KMD 540 Manual de Mantenimiento

COMPONENT MAINTENANCE
MANUAL
KMD 540
MULTI-FUNCTION
DISPLAY
MANUAL NUMBER 006-15608-0004

REVISION 4 JULY, 2004
WARNING
The enclosed technical data is eligible for export under License Designation NLR and is to be
used solely by the individual/organization to whom it is addressed. Diversion contrary to U.S. law
is prohibited.
COPYRIGHT NOTICE
©2000-2001, 2003, 2004 Honeywell International Inc.
REPRODUCTION OF THIS PUBLICATION OR ANY PORTION THEREOF BY ANY MEANS

WITHOUT THE EXPRESS WRITTEN PERMISSION OF HONEYWELL IS PROHIBITED,
EXCEPT TO THE EXTENT REQUIRED FOR INSTALLATION OR MAINTENANCE OF THE
RECIPIENT’S EQUIPMENT. FOR FURTHER INFORMATION CONTACT THE MANAGER,
TECHNICAL PUBLICATIONS, HONEYWELL, ONE TECHNOLOGY CENTER, 23500 WEST
105th STREET OLATHE KS 66061 TELEPHONE: (913) 712-0400.
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KMD 540 COMPONENT MAINTENANCE MANUAL
Component Maintenance Manual

with Illustrated Parts List
006-15608-0004
KMD 540
Multi-Function Display
Part Number 066-04035-XXXX
Including:
KAC 501 Weather Radar Module
KAC 502 EGPWS Module
KAC 503 FIS Module
KAC 504 Traffic Module
Comprising:
KMD 550/850 Systems
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NOTE
IF ANY UNUSUAL OR SPECIFIC SERVICE PROBLEMS ARISE, CONTACT HONEYWELL,

23500 WEST 105TH STREET, OLATHE, KANSAS, 66061. NO EQUIPMENT SHALL BE
RETURNED TO THE CUSTOMER SERVICE DEPARTMENT UNTIL A RETURN
AUTHORIZATION (RA) FORM IS REQUESTED AND RECEIVED FROM HONEYWELL.
PROPRIETARY NOTICE
This document contains proprietary information and

such information may not be disclosed to others for
any purpose, nor used for manufacturing purposes
without written permission from Honeywell.
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REVISION HIGHLIGHTS
006-15608-0004 Rev. 4
July/2004
This is a complete reprint. All pages are revised and reformatted. The revision
highlights are noted below. Revision bars denote specific changes.
Highlight(s) of revision 4:
• Added 066-04035-1101, -1201, -1301 and applicable Environmental Qualifica-

tion Forms.
• Updated to add changes per Application SW version 01/13.
• The Illustrated Parts List has been updated to reflect current parts lists
and assembly drawings. Previous revision information has been retained for
historical reference.
• Added cross-referencing for electronic copy (PDF).
• Added ETSO information.
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THIS PAGE IS RESERVED
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RECORD OF REVISIONS
REV. REVISION DATE DATE

BY BY
NO. DATE INSERTED REMOVED
Complete through
Revision 4
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RECORD OF REVISIONS (cont.)
REV. REVISION DATE DATE

BY BY
NO. DATE INSERTED REMOVED
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The following are released Service/Software Bulletins for the KMD 540 unit
and KAC 50X modules. They are listed by manual revision and date.
SERVICE/SOFTWARE MANUAL MANUAL

BULLETIN NUMBER REVISION REVISION EFFECTIVITY
(Honeywell No.) NUMBER DATE
KMD 540-1 3 Jan/2003 S/N 3300, Mod 1
KMD 540-2 3 Jan/2003 S/N 4203, Mod 2
KAC 501-1 3 Jan/2003 S/N 2197, Mod 1
KAC 502-1 3 Jan/2003 S/N 1928, Mod 1
KAC 503-1 3 Jan/2003 S/N 1644, Mod 1
KAC 504-1 3 Jan/2003 S/N 1912, Mod 1
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Title Page * T-1 July/2004

Proprietary Notice * PN-1 July/2004
Revision Highlights * RH-1 July/2004

* RH-2 July/2004
Record of Revisions * RR-1 July/2004

* RR-2 July/2004
Service Bulletin List * SB-1 July/2004

* SB-2 July/2004
List of Effective Pages * LEP-1 July/2004

* LEP-2 July/2004
* LEP-3 July/2004
* LEP-4 July/2004
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Introduction * INTRO-1 July/2004
Description and Operation * 0 July/2004

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Description and Operation * 11 July/2004

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Check * 5001 July/2004

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Repair * 6001 July/2004

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Assembly * 7001 July/2004

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Special Tools, Fixtures and * 9001 July/2004

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TABLE OF CONTENTS
ITEM PAGE
DESCRIPTION AND OPERATION
1. General ...............................................................1
A. Purpose of the Equipment ........................................1
B. Equipment Part Numbers ..........................................2
C. Related Publications ............................................3
D. ESDS Device Labels and Symbols ..................................3
2. Configurations Available ..............................................5
3. Leading Particulars ...................................................5

A. Unit Specifications .............................................5
B. Environmental Certification .....................................6
4. Brief Description of Equipment .......................................25

A. Mechanical Description .........................................25
B. Electrical Description .........................................25
5. Theory of Operation ..................................................26

A. Overall Operation ..............................................26
B. Simplified Block Diagram Description ...........................26
C. Detailed Theory of Operation ...................................63
TESTING AND TROUBLESHOOTING

1. General ............................................................1001
2. Test Equipment .....................................................1001

A. Test Equipment Required ......................................1001
B. Test Equipment Setup .........................................1001
C. Functional Test Data Sheet ...................................1002
3. Functional Test Procedures .........................................1013

A. Power Application ............................................1013
B. 5 VDC Lighting Bus ...........................................1015
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ITEM PAGE
C. 28VDC Lighting Bus ...........................................1018

D. 5VAC Lighting Bus ............................................1019
E. SW Upgrade Enable ............................................1020
F. NTSC Video Input .............................................1020
G. Discrete Message Alarm .......................................1021
H. Discrete Audio Output ........................................1021
I. Discrete Wx RT On/Off Output .................................1022
J. Discrete EGPWS Control .......................................1022
K. Discrete TRFC Control ........................................1022
L. Heading Input ................................................1023
M. Heading Valid ................................................1023
N. External GPS Input / Output ..................................1024
O. Stormscope Input / Output ....................................1024
P. RS232 CH1 Input / Output .....................................1024
Q. WX/EGPWS RS232 Input / Output ................................1024
R. TRFC RS232 Input / Output ....................................1025
S. RS422 Serial Ports ...........................................1025
T. Weather Radar 429 Serial Outputs .............................1025
U. EGPWS 429 Outputs ............................................1025
V. TRFC 429 Input / Output ......................................1026
W. ARINC 429 Stormscope Input ...................................1026
X. EGPWS ARINC 453 Input ........................................1026
Y. WX ARINC 453 Input ...........................................1026
Z. Brightness ...................................................1027
AA. Function Select Keys .........................................1027
AB. Cooling Fan ..................................................1029
AC. Display ......................................................1030
AD. FIS Module Clock RTC and Memory ..............................1030
AE. Subscription Management Processor (SMP) Test .................1030
AF. Shutdown .....................................................1031
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ITEM PAGE
AG. Field Installation of the KMD 540 and Option Modules. ........1032
4. Troubleshooting Procedures .........................................1032
5. Alignment Procedures ...............................................1032

A. Display Alignment ............................................1032
B. Audio Adjustment .............................................1033
6. Retest Procedure ...................................................1034
7. Service Information ................................................1034
SCHEMATIC DIAGRAMS
1. General ............................................................2001
DISASSEMBLY
1. General ............................................................3001
2. Recommended Disassembly Procedure ..................................3001

A. Unit Right Side Cover Removal ................................3001
B. KAC 50X Interface Modules Removal ............................3001
C. Front Panel Module Removal ...................................3002
D. Case Rear Plate Removal ......................................3003
E. Nav Prog Module Removal ......................................3004
F. Power Supply Module Removal ..................................3004
G. Interface Board Removal ......................................3004
H. Distribution Module Removal ..................................3005
CLEANING
1. General ............................................................4001
2. Recommended Cleaning Materials .....................................4001
3. Recommended Cleaning Procedures ....................................4002

A. Exterior .....................................................4002
B. Interior .....................................................4002
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ITEM PAGE
CHECK
1. General ............................................................5001
2. Inspection Procedures ..............................................5001

A. Cover ........................................................5001
B. Front Panel ..................................................5001
C. Chassis ......................................................5001
D. Hardware, Covers and Shields .................................5001
E. Circuit Boards ...............................................5001
F. Connectors ...................................................5001
G. Terminal Connections .........................................5001
H. Terminal Connections, Soldered ...............................5002
I. Wiring .......................................................5002
J. Capacitors ...................................................5002
K. Resistors and Diodes .........................................5002
L. Filters and Inductors ........................................5002
M. Transformers .................................................5002
N. Transistors and Integrated Circuits ..........................5002
O. Rotary Switches ..............................................5003
P. Insulators ...................................................5003
REPAIR
1. General ............................................................6001
2. Repair Procedures ..................................................6001

