate the large knob until "NEW PERSONAL MESSAGE" is displayed.
Press D , AUX, D .
Rotate the small knob cw until "AUX IO CARD MODE" is displayed.
Press ENT.
Rotate the small knob cw until "TEST" is displayed.
Press ENT.

Set the Serial Selector Switch on the CDI test set cable to 1BIP.
On the PC, type IOMON21 <Enter>.
Verify the right portion of the *DISCRETES* field on the PC display reads "01af".
Set each switch in the following list to the Up position.
Verify the *DISCRETES* 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
Table 101-I: Discrete Field Display
Verify the *REFERENCE* field on the PC display reads 0 0 0 0 0.
Set each switch in the following list to the Up position.
Verify 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
Table 101-J: Reference Field Display
In the *LOOPBACK* field of the PC screen, verify all four of the error counts are less than four.
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 fda6 8 fe97
1 fbc6 9 052a
2 fad6 10 04b5
3 fb4e 11 0441
4 fd2e 12 03cc
5 fe1e 13 0357
6 (not tested) 14 (not tested)
7 (not tested) 15 0000
Table 101-K: Channel Display
Press X followed by Y on the PC to terminate the program.
Press ENT.
Rotate the small knob cw until "NORMAL" is displayed.
Press ENT.
4.5 GPS RECEIVER TESTS
Set the Port Selector Switch on the CDI test set cable to Port 3BIP.
On the PC, type 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 four or more satellites are available and the UUT
is “Doing position fixes” before continuing.

Set the Port Selector Switch on the CDI test set cable to Port 3DIF (PORT 3/422).
On the PC, press the F9 key. Ensure "Doing position fixes" returns and the position data continues
to update.
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, SYNTH, and ENT ANT fail messages.
On the PC, press the F2 key. Enter S/N and/or P/N information. Press ENT to print the results (n/a
for manufacturing pre-burn-in).
Sign the printout, and attach it to the Test Data Record.
On the PC, press <ESC> to terminate the program.
4.6 SERIAL PORT TESTS
4.6.1 Serial Port 2 Tests
Press AUX until "INSTALL SETUP" 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 2 (SERIAL if 241A or 241B).
Press ENT.
Set the Port Selector Switch on the CDI test set cable to Port 2DIF.
On the PC, type READNAV <Enter>.
On the UUT, rotate the small knob ccw until "SERIAL I/O SETUP" is displayed.
Rotate large knob cw to display "Serial-1 in."

Press ENT.
Rotate 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.
Observe the PC screen for continuing position and other data updates.
Press the AUX key until "SYSTEM STATUS" appears briefly.
Rotate the small knob until "PRESENT POSITION" is displayed.
Rotate the large knob to display “PRS ALT."
Observe: PRES ALT 1250.
4.6.2 Serial Port 1 Tests
Set the Port Selector Switch on the CDI test set cable to Port 1DIF.
On the UUT, press AUX until "INSTALL SETUP" is briefly displayed.
Rotate small knob until "AUX I/O SETUP" is displayed.
Rotate large knob until "PRESS ALTITUDE INPUT" is displayed. Press ENT and set to
SERIAL 1 (SERIAL if 241A or 241B).
Press ENT.
Rotate the small knob until "SERIAL I/O SETUP" is displayed.
Rotate large knob to display "Serial-2 in."
Press ENT.

Press ENT.

Rotate the large knob to display "Serial 2-out."
Press ENT.
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-1out.
Press ENT.
Rotate small knob to select K0.
Press ENT.
Observe the PC screen for position and other data.
Observe the PC screen for continuing position and other data updates.
Press the AUX key until "SYSTEM STATUS" appears briefly.
Rotate the small knob until "PRESENT POSITION" is displayed.
Rotate the large knob to display “PRS ALT."
Observe: PRES ALT 1250.
On the PC press X to terminate the program.
4.7 DATA CARD AND BATTERY BACKED TESTS
4.7.1 Data Card Tests
Press NRST and observe data for nearest location.
NOTE: Data may vary between data card cycles.
Repeat the above step for VOR, NDB and INT.
4.7.2 Analog Converter Tests