A. Repair Precautions ...........................................6001
B. Electrostatic Discharge Sensitive (ESDS) Devices .............6002
C. Replacement of Printed Circuit Board Protective Coating ......6004
D. Programmable Read Only Memory (PROM) Replacement .............6005
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ITEM PAGE
ASSEMBLY
1. General ............................................................7001
2. Materials Required For Assembly ....................................7001
3. Recommended Reassembly Procedures ..................................7002

A. Unit Right Side Cover Reassembly .............................7002
B. KAC 50X Interface Modules Reassembly .........................7002
C. Front Panel Module Reassembly ................................7002
D. Case Rear Plate Reassembly ...................................7003
E. Nav Prog Module Reassembly ...................................7003
F. Power Supply Module Reassembly ...............................7004
G. Interface Prog Module Reassembly .............................7004
H. Distribution Module Reassembly ...............................7004
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

1. General ............................................................9001
2. Equipment Required to Test .........................................9001
ILLUSTRATED PARTS LIST
1. General ...........................................................10001
2. Revision Service ..................................................10001
3. List of Abbreviations .............................................10001
4. Typical Parts List ................................................10002
STORAGE
1. General ...........................................................15001
2. Storage Procedures ................................................15001

A. Short-Term Storage ..........................................15001
B. Long-Term Storage ...........................................15001
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ITEM PAGE
Figure 1 KMD 540 Multi-Function Display and Functionality .............2

Figure 2 ESDS Device Labels and Symbols ...............................4
Figure 3 Environmental Certification Categories .......................7
Figure 4 KMD 540 Main Block Diagram ..................................35
Figure 5 KMD 540 Power Supply Block Diagram ..........................37
Figure 6 KMD 540 Interface Board Block Diagram .......................39
Figure 7 KAC 501 Wx Board Block Diagram ..............................43
Figure 8 KAC 502 EGPWS Board Block Diagram ...........................45
Figure 9 KMD 540 Front Panel Board Block Diagram .....................47
Figure 10 KMD 540 Nav Processor Board Block Diagram ...................53
Figure 11 KMD 540 Switch Board Block Diagram ..........................55
Figure 12 KMD 540 Joystick/Knob Board Block Diagram ...................57
Figure 13 KAC 504 TRFC Processor Board Block Diagram ..................59
Figure 14 KAC 503 FIS Processor Board Block Diagram ...................61
Figure 1001 System Configuration (Main Test) Page .....................1015
Figure 1002 KMD 540 Display Lighting Diagram ..........................1016
Figure 1003 KMD 540 Backlighting Diagram ..............................1016
Figure 1004 KMD 540 Indicator Lighting Diagram ........................1017
Figure 2001 KMD 540 Installation Drawing ..............................2005
Figure 2002 KMD 540 End Item Assembly Drawing .........................2007
Figure 2003 KAC 501 Installation Drawing ..............................2015
Figure 9001 KMD 540 Breakout Test Panel Assembly Drawing ..............9003
Figure 9002 KMD 540 Test Equipment Interconnect Drawing ...............9007
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ITEM PAGE
Figure 9003 KMD 540 Breakout Test Panel Schematic .....................9009

Figure 10001 Typical Parts List .......................................10003
Figure 10002 KMD 540 End Item Assembly Drawing ........................10005
Figure 10003 KMD 540 Front Panel Drawing (with Mod 2) .................10017
Figure 10004 KMD 540 Chassis Drawing ..................................10041
Figure 10005 KMD 540 Case Rear Plate Drawing ..........................10055
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ITEM PAGE
Table 1 Related Publications .........................................3

Table 2 Available Versions and Options ...............................5
Table 3 Leading Particulars ..........................................6
Table 4 PC Board and Assembly Designations ..........................25
Table 4001 Recommended Cleaning Materials ............................4001
Table 4002 Unsafe Solvents ...........................................4002
Table 7001 Sealants and Staking Compounds ............................7001
Table 9001 Required Test Equipment ...................................9001
Table 10001 Abbreviations ............................................10001
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INTRODUCTION
The instructions in this manual provide the information necessary to perform
maintenance functions.
The manual is divided into separate sections. Refer to the TABLE OF CONTENTS for
the page location of applicable sections. An asterisk flagnote *[ ] in place
of the page number indicates that no special instructions are provided, since
the function can be performed using standard industry practices.
All weights and measurements in the manual are in English units, unless otherwise
stated.
The manual will be revised as necessary to reflect current information.
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1. Brightness Control
2. Data Card
3. LCD Display
4. Available Function/Overlay Legend
5. On/Off Control
6. Selected Function Indicators
7. Function Select Keys
8. Control Knobs (Inner and Outer)
9. Power Key Labels (Secret Until Lit ‘SUL’ Labels)
10. Soft Labels
11. Joystick
12. Power Keys
13. Fault Indicator
Figure 1 KMD 540 Multi-Function Display and Functionality
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DESCRIPTION AND OPERATION

1. General
This manual contains information relative to the maintenance, alignment,

and procurement of replacement parts for the Honeywell KMD 540 Multi-
Function Display, hereafter referred to as the KMD 540, the Multi-Function
Display (MFD), or by its full nomenclature. This manual also references
the following option modules, the KAC 501 Weather Radar Module, the KAC
502 EGPWS Module, the KAC 503 FIS Module, and the KAC 504 TRFC Module as
required for KMD 540 maintenance purposes. The KMD 540 Multi-Function
Display and functionality is illustrated in Figure 1 KMD 540 Multi-
Function Display and Functionality.
NOTE: References in this manual to KAC 50X refer to the option mod-
ules, i.e. KAC 501, KAC 502, KAC 503, KAC 504, etc.
A. Purpose of the Equipment
The KMD 550/850 systems are based upon the same base unit, the KMD
540. The KMD 540 is a Multi-function Display (MFD) that utilizes a
5" Diagonal LCD to display a detailed moving map using data from the
front loading datacard. The datacard contains application software
and a customized Jeppesen aeronautical database with airports,
victor airways, VORs, NDBs, intersections, and special use airspace
(including altitude limits). It is also an enhanced cartographic
database and includes rivers, roads, lakes, coastlines, cities,
railroad tracks, towers (including AGL and MSL altitudes), regional
topographical/elevation information and topographic shading. The
Data Card must be installed prior to power up. During power up and
normal operation, the KMD 540 will test for the presence of a valid
data card. If the card is not installed or a faulty card is
installed, the KMD 540 will not continue to operate and will display
an error message.
The KMD 540 has the ability to display Stormscope (Goodrich WX-500/
WX-1000E) information as well as NTSC video input (such as a remote
camera). The KMD 540 may host up to four optional modules to expand
the capability of the unit. These modules are installed in the unit
as part of the aircraft installation. Each is treated as an
independent part of the system and has its own top level unit part
number, TSO, and serial tag. The optional modules are described as
follows:
The KAC 501 Weather Radar Module is shipped with every KMD 850 and
represents the distinction between the KMD 550 and KMD 850 systems.
The card allows control and display of the Honeywell RDR 2000/2100
and the RDS 81/82/82VP/84/84VP/86/86VP radars.
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The KAC 502 EGPWS Module enables the display of terrain from the KGP
560 EGPWS and other EGPWS units (i.e., Mk VI). This unit complies
with TSO C151a/ETSO-C151a for terrain warning devices.
The KAC 503 FIS Module enables the display of flight information
services weather data from the Bendix/King Wingman Services.
The KAC 504 Traffic Module enables the processing and display of
traffic from the Honeywell KMH 880/980 or KTA 870/970 Traffic
Awareness System, Goodrich Skywatch, Ryan TCAD, and from any
Honeywell TCAS I/II System. The WX-1000E Stormscope is also
interfaced via the KAC 504 module.
B. Equipment Part Numbers
The Honeywell part numbers assigned to the various configurations

of the system are listed in section 2. Configurations Available).
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C. Related Publications
Table 1 Related Publications references other publications related

to the KMD 540.
PUBLICATION HONEYWELL ATA

IDENTIFICATION IDENTIFICATION
NUMBER NUMBER
KMD 550/850 System 006-10608-XXXX N/A

Installation Manual
KMD 540 Pilot’s Guide 006-18222-0000 N/A
KMD 540 Quick Reference Guide 006-18223-0000 N/A
KAC 501 Wx Module Addendum 006-18235-0000 N/A
KAC 502 EGPWS Module 006-18236-0000 N/A

Addendum
KAC 503 FIS Module Addendum 006-18237-0000 N/A
KAC 504 Traffic Module Addendum 006-18238-0000 N/A
Table 1 Related Publications
D. ESDS Device Labels and Symbols
CAUTION: THIS EQUIPMENT CONTAINS ELECTROSTATIC DISCHARGE SENSITIVE