Press AUX repeatedly until "SYSTEM STATUS" is briefly displayed.
If necessary, rotate the small knob until Date and Time are displayed.
Compare the current time to a clock or watch, and note the difference.
Rotate the small knob cw until "INPUT VOLTAGE" is displayed.
Verify "INPUT VOLTAGE" is 25 to 30 volts.
Verify "INTERNAL TEMP" is 20 to 60 °C for a 2101 I/O with a 30212 GPS card.
Verify "INTERNAL TEMP" is 20 to 75 °C for a 2101 I/O with a 84588 GPS card.
Rotate the large knob cw once.
Verify "CRYSTAL OFFSET" is less than 24 Hz.
Verify "MEMORY BATTERY" is greater than 3.4 V.
Rotate the large knob clockwise once.
Verify "GPS ANTENNA" voltage is between 3 and 5 V.
Verify "GPS ANTENNA CURRENT" is greater than 20 mA.
Disconnect GPS antenna cable.
Verify the antenna voltage is 4.5 to 5.5 V and the current is less than 10 mA.
4.7.3 Real-Time Clock Tests
Turn the UUT OFF, and wait 30 seconds.
Remove database card.
Turn the UUT ON.
After the initial messages scroll past, press the AUX key repeatedly until "SYSTEM STATUS" is
displayed.
NOTE: The unit will report GPS antenna.
Compare the displayed time to the same clock or watch.
Verify the difference between the displayed time and the clock agrees with the difference noted
earlier, within 10 seconds.
If possible, verify Date and Time are within 2 minutes of GMT.

4.7.4 User Waypoint Entry
Press WPT repeatedly until the upper display reads “USER."
Rotate the small knob to view the waypoint recorded in step 4.1.6.
Verify the coordinates are the same as recorded.
4.8 TEST TERMINATION
Return UUT to customer settings.
Turn OFF the equipment and disconnect the UUT.

Record necessary information on the Test Data Record.
SPECS.DAT
-665 -537
-1145 -1017
-1385 -1257
-1265 -1137
-785 -657
-545 -417
-2048 2048
-2048 2048
-424 -296
1258 1386
1141 1269
1025 1153
908 1036
791 919
-2048 2048
-20 20
Table 101-L: Specs.dat File List

2101 I/O Plus Final Test Record

TNL 2101 I/O Plus P/N: 81440-_____-___________Serial#:_________________________

Work Order #: ________________________ SB 1 2 3 4 5 6 7 8 9
Start Date: _ _________________________ 10 11 12 13 14 15 16 17 18
19 20 21 22

[PASSED] [FAILED]
4.1.7 Power Interrupt Test [ ] [ ]
4.2.1 Button Light Tests [ ] [ ]
4.2.2 Knob Input Tests [ ] [ ]
4.2.3 Display Tests [ ] [ ]
4.2.4 Display Intensity Tests [ ] [ ]
4.2.5 Audio Output Tests [ ] [ ]
4.3.1 External CDI Output Test [ ] [ ]
4.4.1 External Lamps and Flags Tests [ ] [ ]
4.4.2 Auxiliary Output Tests VAC1__________ VAC2_ __________ [ ] [ ]
4.4.3 Miscellaneous Output Tests [ ] [ ]
4.4.4 Auxiliary Input Test [ ] [ ]
4.5 GPS Receiver Tests [ ] [ ]
4.6.1 Serial Port 2 Tests [ ] [ ]
4.6.2 Serial Port 1 Tests [ ] [ ]
4.7.1 Data Card Tests [ ] [ ]
4.7.2 Analog Converter Tests [ ] [ ]
4.7.3 Real-Time Clock Tests [ ] [ ]
4.7.4 User Waypoint Entry [ ] [ ]
OVERALL TEST RESULT: [ ] [ ]
Comments: ____________________________________________________________
____________________________________________________________
____________________________________________________________
TESTED BY: ____________________________________________________________

Failed Test Step No. Fault Isolation Procedure Figure No.

4.1.1 Set Up 101
4.1.2 Key Test 102
4.1.3 Power Up 103
4.1.4 Software Configuration 104
4.1.5 System Configuration 105
4.1.6 Save Waypoint 106
4.1.7 Power Interrupt Test 107
4.2.1 Button Light Tests 108
4.2.2 Knob Input Tests 109
4.2.3 Display Tests 110
4.2.4 Display Intensity Tests 111
4.2.5 Audio Output Tests 112
4.3.1.1 No. 1 CDI Test 113
4.3.1.2 No. 2 CDI Test 114
4.4.1 External Lamps and Flags Tests 115
4.4.2 Auxiliary Output Tests 116
4.4.3 Miscellaneous Output Tests 117
4.4.4 Auxiliary Input Tests 118
4.5 GPS Receiver Tests 119
4.6.1 Serial Port 2 Tests 120
4.6.2 Serial Port 1 Tests 121
4.7.1 Data Card Tests 122
4.7.2 Analog Converter Tests 123
4.7.3 Real-Time Clock Tests 124
4.7.4 User Waypoint Entry 125
Table 102: Test to Fault Isolation Cross Reference Software Version-241A and Above