(ESDS) DEVICES. ALL ESDS DEVICES MUST BE HANDLED IN AC-
CORDANCE WITH PROCEDURES OUTLINED IN THIS MANUAL. ESDS
DEVICES INCLUDE, BUT ARE NOT LIMITED TO, CMOS, JMOS, MOS-
FET, HMOS, PMOS, MICROWAVE MIXER DIODES, SOME METAL FILM
RESISTORS, AND SOME BIPOLAR DEVICES.
The labels and symbols shown in Figure 2 ESDS Device Labels and
Symbols are used by Honeywell to identify ESDS applications. The
labels DO NOT appear on units and modules manufactured prior to
adoption of the STANDARD symbol.
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Figure 2 ESDS Device Labels and Symbols
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2. Configurations Available
The following are the available versions of the KMD 550/850 systems.
NOTE: Some part numbers may not be currently available. Consult the
current Honeywell catalog or contact a Honeywell representative
for equipment availability.
Unit/Option Part Number

KMD 540 MFD Base Unit 066-04035-0101/-1101 (BLACK)
KMD 540 MFD Base Unit 066-04035-0201/-1201 (GRAY)
KMD 540 MFD Base Unit 066-04035-0301/-1301 (SILVER CROWN)
KAC 501 Weather Radar Module * 071-00159-0111
KAC 502 EGPWS Module 071-00158-0211
KAC 503 FIS Module 071-00168-0311
KAC 504 TRFC Module 071-00166-0411
Data Card 071-00161-0101 (Americas)
Data Card 071-00161-0102
(Pacific International)
Data Card 071-00161-0103
(Atlantic International)
* The KAC 501 is included as part of the KMD 850 system.
Table 2 Available Versions and Options
3. Leading Particulars
A. Unit Specifications
Table 3 Leading Particulars lists the leading particulars for the KMD 550/
850 system.
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CHARACTERISTIC DESCRIPTION
TSO Compliance TSO C113/ETSO-C113
KMD 540 Display functionality of C110a/ETSO-C110a
TSO Compliance Display functionality of C63c/ETSO-2C63c
KAC 501
TSO Compliance Display functionality of C151a/ETSO-C151a
KAC 502
KAC 503
KAC 504
Environmental Certification: See Figure 3 Environmental Certification Categories
Overall Dimensions: See Figure 2001 KMD 540 Installation Drawing
Weight: See Figure 2001 KMD 540 Installation Drawing
Operating Temperature: -15°C to +70°C
Mounting: Panel, see Figure 2001 KMD 540 Installation Drawing
Altitude: 35,000 ft.
Power Requirements: 10 to 33 VDC,
20 watts nominal,
40 watts maximum
Lighting: +28 VDC or +14 VDC or
+ 5 VDC or 5 VAC
Cooling Requirements: No external cooling required,
cooled by an internal fan
Table 3 Leading Particulars
B. Environmental Certification
The KMD 540 Multi-Function Display and KAC 50X Option Modules meet
the environmental conditions of the Radio Technical Commission for
Aeronautics (RTCA) document number DO-160D, "Environmental
Conditions and Test Procedures for Airline Electronic/Electrical
Equipment and Instruments" (see Figure 3 Environmental
Certification Categories).
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Figure 3 Environmental Certification Categories

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4. Brief Description of Equipment
A. Mechanical Description
The KMD 540 is a panel mounted multi-function display. Cooling is

provided by an internal fan.
B. Electrical Description
The KMD 540 contains several PC boards and assemblies which are
listed in Table 4 PC Board and Assembly Designations along with
reference series and connector information.
ASSEMBLY PART NUMBER REFERENCE CONNECTORS

SERIES
CHASSIS ASSEMBLY 200-09736-0000 N.A. N.A.
CASE / REAR PLATE ASSEMBLY 200-09766-0001 N.A. N.A.
200-09766-0002
JOYSTICK / KNOB BOARD 200-09722-0001 200 J201
SWITCH BOARD 200-09806-0001 1000 J1001
POWER SUPPLY BOARD 200-09702-0001 2000 J2001
INTERFACE BOARD 200-09703-0001 3000 J3001, J3002, J3003,
J3004
DISTRIBUTION BOARD 200-09704-0001 4000 J4001, J4002, J4003,
J4004, J4005, J4006,
J4007, J4008, J4009,
J4010, J4011, J4012,
J4013
KAC 502 EGPWS / 200-09705-0001 5000 J5001
KAC 501 WX BOARD
FRONT PANEL BOARD 200-09706-0002 6000 J6001, J6002, J6003,
200-09808-0001* J6004, J6005, J6006,
J6007
NAV PROCESSOR BOARD 200-09707-0001 7000 J7001, J7002
KAC 504 TRFC PROCESSOR BOARD 200-09773-0001 9000 J9001
KAC 503 FIS PROCESSOR BOARD 200-09807-0001 8000 J8001
FRONT PANEL ASSEMBLY 200-09734-00XX N.A. N.A.
* Mod 2 change
Table 4 PC Board and Assembly Designations
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5. Theory of Operation
A. Overall Operation
The KMD 540 is a multiple microprocessor unit. In its basic

configuration as a moving map unit (i.e. NAV function only enabled)
there are three microprocessors in operation. One processor is
located on the front panel PCB and handles all the front panel
controls, the indicator lamps and the video images being sent to the
display. The second processor is located on the interface PCB and
handles all the system I/O. The third processor is on the NAV PCB
and handles the primary NAV function and the interface to the PCMCIA
data card.
Additional functions such as WX Radar, EGPWS etc. are handled by

separate processor PCBs which plug into expansion slots within the
unit.
The three standard processors plus any other processors that are
fitted on plug in cards all communicate with each other over an
internal high speed network. The system architecture is analogous
to a small business office with several PCs linked together on a
network. The interface PCB can be thought of as the server.
In this architecture, each processor board is running continuously,

processing its own data and carrying out its own functions with the
full resources of the processor. When a primary function is
selected, data for display is already prepared and current, enabling
the function to be accessed immediately without PLEASE WAIT
messages. When a primary function (such as EGPWS) is not selected
as the currently displayed mode, it continues to run in the
background at full processor power and sends any warning messages
necessary to the currently active processor board for immediate
display.
B. Simplified Block Diagram Description
Refer to Figure 4 KMD 540 Main Block Diagram as required.
(1) General Circuitry
The circuitry of the KMD 540 is distributed across a maximum

of eleven printed circuit cards (boards). These boards can
be split into two groups.
The first group forms the basic platform on which the KMD 540
system operates, and consists of the following:
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(a) Distribution board.
(b) Power Supply board.
(c) Interface Processor board.
(d) Front Panel board.
(e) Switch board.
(f) Joystick Knob board.
(g) Nav Processor board.
The second group consists of Modular Processor boards, which

perform dedicated functions as follows:
(h) KAC 501 Wx Processor module.
(i) KAC 502 EGPWS Processor module.
(j) KAC 504 TRFC Processor module.
(k) KAC 503 FIS Processor module.
The KMD 550/850 system is designed to be expandable. The

basic KMD 540 Mapping system represents the minimum sys-
tem configuration and will comprise seven boards. These
are the first six system platform boards (a) through (f)
plus the Nav Processor board (g). The additional four
Modular Processor board slots are reserved for func-
tions such as Weather Radar, Traffic information, EGP-
WS, FIS, etc.
Each of these Modular Processor boards contains its own

microprocessor, which will run a self-contained suite
of software from on board Flash memory. Each of these
boards also contain a memory mapped video interface, any
one of which can be routed through an eight bit parallel
video bus to be displayed on the front panel LCD.
The Front Panel Assembly (F/P) consists of the display,

front panel board, switch board, and joystick/knob
board. A Front Panel microcontroller, and Interface mi-
croprocessor are used to control and condition I/O data
and F/P switch commands which are packaged and broadcast
to all Modular Processor boards using a high speed se-
rial CAN bus interface.
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In addition, each module is capable of communicating

with any other module via this CAN bus. This allows any
Modular Processor board that is not selected for dis-
play, to transmit graphical overlay information to a se-
lected video channel board, for processing and display
on the front panel LCD, via the CAN bus.
The system incorporates a single Power Supply board,

which converts aircraft power and provides regulated
power supply voltages for the logic and display func-
tions via the Distribution board. The KMD 540 incorpo-
rates a 12V fan mounted on the rear panel to extract air
and provide cooling for the internal boards. The fan
will only operate when the KMD 540 is switched on, and
internal temperature sensors will switch the fan off if
the internal ambient temperature is below 10°C.
(2) Power Supply Board
Refer to Figure 5 KMD 540 Power Supply Block Diagram as re-