Figures 101 through 126 refer to software version -241A and above.
Tests are found in Table 101, Section 4.0.
Figure 101: Set Up

Figure 102: Key Test

TURN ON TEST SET

POWER SUPPLY.
TURN RDU ON.
REMOVE POWER
RDU FROM TEST SET.
TURNS NO
DISCONNECT J1 AND
ON? J2 FROM RDU.
YES
CONTINUITY
BETWEEN NO REPLACE ON/OFF
CENTER AND PIN 2 SWITCH RETEST RDU
OF ON/OFF
SWITCH?
YES
FREEFLIGHT NO
2101 I/O
DISPLAYED ON REPLACE A1 CCA
RDU?
YES
NAV
COMPUTER OK NO
RDU?
YES
GPS
COMPUTER OK NO
RDU?
YES
AUX IO
COMPUTER OK NO
RDU?
YES
DATA-
BASE OK
OR EXPIRED NO DATABASE NA REPLACE
DISPLAYED DISPLAYED ON RDU. DATABASE CARD
ON RDU?
YES
END V01109
Figure 103: Power Up

REPROGRAM
FAIL SECOND TIME?
Figure 104: Software Configuration

Figure 105: System Configuration (Sheet 1 of 3)



Figure 106: Save Waypoint

Figure 107: Power Interrupt Test

Figure 108: Button Light Tests (Sheet 1 of 2)

Figure 108: Button Light Tests (Sheet 2 of 2)

Note: 241C or higher is 8 clicks
Figure 109: Knob Input Tests (Sheet 1 of 2)

Figure 109: Knob Input Tests (Sheet 2 of 2)

Figure 110: Display Tests

Figure 111: Display Intensity Tests

Figure 112: Audio Output Tests

Figure 113: No. 1 CDI Test

Figure 114: No. 2 CDI Test

Figure 115: External Lamps and Flags Tests

Figure 116: Auxiliary Output Tests (Sheet 1 of 3)

Figure 116: Auxiliary Output Test (Sheet 2 of 3)

Figure 116: Auxiliary Output Tests (Sheet 3 of 3)

Figure 117: Miscellaneous Output Tests

Figure 118: Auxiliary Input Tests (Sheet 1 of 7)







VERIFY RDU ON
AND POWERED UP
SET CD PORT
SELECTOR SWITCH
TO 3BIP
TYPE NAVFT
FOLLOWED BY
<ENTER> ON THE PC
"DOING
POSITION NO
FIXES" ON WAIT 5 MINUTES
PC SCREEN?
YES
RETEST RDU
"DOING
YES POSITION
SET CDI SELECTOR FIXES" ON
SWITCH TO 3DIF PC SCREEN?
POSITION NO NO
DATA STILL REPLACE A5 CCA
UPDATES
YES
PRESS F1 ON PC AND YES

WAIT FOR TEST TO
COMPLETE
"INVALID
TEST" NO PRESS F2
APPEARS ON TO PRINT TEST
PC?
YES
PRESS F9 THEN F1 TO PRESS <ESC> On PC

REPEAT TEST
NOTE: END
DISREGARD TEMP, SYNTH,
AND ENT ANT FAIL MESSAGES V01143
Figure 119: GPS Receiver Tests

Note: If 241A or 241B = Serial

-2
Figure 120: Serial Port 2 Tests (Sheet 1 of 4)




ROTATE LARGE
KNOB UNTIL PRESS
ALTITUDE INPUT
IS DISPLAYED
SET TO SERIAL-2
Note: If 241A or 241B = Serial



Figure 122: Data Card Tests

Figure 123: Analog Converter Tests (Sheet 1 of 2)

Figure 123: Analog Converter Tests (Sheet 2 of 2)

Figure 124: Real-Time Clock Tests

Figure 125: User Waypoint Entry

DISASSEMBLY
1. Task
Use these procedures to remove parts from the 2101 I/O Plus RDU to do cleaning, checks, and replacement of parts
as necessary. Refer to figure and item numbers in the ILLUSTRATED PARTS LIST (IPL) to 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.
NOTE: Equivalent alternatives are permitted for the equipment and materials in this list.
A. Equipment
None.
B. Materials
None.
3. Procedures

A. Upper Case Removal
(1) Remove eight screws (20, IPL Figure 1) securing sides of the upper case (40) to the lower case (145).
(2) Remove one screw (30) securing top of the upper case (40).
(3) Remove two screws (20) securing the bottom flange of the upper case (40) to the lower case (145).
(4) Remove nut and lock washer securing cable assembly (95) to upper case (40).
(5) Rotate the antenna connector slightly to align flat side of connector with flat side of hole in the case.
(6) Separate connector from case.
(7) Remove eight screws (25) securing CCA A3/A2 (75) to back of upper case (40).
(8) Remove upper case (40).
B. Lower Case Removal
(1) Remove four screws (45) securing lower case (145) to display assembly (135).
CAUTION: THERE ARE MATING CONNECTORS HOLDING THE DISPLAY

ASSEMBLY (135) TO CCA A1 (55) AND CCA A6 (125) BOARDS.