quired.
The Power Supply Board contains circuitry to convert the Air-

craft supply into the regulated secondary power supplies re-
quired by the internal system components. The Power Supply
Board also contains circuitry to provide system power on reset
signals, power shutdown warning signals, power interruption
hold-up, and over and under voltage shutdown protection for
the main +5V secondary supply.
The Power Supply Board contains a power-switching element to

enable power conversion. This is controlled by the F/P ON/
OFF switch. A latching circuit is controlled by the F/P tem-
perature monitor, and will shut down the power conversion in
an over temperature situation to protect system components.
This board contains a large number of leaded components such

as power transformers, power transistors & Heatsink, and ra-
dial electrolytic capacitors. It is the largest and heaviest
board within the KMD 540. The presence of the regulated Power
Supply outputs is indicated by four LEDs on the edge of the
board.
(3) Interface Processor Board
Refer to Figure 6 KMD 540 Interface Board Block Diagram as

required.
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The Interface Processor board connects directly to the air-

craft power supply and lighting bus, and other avionics equip-
ment within the aircraft via the two rear panel 37 pin D-Type
connectors. Almost all of these external I/O lines are fil-
tered and protected by transient suppressors. This provides
a high level of protection against indirect lightning effects.
The on-board microprocessor executes code from an operating
system which can be downloaded via a high speed serial CAN bus
interface into Flash memory. A separate Boot Flash EPROM is
provided for the initial Boot up. The microprocessor controls
a quad UART for RS232 I/O and also communicates directly with
the Front Panel microcontroller via an RS232 link. It then
processes and packages the front panel switch status, and ex-
ternal input data, before transmitting it to all processor
modules via the CAN bus. The Interface Processor board also
controls an Audio output, and a number of discrete I/O lines
which are constantly monitored and shut down in the event of
an current overload condition. The microprocessor system in-
corporates high speed RAM and serial EEPROM for fast, non-
volatile configuration data retention.
The Interface Processor board also contains buffer circuitry

for ARINC 429 transmission and routes some of the external I/
O lines from the rear D-Types directly onto the Distribution
Board providing direct connection between the external avion-
ics equipment and the modules within the KMD 540. The status
of the Interface Processor can be indicated via four LEDs
mounted on the edge of the board.
Four configuration switches can also be read by the micropro-

cessor and are used to initiate manual program upgrades and
self test routines.
(4) Distribution Board
The Distribution Board (refer to Figure 4 KMD 540 Main Block

Diagram) does not contain any active circuitry. It contains
a large number of sockets, and is used to distribute Power,
CAN bus, Communication, and control signals between the var-
ious microprocessor boards. It also contains the Video clock
and Video bus signals which are routed from the various mi-
croprocessor boards to the Front Panel Control board via a 50
way flexible Ribbon Cable. The Front Panel PCMCIA card socket
is mounted on the Distribution board and routed to the Nav
Processor board connector. The rear panel fan also connects
to the Distribution board.
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(5) KAC 502 EGPWS / KAC 501 Wx Processor Board
Refer to Figure 7 KAC 501 Wx Board Block Diagram and Figure

8 KAC 502 EGPWS Board Block Diagram.
The EGPWS / Wx Processor board is used for Wx and EGPWS func-

tions depending on the operating system that has been down-
loaded into it’s flash memory. This depends on which position
the board occupies on the Distribution board (refer to Figure
4 KMD 540 Main Block Diagram). The theory of operation for
both functions is essentially the same, although I/O pin la-
bels are different.
The Wx Processor board is used to interface the KMD 540 to a

Weather Radar head such as the ART 2000. An ARINC 453 capture
circuit is provided to clock radial KC Picture Bus data into
a FIFO at high speed. The on-board microprocessor executes
code from an operating system which can be downloaded via a
high speed serial CAN bus interface into Flash memory. A sep-
arate Boot Flash EPROM is provided for the initial Boot up.
The microprocessor reads the ARINC 453 FIFO picture data and
builds a video image in the on board video memory. When se-
lected by the F/P microcontroller, this video image is clocked
into the F/P Video Field Memory via the Video bus, for display
on the LCD.
The microprocessor system also incorporates high speed RAM and

serial EEPROM for fast, non-volatile configuration data re-
tention.
The Wx Processor board also contains circuitry for ARINC 429

generation to provide control and set-up information for the
Radar Head. These signals are routed to the Interface board
where they are buffered for transmission to the external Radar
Head via the rear panel D-Type connectors.
The microprocessor can also provide graphical overlay infor-

mation to other processor modules via the onboard CAN bus in-
terface. The status of the Wx Processor can be indicated via
four LEDs mounted on the edge of the board. Four configura-
tion switches can also be read by the microprocessor and are
used to initiate manual program upgrades and self test rou-
tines.
(6) Front Panel (F/P) Control Board
Refer to Figure 9 KMD 540 Front Panel Board Block Diagram as

required.
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The Front Panel Control Board is used to interface the F/P

switches, Joystick, rotary controls, and LEDs to the Processor
modules within the KMD 550/850 system. This board also con-
tains a Field Memory and RGB drivers which provide Video image
buffering between a selected Processor module video memory and
the LCD module. The Front Panel Control PCB contains a PIC
microcontroller with a OTP operating system. Unlike the Pro-
cessor modules, the PIC operating system software cannot be
upgraded via the PCMCIA card. The PIC microcontroller commu-
nicates directly with the Interface board via an RS232 serial
interface. The Interface board then packages the F/P switch
data and distributes it to other Processor modules within the
system via the CAN bus. Similarly, any module wishing to com-
municate with the Front Panel Control board will do so using
the CAN bus, via the Interface board.
The Front Panel Control board also contains circuitry to mon-

itor the Lighting bus and Aircraft supply voltages, the in-
ternal case temperature, and the F/P Brightness knob setting.
This information is used by the PIC microcontroller to control

the intensity of the LCD and key backlighting via the PWM out-
puts, and to control the rear panel fan. The PIC microcon-
troller also has the ability to shutdown the power supply mod-
ule if an over temperature situation is detected. A linear
regulator circuit is provided to give even backlighting on the
F/P keys when the unit is switched off.
The Front Panel Control board contains high intensity LEDs to

provide illumination of the Secret Until Lit labels on the F/
P Bezel. The F/P switches, indicator LEDs, and backlighting
LEDs are mounted on separate Switch and Joystick/Knob boards
which are connected to the Front Panel board via 2mm double
row headers.
An NTSC Composite Video input is available on the rear panel.

For units without Mod 2 incorporated, it is routed directly
to the Front Panel Control board where it is monitored and
applied to the LCD module input.
For units with Mod 2 incorporated, it is still routed directly

to the Front Panel Control board; however, it is now monitored
and then fed to a video signal processor. This converts the
composite video into RGB components which are applied to the
LCD module input.
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The PIC microcontroller has the ability to switch between the

internal RGB video signal, and the external Composite video
signal.
(7) Nav Processor Board
Refer to Figure 10 KMD 540 Nav Processor Board Block Diagram

as required.
The Nav Processor Board is used to generate the video map im-
age and overlays for a given Lat, Long position. Panning and
zooming are also performed depending on F/P switch status
which is received via the onboard high speed serial CAN bus
interface.
The on-board microprocessor executes code from an operating

system, which can be downloaded from the onboard PCMCIA card
provided for the initial Boot up. The microprocessor is also
capable of reading from the PCMCIA card, and re-transmitting
operating system upgrades to other Processor modules within
the system via the high speed serial CAN bus interface.
This can only be achieved if the external Software Upgrade

link is fitted to the rear panel D-Type. The link status is
read by the Nav microprocessor, which controls a FET switch
to apply a programming voltage to the Flash memory of all pro-
cessor modules in the system.
During the Map calculation, vectored map and elevation data

is read directly from the PCMCIA card and used to generate a
map image in the onboard video memory. When the Map function
is selected, the video image is transferred to the F/P field
memory via the Video bus, and displayed on the LCD.

tention.

mation to other processor modules via the high speed CAN bus
interface. The status of the Nav Processor can be indicated
via four LEDs mounted on the edge of the board. Four config-
uration switches can also be read by the microprocessor and
are used to initiate manual program upgrades and self test
routines.
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(8) Switch Board
Refer to Figure 11 KMD 540 Switch Board Block Diagram as re-

quired.
The Switch Board is located directly behind the Front Panel

Bezel, and contains switches for Function key and Menu selec-
tion, and LEDs for Function key indicators and Front Panel
backlighting. The Switch Board is connected to the Front Pan-
el board via 2mm double row headers.
(9) Joystick / Knob Board
Refer to Figure 12 KMD 540 Joystick/Knob Board Block Diagram

as required.
The Joystick / Knob Board is located directly behind the Front

Panel Bezel and the Switch board.
It contains the Joystick switches, Rotary Knob optical encod-

ers, and backlighting LEDs for these functions. The Joystick
/ Knob Board is connected to the Switch board via 2mm double
row headers.
(10) KAC 504 TRFC Processor Board
Refer to Figure 13 KAC 504 TRFC Processor Board Block Diagram

as required.
The TRFC board is used to interface the KMD 540 to TCASI/

TCASII/TAS systems. An ARINC 429 transceiver is used to in-
terface to the external TCAS system via the Interface board
connectors. A Heading Synchro input capture circuit and A/D
provide heading information to the KMD 550/850 system. The
on-board microprocessor executes code from an operating sys-
tem which can be downloaded via a high speed serial CAN bus
provided for the initial Boot up. The video image is gener-
ated from the ARINC 429 information. When selected by the F/
P microcontroller, this video image is clocked into the F/P
Video Field Memory via the Video bus, for display on the LCD.

tention.
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mation to other processor modules via the onboard CAN bus in-
terface. The status of the TRFC Processor can be indicated
via four LEDs mounted on the edge of the board.
Four configuration switches can also be read by the micropro-

cessor and are used to initiate manual program upgrades and
self test routines.
(11) KAC 503 FIS Processor Board
Refer to Figure 14 KAC 503 FIS Processor Board Block Diagram

as required.
The FIS Processor board is used to interface the KMD540 to a

VDL Mode 2 receiver such as the KDR 510. An on-board RS422 /
485 buffer converts the FIS RS422 I/O data from the rear panel
D-Type connectors, providing a level shifting interface to the
microprocessor. The on-board microprocessor executes code
from an operating system which can be downloaded via a high
speed serial CAN bus interface into Flash memory.
A separate Boot Flash EPROM is provided for the initial Boot

up. The microprocessor system reads the RS 422 data, decrypts
and builds compressed video image pages in the 4M Bytes of on
board SRAM. These images are then decompressed into 16M Bytes
of on board SDRAM. The processed images are then transferred
to video memory. When selected by the F/P microcontroller,
this video image is clocked into the F/P Video Field Memory
via the Video bus, for display on the LCD.
The microprocessor system also incorporates serial EEPROM for

fast, non-volatile configuration data retention. The micro-
processor can also provide graphical overlay information to
other processor modules via the onboard CAN bus interface. The
status of the FIS Processor can be indicated via four LEDs
mounted on the edge of the board. Four configuration switches
can also be read by the microprocessor and are used to ini-
tiate manual program upgrades and self test routines.
The FIS Processor board contains an SMP (subscription manage-

ment processor) chip which manages FIS subscriptions. It does
this by hardware decoding subscription information using an
I2C serial interface.
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Figure 4 KMD 540 Main Block Diagram
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Figure 5 KMD 540 Power Supply Block Diagram
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Figure 6 KMD 540 Interface Board Block Diagram

(Sheet 1 of 2)
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Figure 6 KMD 540 Interface Board Block Diagram

(Sheet 2 of 2)
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Figure 7 KAC 501 Wx Board Block Diagram
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Figure 8 KAC 502 EGPWS Board Block Diagram
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Figure 9 KMD 540 Front Panel Board Block Diagram

(With Mod 2, Sheet 1 of 2)
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(Without Mod 2, Sheet 1 of 2)
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(Sheet 2 of 2)
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Figure 10 KMD 540 Nav Processor Board Block Diagram
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Figure 11 KMD 540 Switch Board Block Diagram
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Figure 12 KMD 540 Joystick/Knob Board Block Diagram
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Figure 13 KAC 504 TRFC Processor Board Block Diagram
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Figure 14 KAC 503 FIS Processor Board Block Diagram
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C. Detailed Theory of Operation
This manual has been written as a “level 2” or board level component

maintenance manual. Therefore, no detailed theory of operation will
be provided.
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TESTING AND TROUBLESHOOTING

1. General
This section of the manual contains functional test, troubleshooting, and

alignment procedures for the KMD 540. The functional test is a cover-on
test to determine the operational status of the unit.
NOTE: Refer to Figure 1 KMD 540 Multi-Function Display and Function-

ality for a unit pictorial and list of functions.
NOTE: SUL is an acronym for “Secret Until Lit”. These are equivalent
to the five Power Key Labels.
CAUTION: THIS EQUIPMENT CONTAINS ELECTROSTATIC DISCHARGE SENSITIVE (ES-

DS) DEVICES. ALL MODULES CONTAINING ESDS DEVICES ARE FLAGGED OR
IDENTIFIED ON SCHEMATICS AND ASSEMBLY ILLUSTRATIONS, AND ARE
INDIVIDUALLY IDENTIFIED IN THE PARTS LIST. ALL ESDS DEVICES MUST
BE HANDLED IN ACCORDANCE WITH PROCEDURES OUTLINED IN THE REPAIR
SECTION OF THIS MANUAL.
ESDS DEVICES INCLUDE, BUT ARE NOT LIMITED TO, CMOS, JMOS, PMOS,
NMOS, SOCMOS, HMOS, MOS/FET, MICROWAVE MIXER DIODES, SOME BI-
POLAR DEVICES, AND SOME METAL FILM RESISTORS.
MOST DAMAGE TO ESDS DEVICES RESULTS IN DEGRADED PERFORMANCE OR

PREMATURE FAILURE, NOT IN CATASTROPHIC FAILURE AT THE TIME EX-
PERIENCED.
2. Test Equipment
A. Test Equipment Required
For list of required test equipment see Table 9001 Required Test
Equipment. The test equipment should have been properly checked
out, setup, and otherwise configured before functional test is
attempted.
B. Test Equipment Setup
Refer to Figure 9001 KMD 540 Breakout Test Panel Assembly Drawing
and Figure 9002 KMD 540 Test Equipment Interconnect Drawing.
(1) Connect the power supply to the KMD540 Breakout Panel.
(2) Connect banana jacks to the DMM and set it to volts DC.
(3) Remove locking bar, see Figure 10002 KMD 540 End Item Assembly
Drawing item 13.
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(4) Open the side covers, see Figure 10002 KMD 540 End Item As-
sembly Drawing item 12, and install the following option mod-
ules:
NOTE: Only install the option modules that are not found
in the UUT.
(a) A Test Weather Board into slot 2 (green).
(b) A Test EGPWS Board into slot 3 (red).
(c) A Test Traffic Board into slot 4 (yellow).
(d) A Test FIS Board into slot 5 (blue).
(5) Reinstall locking bar.
(6) Reinstall side cover.
(7) Switch the "SW UPGRADE ENABLE" switch to the Down (Enabled)
position.
(8) Remove all loop-back wires and loop-back cables from the
KMD540 Breakout Panel.
(9) Connect the RS232 PC cable to the SPARE CH2 banana jacks on
the KMD540 Breakout Panel.
NOTE: A message shown as a "SYSTEM ALERT" at anytime dur-

ing the test process, and not addressed in this pro-
cedure, is a failure.
C. Functional Test Data Sheet
The following may be used as a “Functional Test Data Sheet”. The

checkoff information corresponds to the Functional Test Procedures
detailed in section 3. Functional Test Procedures.
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KMD540
MULTI-FUNCTION DISPLAY
FUNCTIONAL TEST DATA SHEET
Serial Number: __________________________
Version (Flavor): __________________________
Procedure/Test Measured Data Voltage/Limits
A. Power Application
Backlighting on knobs, _________ OK Backlighting On
keys, and joystick w/ 14 ± 0.2 VDC
LCD screen SUL labels, _________ OK Extinguished
function indicator LED’s
LED’s sequence through _________ OK LED’s sequenced
selftest
Current draw _________ Vdc less than or equal to
2.5Vdc
ON/OFF knob nomenclature _________ OK In-Line with ON text
Loads software _________ OK Software Loaded
Failure free _________ OK No Failures
Backlighting on knobs, _________ OK Backlighting On
keys, and joystick w/ 30.0 +.5V -0.0 VDC
30 Vdc current draw _________ Vdc less than or equal to
2.5Vdc
Unit off current draw _________ mVdc less than or equal to
w/ 27.5 ± 0.5 VDC 100mVdc
All Boards - Self-test _________ OK Green Check Marks
status
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B. 5 VDC Lighting Bus

Lighting Bus Percentage _________ % greater than 90%
Lighting Bus Dimming _________ OK Front Panel Dims
Lighting Bus Dimming _________ OK All Knobs Dims
Lighting Bus Dimming _________ OK All Keys Dims
Lighting Bus Dimming _________ OK Joystick Dims
Lighting Bus Percentage _________ % less than 5%
C. 28 VDC Lighting Bus

D. 5 VAC Lighting Bus

E. SW Upgrade Enable
Major Upgrade Link _________ OK Enabled
Major Upgrade Link _________ OK Disabled
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F. NTSC Video Input

Color Bar Pattern - _________ OK White
Left to right
Color Bar Pattern - _________ OK Yellow
Left to right
Color Bar Pattern - _________ OK Cyan
Left to right
Color Bar Pattern - _________ OK Green
Left to right
Color Bar Pattern - _________ OK Magenta
Left to right
Color Bar Pattern - _________ OK Red
Left to right
Color Bar Pattern - _________ OK Blue
Left to right
Color Bar Pattern _________ OK Parallel and even
G. Discrete Message Alarm