THE DISPLAY ASSEMBLY SHOULD BE REMOVED CAREFULLY

TO AVOID PIN DAMAGE TO THE MATING CONNECTORS.
(2) Remove display assembly (135) from lower case (145).
(3) Remove seven screws (45) securing lower case (145) to circuit board assembly A6 (125).
(4) Remove two screws (50) securing CCA A1 (55) to side of lower case (145).
(5) Remove lower case (145).
C. Circuit Card Assembly Stack Removal
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
A4 Interface 90, 90A
A5 GPS Sensor 105, 105A
A6 Processor Board 125, 125A
A7 Display Assembly 135, 135A, 135B, 135C, 135D, 135E, 135F
Table 301: CCA / IPL Cross Reference

(1) CCA A1
(a) Disconnect Filter/Power cable assembly (60) from CCA A1 (55).
(b) Separate CCA A1 (55) from CCA A6 (125) by pulling straight upward.
(2) CCA A3/A2
(a) Remove one screw (65) and four screws (70) securing CCA A3/A2 (75) to standoffs (85).
CAUTION: DO NOT STRESS THE RIGID/FLEX CONNECTION BETWEEN THE A3 AND A2

COMPONENTS OF CCA A3/A2. DAMAGE TO THE CIRCUIT LAYERS MAY RESULT.
(b) Separate CCA A3/A2 (75) from CCA A4 (90) and CCA A6 (125)
connectors.
(3) CCA A4
(a) Remove five standoffs (85) securing CCA A4 (90) to standoffs (100).

(b) Disconnect control cable (80) from CCA A4 (90).
(b) Separate CCA A4 (90) from CCA A5 (105) by pulling straight upward.
(4) CCA A5
(a) Remove five standoffs (100) securing CCA A5 (105) to four standoffs (120) and one standoff (115).
(b) Carefully separate CCA A5 (105) from CCA A6 (125) by pulling straight upward.

CLEANING
1. Task
To clean the 2101 I/O Plus 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.
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.
A. Equipment

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
B. Materials

HAZARD CODE 130D
Solvent — Isopropyl alcohol (99%); Optional source
Nonvinegar based glass cleaner
Crocus cloth, Grade 4/0 — Optional source
3. 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.

CAUTIONS
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.
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.
(4) 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.
CAUTION: DO NOT clean A7 CCA (135, 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 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.
D. Clean Mechanical Parts

CAUTION: WHEN YOU REMOVE CORROSION, MOVE THE CROCUS CLOTH PARALLEL TO THE AXIS
OF THE PART. IF YOU MOVE THE CROCUS CLOTH ACROSS THE AXIS, YOU CAN CAUSE
DAMAGE TO THE FINISH.
(1) Remove corrosion from metal parts with 4/0 crocus cloth.
(2) Clean metal parts in a bath of isopropyl alcohol. If submersion can cause damage to a part, wipe the part
fully with a cloth moistened with isopropyl alcohol. Dry parts with pressurized air.

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.
None.
3. 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
(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.
C. Check Lithium Battery:

(1) To ensure there are no cracks or bulges in the battery container.
(2) To ensure there are to signs of leakage of the thionyl chloride electrolyte.

REPAIR
1. Task
Repair of the 2101 I/O Plus 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 Plus 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.

The 2101 I/O Plus contains lithium batteries. Before you do any maintenance procedures, read the instructions on
these batteries in paragraph 3 for your protection.
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
B. Materials
Sleeving, non-rigid, insulation, crosslinked, flexible polyolefin, heat shrinkable, electrical, clear (flammable),
0.250-in. 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, South El Monte, CA
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, New York, NY
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. Precautions for Lithium Batteries
To keep the batteries reliable, it is important to (1) prevent damage to the battery container and (2) to not do any
maintenance procedures that could cause the loss of cell capacity, the cell to overheat and explode, or the electrolyte
to leak.
A. How to Prepare for Maintenance

The battery is made with a lithium electrode and thionyl chloride (liquid electrolyte). If the container breaks
open and moisture or water reaches the lithium, sudden flames can occur. Use graphite powder, not water, to
extinquish any flames. Fumes from lithium and thionyl chloride electrolyte are poisonous and caustic. If a failure
occurs, do not breathe in the fumes nor touch the battery.