Message Alarm output _________ OK Does not "Overload"
Message Alarm LED _________ OK Illuminates
H. Discrete Audio Output

Audio output voltage _________ Vac 2.5 ± 0.5Vac
Audio output frequency _________ KHz 1.6 ± 0.24KHz
I. Discrete Wx RT On/Off
Output
WX RT Control _________ OK Does not "Overload"
WX INTERRFACE on test _________ OK Illuminates
panel
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J. Discrete EGPWS Control

EGPWS Control _________ OK Does not "Overload"
EGPWS INTERRFACE on _________ OK Illuminates
test panel
K. Discrete TRFC Control

TRFC Control _________ OK Does not "Overload"
TCAS INTERRFACE on _________ OK Illuminates
test panel
L. Heading Input
45° heading _________ ° 45 ± 2 °
130° heading _________ ° 130 ± 2 °
M. Heading Valid
Heading Valid Input _________ OK Low
Heading Valid Input _________ OK High
N. External GPS Input /

Output
EXT GPS _________ OK Red X
EXT GPS _________ OK Green Check Mark
O. Stormscope Input / Output

Stormscope _________ OK Red X
Stormscope _________ OK Green Check Mark
P. RS232 Ch1 Input / Output

RS232 CH1 _________ OK Red X
RS232 CH1 _________ OK Green Check Mark
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Q. WX/EGPWS RS232 Input /

Output
WX RS232 _________ OK Red X
WX RS232 _________ OK Green Check Mark
R. TRFC RS232 Input / Output

TRFC RS232 _________ OK Red X
TRFC RS232 _________ OK Green Check Mark
S. RS422 Serial Ports

FIS RS422 _________ OK Red X
FIS RS422 _________ OK Green Check Mark
T. Weather Radar 429 Serial

Outputs
AR429 CH3 (WX) _________ OK Red X
AR429 CH3 (WX) _________ OK Green Check Mark
U. EGPWS 429 Output

AR429 CH3 (TERR) _________ OK Red X
AR429 CH3 (TERR) _________ OK Green Check Mark
V. TRFC 429 Input/Output

AR429 CH4 (TRFC) _________ OK Red X
AR429 CH4 (TRFC) _________ OK Green Check Mark
W. ARINC 429 Stormscope Input

(Record “N/A” for pre-mod 1
units).
AR429 CH1 (WX) _________ OK Red X
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AR429 CH1 (WX) _________ OK Green Check Mark
X. EGPWS ARINC 453 Inputs
TERR AR453 _________ OK Red X
TERR AR453 _________ OK Green Check Mark
Y. WX ARINC 453 Inputs

WX AR453 _________ OK Red X
WX AR453 _________ OK Green Check Mark
Z. Brightness
Brightness graph _________ % less than 10%
Brightness of the LCD and _________ OK Dimmed
Select Function
Brightness graph _________ % greater than or equal
to 99%
Brightness of the LCD _________ OK Brighter
and Select Function
Brightness of the SUL’s _________ OK Dimmed
AA. Function Select Keys

MAP Processor Test _________ OK Appears
Screen
Select Function above _________ OK Illuminates
MAP key
No other indicators are _________ OK
illuminated
Inner knob CW _________ OK Count increases
Inner knob CCW _________ OK Count decreases
All 5 SUL’s are _________ OK
illuminated
Each SUL extinguishes _________ OK Power Key press
and re-illuminates
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Cursor up _________ OK Smooth and flicker
free
Cursor down _________ OK Smooth and flicker
free
Cursor right _________ OK Smooth and flicker
free
Cursor left _________ OK Smooth and flicker
free
Cursor up/right _________ OK Smooth and flicker
free
Cursor up/left _________ OK Smooth and flicker
free
Cursor down/right _________ OK Smooth and flicker
free
Cursor down/left _________ OK Smooth and flicker
free
Outer knob CW _________ OK White screen
Outer knob CW _________ OK Black screen
Outer knob CW _________ OK Red screen
Outer knob CW _________ OK Blue screen
Outer knob CW _________ OK Green screen
Outer knob CW _________ OK Animated screen
Order reversed in CCW _________ OK
direction
WX PROCESSOR Test Screen _________ OK Appears
WX Select Function _________ OK Illuminates
Indicator
Other Select Function _________ OK Extinguished
Indicators
FIS Test Screen _________ OK Appears
WX Select Function _________ OK Illuminates
Indicator
Indicators
TRFC Test Screen _________ OK Appears
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TRFC Select Function _________ OK Illuminates
Indicator
Indicators
TERR Test Screen _________ OK Appears
TERR Select Function _________ OK Illuminates
Indicator
Indicators
System Configuration _________ OK Appears
Screen
AUX Select Function _________ OK Illuminates
Indicator
Indicators
AB. Cooling Fan

Cooling Fan _________ OK Running
AC. Display
Outer knob on Map screen - _________ OK No lineouts and no more
White screen than 3 stuck pixels
Black screen than 3 stuck pixels
Red screen than 3 stuck pixels
Blue screen than 3 stuck pixels
Green screen than 3 stuck pixels
Outer knob on Map screen - _________ OK Not flickering
Animated screen
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AD. FIS Module Clock

Verify that the system _________ OK +/- 10 %
time indicates the time
duration since it was
reset
AE. SMP Test

Non-zero value _________ OK Displayed
“SMP not working” warning _________ OK Not Displayed
message
AF. Shutdown
No failures seen through _________ OK
out test not explained
Dash (-) next to heading _________ OK
MAP Board Serial Number Record to the __________________
right
MAP Board Mod Level Record to the __________________
right
Verify that above numbers _________ OK Completed
match unit paperwork
Verify that MAP data _________ OK
changed on More Info page
INTERFACE Board Serial Record to the __________________
Number right
INTERFACE Board Mod Record to the __________________
Level right
Verify that above numbers _________ OK Completed
match unit paperwork
Verify that IFACE data _________ OK
changed on More Info page
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On the FIS Clock Status _________ OK
Page, verify that the
STATIC MEMORY BACKUP and
CLOCK VALID have green
ticks beside them
Switch off unit power _________ OK Completed
knob
Test Software Card _________ OK Removed
Turn off KMD 540 _________ OK Completed
Breakout Panel
Stamp, date, and write _________ OK Completed
unit serial number on NV
Data printouts for MAP
and IFACE boards
Tested By: ________________________________________________
Date: ______________________________
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3. Functional Test Procedures
The purpose of the functional test procedures is to determine the

operational status of the unit. Functional test procedures are provided
for a Return to Service condition. If an in-service unit tests within the
acceptable limits given in this test procedure, no further testing is
required and the unit should be considered suitable for installation in
an aircraft.
In general, after fault repair and/or assembly replacement, the unit

should be tested again to make sure that it meets the performance criteria.
A. Power Application
(1) Ensure the unit power knob on the bezel is rotated to the ‘OFF’
position.
(2) Connect the unit under test to the test cables.
(3) Connect the auxiliary video cable from the NTSC generator to
the unit under test.
(4) Connect the DMM to the "CURRENT MONITOR" banana jacks on the
(5) Set the DMM to volts DC.
(6) Insert the diagnostic test software PCMCIA card.
(7) Turn ON the External Power Supply.
(8) Adjust the External Power Supply to 14 ±0.2 Vdc.
(9) Switch the "UNIT POWER" switch on the KMD 540 Breakout Panel
to the ‘ON’ position.
(a) Verify the backlighting on the knobs, keys, and joystick

illuminates.
(b) Verify the LCD screen, SUL labels, and function indica-
tor LED’s are extinguished.
(10) Switch the unit power knob on the bezel to the ‘ON’ position.
(a) Verify that all front panel LED’s illuminate briefly and
then extinguish as they sequence through their self-
test.
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(b) Verify the current reading does not exceed 2.5V.
(c) Verify the white marking on the knob lines up with the
"ON" nomenclature.
(d) Verify the unit loads software by observing the software

loading screen after initial turn on with test software.
(e) Verify the unit has no failures displayed.
(11) Switch the unit power knob on the bezel to the ‘OFF’ position
when software downloading and self-test are complete.
(12) Adjust the External Power Supply to 30.0 -0.0 +0.5Vdc. Verify
the backlighting on the unit illuminates.
Verify the current reading does not exceed 2.5V.
(14) Switch the unit power knob on the bezel to the ‘OFF’ position.
(15) Adjust the External Power Supply to 27.5 ± 0.5Vdc. With the
unit off, verify the current reading is less than 100mV.
(17) Press the "OK" key.
NOTE: The following modules may already be configured

(steps 18-25).
NOTE: Refer to Figure 1001 System Configuration (Main

Test) Page, the System Configuration Page, when
performing the following steps.
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Figure 1001 System Configuration (Main Test) Page
(18) Using the joystick, move the cursor until the EMPTY text next
to slot 2 is highlighted.
(19) Press the joystick up to enable the "WX PROCESSOR IND 1".
(20) Using the joystick, move the cursor over and down until the
EMPTY text next to slot 3 is highlighted.
(21) Press the joystick up to enable the "TERRAIN PROCESSOR".
(23) Press the joystick up to enable the "TRAFFIC PROCESSOR".
(25) Press the joystick up to enable the "FIS PROCESSOR".
(26) Verify all modules have a Green check mark indicating a pass.
B. 5 VDC Lighting Bus
NOTE: For Lighting Bus sections (B, C, and D.) refer to Figure
1002 KMD 540 Display Lighting Diagram, Figure 1003 KMD
540 Backlighting Diagram, and Figure 1004 KMD 540 Indi-
cator Lighting Diagram.
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1. Brightness Level Setting Associated To Selected Configuration Point

2. Present Setting of the Brightness Knob
3. Adjustable Configuration Setup Point
Figure 1002 KMD 540 Display Lighting Diagram
1. Lighting Bus Level Input (relative to the Aircraft’s Lighting Bus Control)
Figure 1003 KMD 540 Backlighting Diagram
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Figure 1004 KMD 540 Indicator Lighting Diagram
(1) On the KMD 540 Breakout Panel, switch the "AC/DC" lighting bus
switch the ‘DC’ position.
(2) On the KMD 540 Breakout Panel, switch the "OFF" lighting bus
switch to the UP position.
(3) Connect a cable between the "LIGHTING BUS INPUT" banana jacks
on the KMD 540 Breakout Panel to an external power supply.
(4) Set the lighting bus power supply for 5 ±0.15Vdc.
(5) Press “SYSTEM SETUP” key (refer to Figure 1001 System Config-
uration (Main Test) Page for location). Then press the "LIGHT
CURVE" key to get to the Display Lighting Curve setup screen
(refer to Figure 1002 KMD 540 Display Lighting Diagram).
(6) Press the "NEXT" key until the Backlighting Curve page is dis-
played.
(7) Press the "LBUS VOLT." key until the LIGHTING BUS VOLTAGE:5Vdc
page is displayed.
NOTE: 28Vdc is depicted above.
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(8) Press the "PREV PAGE" key.
(9) Move the cursor to the "-" next to the FRONT PANEL text and
press the "MORE INFO" key. Verify the LIGHTING BUS percentage
is >90%.
(10) Reduce the voltage slowly and verify the following dim:
(a) Front panel backlighting.
(b) All knobs.
(c) All keys.
(d) Joystick.
(11) Reduce the lighting bus voltage to 0.0 ± 0.1Vdc. Verify the
LIGHTING BUS percentage is <5%.
C. 28VDC Lighting Bus
NOTE: Refer to Figure 1001 System Configuration (Main Test)

Page, Figure 1002 KMD 540 Display Lighting Diagram, Fig-
ure 1003 KMD 540 Backlighting Diagram, and Figure 1004
KMD 540 Indicator Lighting Diagram as necessary.
(2) Press the "LIGHT CURVE" key to get to the Display Lighting
Curve setup screen.
played.
(4) Press the "LBUS VOLT." key until the LIGHTING BUS VOLTAGE:28V
page is displayed.
(6) Press the "MORE INFO" key.
(7) Set the lighting bus power supply for 28 ± 0.5Vdc. Verify the
LIGHTING BUS percentage is >95%.
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(8) Reduce the voltage slowly and verify the following dim:
(a) Front panel backlighting
(b) All knobs
(c) All keys
(d) Joystick
(9) Reduce the lighting bus voltage to 0.5 +0 -0.5Vdc. Verify the
LIGHTING BUS percentage is <5%.
D. 5VAC Lighting Bus
NOTE: Refer to Figure 1001 System Configuration (Main Test)

Page, Figure 1002 KMD 540 Display Lighting Diagram, Fig-
ure 1003 KMD 540 Backlighting Diagram, and Figure 1004
KMD 540 Indicator Lighting Diagram as necessary.
(1) On the KMD 540 Breakout Panel, switch the "AC/DC" lighting bus
switch the ‘AC’ position.
(2) On the KMD 540 Breakout Panel, switch the "AC/LOW", Lighting
Bus switch, to the Up position.
(4) Press the "LIGHT CURVE" key to get to the Display Lighting
Curve setup screen.
played.
(6) Press the "LBUS VOLT." key until the LIGHTING BUS VOLTAGE:5Vac
page is displayed.
NOTE: 28Vdc is depicted above.
(8) Press the "MORE INFO" key. Verify the LIGHTING BUS percentage
is >95%.
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(9) Switch the "OFF" lighting bus switch to the ‘OFF’ position and
verify the following:
(a) Front panel backlighting darken
(b) All knobs darken
(c) All keys darken
(d) Joystick darken
(e) LIGHTING BUS percentage is <5%.
10. Press the "PREV PAGE" key.
E. SW Upgrade Enable
(1) Switch the "SW UPGRADE ENABLE" switch on the KMD540 Breakout
Panel to the Down position. Verify the display shows "MAJOR
UPGRADE LINK:ENABLED".
Panel to the Up position. Verify the display shows "MAJOR
UPGRADE LINK:DISABLED".
Panel to the Down position.
F. NTSC Video Input
(1) Ensure coax cable connection from the BNC jack on the rear of
the unit to the NTSC generator’s COMPOSITE VIDEO jack.
(2) Press the "POWER" key on the NTSC generator to turn it On.
(3) Press the "NTSC BARS" key on the NTSC generator.
(4) Ensure the "COLORS OFF" key is out to enable colors.
(5) Rotate the "COMPOSITE VIDEO" knob on the NTSC generator fully
counter-clockwise.
(6) Press the "AUX" key to enable the NTSC input.
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(7) Verify the color bar pattern is clear and in the following (a-
g) order from left to right:
(a) White
(b) Yellow
(c) Cyan
(d) Green
(e) Magenta
(f) Red
(g) Blue
(8) Verify the color bar pattern vertical bars are parallel and
even.
(9) Press the "AUX" key to get back to the System Maintenance
page.
G. Discrete Message Alarm
(1) Press the "TEST PORTS" key.
(2) Move the cursor to the "OFF’ text next to MESSAGE ALARM.
(3) Move the joystick Up to enable the MESSAGE ALARM.
(a) Verify the output, as displayed on the screen, does not

‘Overload’.
(b) Verify the "MESSAGE ALARM" LED on the KMD540 Breakout

Panel illuminates.
(4) Move the joystick Up to disable the MESSAGE ALARM.
H. Discrete Audio Output
(1) Move the cursor down to highlight the "AUDIO ALARM" text.
(2) Move the cursor over to highlight the "OFF" status text.
(3) Connect the DMM test leads to the "AUDIO OUT" jacks on the
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(4) Set the DMM for Volts AC.
(5) Move the cursor Up to enable the audio output. Verify the
output is 2.5 ±0.5Vac.
(6) Set the DMM to measure frequency. Verify the output is 1.6
±0.24 KHz.
(7) Move the cursor up to disable the audio output.
I. Discrete Wx RT On/Off Output
(1) Move the cursor to the "OFF’ text next to WX RT CONTROL.
(2) Move the joystick Up to enable the WX RT CONTROL.

‘Overload’.
(b) Verify the WX INTERFACE LED on the KMD540 Breakout Panel

illuminates.
(3) Move the joystick Up to disable the WX RT CONTROL.
J. Discrete EGPWS Control
(1) Move the cursor to the "OFF’ text next to EGPWS CONTROL.
(2) Move the joystick Up to enable the EGPWS CONTROL.

‘Overload’.
(b) Verify the EGPWS INTERFACE LED on the KMD540 Breakout

Panel illuminates.
(3) Move the joystick Up to disable the EGPWS CONTROL.
K. Discrete TRFC Control
(1) Move the cursor to the "OFF’ text next to TRFC CONTROL.
(2) Move the joystick Up to enable the TRFC CONTROL.