(1) Wear gloves for protection from the corrosive electrolyte that can leak from the battery container.
(2) Wear full safety goggles for protection from a possible battery explosion.
B. Warning Label on the Battery Container
Read the warning that tells the risk of fire and explosion. This battery is a primary cell and is not designed to be
charged or force-charged. Do not open or disassembe the battery.
C. Replacement Procedure
When you solder to the terminals of the battery, be careful not to damage the cell.
(1) Do not solder any leads to the battery container—it can cause seal leakage or explosion of the cell.
(2) During the solder process, do not apply heat for more than 5 seconds at 260 °C (500 °F) to prevent leakage
or cell explosion.

D. Discard Procedure

When a defective battery is replaced, discard the replace battery in accordance with federal, state, or local
regulation. Do not put in in an incinerator or where the temperature exceeds 150 °C (302 °F)
4. 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.

(2) Replace Battery
(a) For access to CCA A6 (125, 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 battery (130), Part No. 12047, noting polarity.
(d) Dispose of battery properly.
(e) Add insulation sleeve to positive side of battery lead.
(f) Place battery (130), Part No. 12047 on CCA A6 (125) observing correct polarity.
(g) Heatsink and solder each battery lead.
(h) Install CCA A6 (125) according to the procedures in ASSEMBLY.
(i) Test battery using procedures in TESTING AND FAULT ISOLATION.
B. Paint Touch-up Procedures
(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 1/155
Display Assembly Semi-gloss black 1/45
Display Assembly Cadet gray 1/45
Table 601: Paint Touch-up

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.
Refer to figure and item numbers in the ILLUSTRATED PART LIST (IPL) to 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
number 4 for storage instructions.
A. Equipment

None.
B. Materials
None.
3. Procedures

A. Circuit Card Assembly Stack
(1) CCA A5
(a) Install and tighten four standoffs (120) and one standoff (115) to CCA A6 (125).
Do not over tighten.
(b) Carefully mate connector A5P1 with connector A6J502.
(c) Secure CCA A5 (105) to CCA A6(125) with five standoffs (100). Do not
over tighten standoffs.
(2) CCA A4
(a) Carefully mate connector A4P1 with connector A5P3.
(b) Secure CCA A4 (90) to CCA A5(105) with five standoffs (85). Do not
over tighten standoffs.
(c) Connect control cable (80) from CCA A4 (90) to CCA A6 (125). See Figure 701 for correct connector
positioning.
(3) CCA A3/A2
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 (90) connectors J2A and J2B and CCA

Figure 701: Control Cable Connection
A6 (125) connector P701.

(b) Secure CCA A3/A2 (75) to standoffs (85) with one screw (65) and four screws (70).
(4) CCA A1
(a) Carefully mate CCA A1 (55) connectors J505 and J506 to CCA A6 (125) connectors P505 and P506.
(b) Connect lead assembly connecting CCA A3/A2 (75) to mating connector on CCA A1 (55).
(c) Connect filter/power cable assembly (60) from CCA A3/A2 (75) to mating connector on CCA A1 (55).
See Figure 702 for correct connector positioning.
B. Lower Case Installation
(1) Position circuit card assembly stack in lower case (145).
(2) Attach lower case (145) to side of CCA A1 (55) with two screws (50).
(3) Attach lower case (145) to CCA A6 (125) with seven screws (45).
(4) Mate Display Assembly A7 (135) connector to CCA A6 (125) connector.
(5) Attach Display Assembly (A7) (135) to lower case (145) with four screws (45).
C. Upper Case Installation
(1) Install cable assembly (95) through rear of upper case.
(2) Make sure that gasket is in place on connector.

Figure 702: Filter/Power Cable Connection
(3) Install lock washer and nut onto connector, and tighten.
(4) Set upper case (40) over lower case (145).
(5) Slide forward over connectors A2J1 and A2J2.
(6) Attach CCA A3/A2 (75) to back of upper case (40) with eight screws (25).
(7) Attach the bottom flange of the upper case (40) to the lower case (145) with two screws (20).
(8) Attach sides of the upper case (40) to the lower case (145) with eight screws (20).
(9) Attach upper case (40) to the CCA rack with one screw (30) in top of upper case (40).
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 RDU. 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 FreeFlight 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 in. 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 ft.
Top: 8 by 8 by 4 inches with 1.5 in. nubbins

Bottom: 10 by 10 by 7.5 inches with 1.5 in. nubbins

C. Procedures
CAUTIONS: 1. THIS EQUIPMENT IS ELECTROSTATIC DISCHARGE SENSITIVE. DO NOT PUT IT NEAR

STRONG ELECTROSTATIC, ELECTROMAGNETIC, MAGNETIC, 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 CCA.

(2) Fold the mouth of the bag over to enclose the CCA. Do not seal the bag.
(3) Place the CCA into the container on top of a layer of foam protection.
(4) Place top layer of foam protection over the CCA.

(5) Close the container.
(6) Secure the container with two bands of strapping.
(7) 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.
(8) Mark the container to identify the contents and the date the CCA was packed.

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 RDU. 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 RDU.
2. Special Tools, Fixtures, and Equipment
NOTE: Equivalent alternatives are permitted for the equipment in this list.
A. Available from FreeFlight Systems, Waco, Texas (IWAN0):
Navigation Database Card — Jeppsen P/N 81461-1X
In addition to the Navigation Database Card, use either:
Navigator Test Set, FreeFlight Part No. 82298-00

GPS Antenna, FreeFlight Part No. 16248-11 or 81194
Cable Assembly, 37 Pin, FreeFlight Part No. 82991-00
Cable Assembly, 66 Pin, FreeFlight Part No. 82992-00
Cable, AIO Test Set, 66 Pin

The following software should be installed on the PC:
Software Release Date or Later

IOMON21.EXE 8/30/94
SPECS.DAT 1/16/97
NAVFT.EXE 1/29/98
NAVFT.REF 6/23/05
READNAV.EXE 2/2/95
Table 901: Software by Release Date
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, HP 3466 or equivalent

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

DC Power Supply, 28 V ± 1 V @ 3 Ampere
Serial cable, test set to PC

Cable, RDU to GPS Antenna

Cable, DC Power, two-wire, 22 AWG minimum with bare wire or banana plug terminations at both ends.
Power Supply, 115 V ac, 400 Hz

ILLUSTRATED PARTS LIST
1. Introduction
The Illustrated Parts List gives the parts used to make the 2101 I/O Plus RDU. 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 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).
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 FreeFlight 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 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
FreeFlight 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 FreeFlight part number. When this column shows the FreeFlight 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.
(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.
(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

These symbols are used on illustrations:
*HAZARDOUS MATERIAL* For hazardous materials.
For static sensitive or ESDS.

CODE SUPPLIER CODE SUPPLIER
1WAN0 FREEFLIGHT SYSTEMS

3700 IH 35 S.
WACO, TX 76706
Table 1001: List of Suppliers

EQUIPMENT DESIGNATOR INDEX

EQUIPMENT FIG. ITEM PART EQUIPMENT FIG. ITEM PART
DESIGNATOR NUMBER DESIGNATOR NUMBER
A1 1 55 80932-10
A1 1-55A 80932-00
A3/A2 1 75 81675-00-A
A4 1 90 81874-00-A
A5 1-105 84588-10
A5 1-105A 30212-10
A6 1-125 82875-01-A
A6 1-125A 82875-00-A
A7 1 135 83480-10
A7 1-135A 83480-12
A7 1-135B 82550-10
A7 1-135C 82550-12
A7 1-135D 83549-00
A7 1-135E 84720-16
A7 1-135F 84720-12
Table 1002: Equipment Designation Index

NUMERICAL INDEX
AIRLINE FIG. TTL

PART NUMBER STOCK NO. ITEM REQ
12047 1 130 1
12584 1 65 1
12815 1 70 4
16919 1 5 1
20692 1 95 1
30212-10 1 105A 1
80064 1 15 1
80229 1 145 1
80232 1 140 1
80235-00 1 80 1
80238-00 1 60 1
80286 1 25 8
80420 1 35 1
80425 1 100 5
80447 1 45 12
80448 1 30 3
80932-00 1 -55A 1
80932-10 1 55 1
81338 1 85 5
81339 1 120 4
81340 1 115 1
81373 1 40 1
81434 1 20 10
81440-02 1 - 1 RF
81440-03 1 - 1A RF
81675-00-A 1 75 1
81874-00-A 1 90 1
82550-10 1 135B 1
82550-12 1 -135C 1
82875-00-A 1 125A 1
83480-10 1 135 1
83480-12 1 -135A 1
83549-00 1 -135D 1
84588-10 1-105 1
82875-01-A A-125 1
84720-16 1-135E 1
84720-12 1-135F 1
Table 1003: Part Number / Figure Cross Reference

30
11
46 1
Figure 1001: Receiver Display Unit (Sheet 1 of 2)
Revision B
March 15, 2009 Use or disclosure of information on this page is subject to the restrictions of the Proprietary Notice on page TITLE-2 of this document. Page 1007
Figure 1001: Receiver Display Unit (Sheet 2 of 2)

UNIT
FIG. PART AIRLINE NOMENCLATURE EEF PER
ITEM NUMBER STOCKNO. 1234567 CODE ASSY
USABLE ON CODES
CODE A 81440-02
CODE B 81440-03
CODE C 81440-12
CODE D 81440-32
CODE E 81440-33
CODE F 81440-42
1 -1 81440-02 DISPLAY UNIT,RECEIVER, BLACK FACE A RF

(ESDS)
-1A 81440-03 DISPLAY UNIT,RECEIVER, GREY FACE B RF
(ESDS)
-1B 81440-12 DISPLAY UNIT, RECEIVER, BLK NVG C RF
-1C 81440-32 DISPLAY UNIT, RECEIVER, BLACK FACE D RF
(ESDS)
-1D 81440-33 DISPLAY UNIT, RECEIVER, GREY FACE E RF
(ESDS)
-1E 81440-42 DISPLAY UNIT, RECEIVER BLK NVG F RF
(ESDS)
5 16919 .LABEL,COPYRIGHT 1
SILICON SOFTWARE
10 83056 .LABEL,IDENTIFICATION 1
15 80064 .LABEL,SERVICE BULLETIN 1
20 81434 .SCREW 10
PL 100 FLH 2-56X0.125
SS BLK
25 80286 .SCREW 8
PL FLH 4-40X0.25
SS BLK
30 80448 .SCREW 2-56X3/16 100 FH PLSS BLNY 3
35 80420 .DOME 1
40 81373 .CASE,UPPER 1
45 80447 .SCREW 11
PL 100 FLH 4-40X0.25
SS BLK
46 21659 .SCREW
188 PL FLH 4-40X0/375
SS BLK NY 1
55 80932-10 .CIRCUIT CARD ASSEMBLY- 1
POWER SUPPLY
(ESDS)
(A1)
(PREFERRED PART)
- 55A 80932-00 .CIRCUIT CARD ASSEMBLY- 1
POWER SUPPLY
(ESDS)
(A1)
(ALTERNATE PART)
60 80238-00 .CABLE ASSEMBLY- 1
FILTER/POWER
Table 1004: Parts

- ITEM NOT ILLUSTRATED

UNIT
65 12584 .SCREW 1
PL PH 4-40X0.31
SS

70 12815 .SCREW 4
PL PH 4-40X0.25
SS
1 75 81675-00-A .CIRCUIT CARD ASSEMBLY- 1
SYNCHRO POWER/FILTER
(ESDS)
(A3/A2)
80 80235-00 .CABLE, CONTROL 1
85 81338 .STANDOFF, M-F 3-16 HEX 5
4-40X0.25
90 81874-00-A .CIRCUIT CARD ASSEMBLY- 1
INTERFACE
(ESDS)
(A4)
(PREFERRED PART)
95 20692 .CABLE ASSEMBLY 1
GPS SIGNAL
100 80425 .STANDOFF, M-F 4-40X0.562 5
105 84588-10 .CIRCUIT CARD ASSEMBLY- D, E, F 1
GPS SENSOR
(ESDS)
(A5)
105A 30212-10 .CIRCUIT CARD ASSEMBLY- A, B, C 1
GPS SENSOR
(ESDS)
(A5)
1 115 81340 .STANDOFF, F-F 4-40X0.437 1
120 81339 .STANDOFF, M-F 4-40X0.437 4
125 82875-01-A .CIRCUIT CARD ASSEMBLY- 1
PROCESSOR BOARD 4MB
(ESDS)
(A6)
125A 82875-00-A .CIRCUIT CARD ASSEMBLY- 1
PROCESSOR BOARD
(ESDS)
(A6)
(PREFERRED PART)
130 12047 ..BATTERY 1
*HAZARDOUS MATERIAL*
(A6BT401)
135 83480-10 .DISPLAY ASSEMBLY BLK A, D 1
(A7) (ALTERNATE PART)
135A 83480-12 .DISPLAY ASSEMBLY GREY B, E 1
135B 82550-10 .DISPLAY ASSEMBLY BLK A, D 1
135C 82550-12 .DISPLAY ASSEMBLY GRY B, E 1
Table 1004: Parts (con't.)

UNIT
135D 83549-00 .DISPLAY ASSEMBLY BLK NVG C, F 1

(A7)
135E 84720-16 .DISPLAY ASSEMBLY BLK NVG C, F 1
(A7) (PREFERRED PART)
135F 84720-12 .DISPLAY ASSEMBLY GRY B, E 1
(A7) (PREFERRED PART)
140 80232 .GUIDE, CARD 1
145 80229 .CASE, LOWER 1
150 81941 .LABEL, PART NUMBER 1

Table 1004: Parts (con't.)


Figure 1002: Display Assembly - P/N 83480 and 82550 only (Non-NVG)

For use on 83480 and 82550 faceplates ONLY
UNIT
2 10 83480-SA02 .BEZEL ADDY BLK I/O PLUS A 1

10A 83480-SA05 .BEZEL ASSY GRY I/O PLUS B 1
15 83981 KNOB 1
20 16572 DUAL KNOB 1
25 84061-00 RUBBER KEYPADS 1
30 84065 KEY PLUNGER 9
35 84064 STAINLESS DOME 9
40 84063 GOLD DOME 9
45 84072 ROTARY SWITCH ENCODER 1
(PREFERRED PART)
45A 14297 ROTARY SWITCH ENCODER 1
(ALTERNATE PART)
45B 14297-00 ROTARY SWITCH ENCODER 1
(ALTERNATE PART)
50 80298 ON / OFF SWITCH 1
55 84066 #4 PAN HEAD SS PH NYLOK 3
60 84068 #4 FLAT HEAD 82° SS PH NYLOK 1
65 84067 #2 FLAT HEAD 82° SS PH NYLOK 1
70 84062-00-E PCB ASSY W/HEATSINK 1

Table 1005: 83480 / 82250 Faceplate Parts


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COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST

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

Use or disclosure of information on this page is subject to the Revision B

Your Name Company Airline

State Country Zip

Telephone No. FAX Date

FreeFlight Pub. No. ATA No.

LOCAL REPRODUCTION ENCOURAGED

REPORT OF POSSIBLE DATA ERROR

Your Name Company Airline

State Country Zip

Telephone No. FAX Date

FreeFlight Pub. No. ATA No.

PAGE NO. PARA­GRAPH FIGURE NO. TABLE NO. PROBLEM

MATERIALS HAZARD RATING CODE

POSITION 1: HEALTH HAZARD POSITION 2: FIRE HAZARD

POSITION 3: REACTIVITY HAZARD POSITION 4: STORAGE GROUP

Revision B Use or disclosure of information on this page is subject to the

HEALTH HAZARD RATING IN POSITION 1

Rating Description Effect of Exposure

3 Dangerous health Short exposures could cause DANGEROUS TEMPORARY OR

2 Hazardous Intense or continued exposure could cause TEMPORARY

1 Irritant May cause IRRITATION on exposure. Only SMALL REMAINING

0 No important Not hazardous for usual conditions. Special personal

FIRE HAZARD RATING IN POSITION 2

Rating Description Effect of Exposure

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

Use or disclosure of information on this page is subject to the Revision B

Revision B Use or disclosure of information on this page is subject to the

RECORD OF TEMPORARY REVISIONS

Temporary Date Date Date

Revision B Use or disclosure of information on this page is subject to the

SERVICE BULLETIN LIST

Service Identified Date Included

Revision B Use or disclosure of information on this page is subject to the

Release of operating system –241L.

Installation of software version -241L also requires implementation of hardware

• Update software to accept 4 MB Nav database.

September 26, 2008 SB 81440-XX-00-21 PAGE 1 of 14

3700 Interstate 35 S., WACO, TX 76706 Telephone: 254-662-0000 Fax: 254-662-9451

Units Compliance Man Hours

F. Weight and Balance

I. Other Publications Affected

J. Interchangeability and Identification

September 26, 2008 SB 81440-XX-00-21 PAGE 2 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 3 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 4 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 5 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 6 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 7 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 8 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 9 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 10 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 11 of 14

September 26, 2008 SB 81440-XX-00-21 PAGE 12 of 14

Ready for Navigation

September 26, 2008 SB 81440-XX-00-21 PAGE 13 of 14

NAV, NRST and –D-

End of Reset Procedure

F. Restore Configuration Settings

September 26, 2008 SB 81440-XX-00-21 PAGE 14 of 14

Release of operating system –241M.

PAGE NO. PARAGRAPH FIGURE NO. TABLE NO. PROBLEM