‘Overload’.
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(b) Verify the TCAS INTERFACE LED on the KMD540 Breakout

Panel illuminates.
(3) Move the joystick Up to disable the TRFC CONTROL.
L. Heading Input
(1) Connect the Heading Simulator panel S1 output to the X HEADING

jack on the KMD540 Breakout Panel.
(2) Connect the Heading Simulator panel S3 output to the Y HEADING

jack on the KMD540 Breakout Panel.
(3) Connect the Heading Simulator panel 26R output to the Red Ref-
erence jack on the KMD540 Breakout Panel.
(4) Connect the Heading Simulator panel RL output to the Black

Reference jack on the KMD540 Breakout Panel.
(5) Connect wire between RL and S2 on Simulator.
(6) Switch the "OFF" lighting bus switch to the Up position.
(7) Ensure the "AC/DC" lighting bus switch is in the ‘AC’ posi-
tion.
(8) Press the "PREV PAGE" key (returns to the DATA I/O page.
(9) Press the “HDG SRCS” key.
(10) Ensure that the VALID switch is in the Up position on the panel
and that SENSE is High on the unit.
(11) Key in 45 degrees into the Heading Simulator. Verify that the
heading displayed on the unit is 45 ± 2°.
(12) Key in 130 degrees into the Heading Simulator. Verify that
the heading displayed on the unit is 130 ± 2°.
M. Heading Valid
(1) Switch the "HEADING VALID" switch on the KMD540 Breakout Panel
to the Down position. Verify the display shows "HEADING VALID
INPUT:LOW".
(2) Switch the "HEADING VALID" switch on the KMD540 Breakout Panel
to the Up position. Verify the display shows "HEADING VALID
INPUT:HIGH".
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N. External GPS Input / Output
(1) Press the “TEST PORTS” key.
(2) Press the “NEXT” key.
(3) Verify a Red X in the PASS column next to EXT GPS.
(4) Connect a loop back wire into the Yellow and Green EXT GPS
banana jacks. Verify a Green check mark in the PASS column
next to EXT GPS.
(5) Remove the loop back wire.
O. Stormscope Input / Output
(1) Verify a Red X in the PASS column next to STORMSCOPE.
(2) Connect a loop back wire into the Yellow and Green STORMSCOPE
next to STORMSCOPE.
P. RS232 CH1 Input / Output
(1) Verify a Red X in the PASS column next to RS232 CH1.
(2) Connect a loop back wire into the Yellow and Green SPARE CH 1
next to RS232 CH1.
Q. WX/EGPWS RS232 Input / Output
(1) Verify a Red X in the PASS column next to WX RS232.
(2) Connect a loop back wire into the Yellow and Green WX/EGPWS
next to WX RS232.
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R. TRFC RS232 Input / Output
(1) Verify a Red X in the PASS column next to TRFC RS232.
(2) Connect a loop back wire into the Yellow and Green TIS INPUT
next to TRFC RS232.
S. RS422 Serial Ports
(1) Verify a Red X in the PASS column next to FIS RS422.
(2) Connect a phone jack loop back cable into the FIS INTERFACE,
ARINC 422 IN and OUT phone jacks. Verify a Green check mark
in the PASS column next to FIS RS422.
(3) Remove the loop back cable.
T. Weather Radar 429 Serial Outputs
(1) Press the "NEXT" key. Verify a Red X in the PASS column next
to AR429 CH3 (WX).
(2) Connect a one end of a phone jack loop back cable into the
SPARE 429 INPUTS, CH3 jack.
(3) Connect the other end of the phone jack loop back cable into
the WX INTERFACE, ARINC 429 jack. Verify a Green check in the
PASS column next to AR429 CH3 (WX).
(4) Remove the loop back cable from the WX INTERFACE, ARINC 429
jack.
U. EGPWS 429 Outputs
(1) Verify a Red X in the PASS column next to AR429 CH3 (TERR).
(2) Connect the loose end of the phone jack loop back cable into
the EGPWS INTERFACE, ARINC 429 jack. Verify a Green check in
the PASS column next to AR429 CH3 (TERR).
(3) Remove the loop back cable from the KMD540 Breakout Panel.
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V. TRFC 429 Input / Output
(1) Verify a Red X in the PASS column next to AR429 CH4 (TRFC).
(2) Connect a phone jack loop back cable into the TCAS INTERFACE,
ARINC 429 IN and OUT jacks. Verify a Green check in the PASS
column next to AR429 CH4 (TRFC).
W. ARINC 429 Stormscope Input
(not applicable to pre Mod 1 units)
(1) Verify a Red X in the PASS column next to AR429 CH1 (WX).
(2) Connect a phone jack loop back cable into the WX INTERFACE,
ARINC 429 jacks and the SPARE 429 INPUTS, CH1 jack. Verify a
Green check in the PASS column next to AR429 CH1 (WX).
X. EGPWS ARINC 453 Input
(1) Verify a Red X in the PASS column next to TERR AR453.
(2) Connect the loose end of the 453 Simulator cable into the EG-
PWS INTERFACE, ARINC 453 jack. Verify a Green check in the
PASS column next to TERR AR453.
(3) Remove the 453 Simulator cable from the EGPWS INTERFACE, ARINC
453 jack.
Y. WX ARINC 453 Input
(1) Verify a Red X in the PASS column next to WX AR453.
(2) Connect the loose end of the 453 Simulator cable into the WX
INTERFACE, ARINC 453 jack. Verify a Green check in the PASS
column next to WX AR453.
(3) Remove the 453 Simulator cable from the WX INTERFACE, ARINC
453 jack.
(4) Press the "OK" key.
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Z. Brightness
NOTE: Ensure the cursor is highlighting the "-" next to the

Front Panel board.
(1) Press the "MORE INFO" key.
(2) Rotate the Brightness knob on the unit full Counter-Clockwise.
(a) Verify the "BRIGHTNESS" graph shows < 10%.
(b) Verify the brightness of the LCD display and Select

Function keys have dimmed.
(3) Rotate the Brightness knob on the unit full Clockwise.
(a) Verify the Brightness graph shows > 99%.
(b) Verify the brightness of the LCD display and Select

Function keys are brighter than the previous step.
(4) Press the "MAP" key.
(5) Rotate the Brightness knob Counterclockwise on the unit and

verify the SUL’s dim.
(6) Increase brightness.
AA. Function Select Keys
(1) Ensure the "MAP" Select Function Indicator is illuminated.
(a) Verify the "MAP PROCESSOR" test screen appears.
(b) Verify the Select Function Indicator above the "MAP" key
illuminates.
(c) Verify no other Select Function Indicator illuminates.
(2) Rotate the inner knob on the unit clockwise. Verify the "IN-
NER ROTARY COUNT" increases once per indent.
(3) Rotate the inner knob on the unit counter-clockwise. Verify

the "INNER ROTARY COUNT" decreases once per indent.
(4) Verify that all five SUL’s are illuminated.
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(5) Press each Power key, one at a time. Verify that each corre-
sponding SUL extinguishes, then re-illuminates when released.
(6) Move the cursor Up. Verify the pointer on the screen moves
smoothly and free from flicker.
(7) Move the cursor Down. Verify the pointer on the screen moves
(8) Move the cursor Right. Verify the pointer on the screen moves
(9) Move the cursor Left. Verify the pointer on the screen moves
(10) Move the cursor Diagonally Up/Right. Verify the pointer on

the screen moves smoothly and free from flicker.
(11) Move the cursor Diagonally Up/Left. Verify the pointer on the
screen moves smoothly and free from flicker.
(12) Move the cursor Diagonally Down/Right. Verify the pointer on

(13) Move the cursor Diagonally Down/Left. Verify the pointer on

(14) Rotate the outer knob on the unit clockwise and verify each
of the following are displayed for each indent:
(a) White screen.
(b) Black screen.
(c) Red screen.
(d) Blue screen.
(e) Green screen.
(f) Animated screen.
(15) Verify the order is reversed when the outer knob is rotated
counter-clockwise.
(16) Press the "WX" key.
(a) Verify the WX PROCESSOR test screen appears.
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(b) Verify the Select Function Indicator above the "WX" key
illuminates.
NOTE: If screen says FIS, press the WX key again.
(17) Press the "WX" key again to verify the FIS board.
(a) Verify the FIS PROCESSOR test screen appears.
(b) Verify the Select Function Indicator above the "WX" key
illuminates.
(18) Press the "TRFC" key.
(a) Verify the TRFC PROCESSOR test screen appears.
(b) Verify the Select Function Indicator above the "TRFC"

key illuminates.
(19) Press the "TERR" key.
(a) Verify the TERR PROCESSOR test screen appears.
(b) Verify the Select Function Indicator above the "TERR"

key illuminates.
(20) Press the "AUX" key.
(a) Verify the System Configuration page appears.
(b) Verify the Select Function Indicator above the "AUX" key
illuminates.
AB. Cooling Fan
(1) Verify the cooling fan is running and the air is exiting the
rear of the unit.
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AC. Display
(1) Place unit in a darkened environment.
(2) Press the "MAP" key.
(3) Rotate the outer knob on the unit clockwise and verify each
of the following are displayed for each indent:
(a) White screen with no lineouts and no more than 3 stuck

pixels.
(b) Black screen with no lineouts and no more than 3 stuck

pixels.
(c) Red screen with no lineouts and no more than 3 stuck

pixels.
(d) Blue screen with no lineouts and no more than 3 stuck

pixels.
(e) Green screen with no lineouts and no more than 3 stuck

pixels.
(f) Animated screen with no flicker.
AD. FIS Module Clock RTC and Memory
(1) Press the AUX button to get to the Configuration Page.
(2) On the system configuration page, press the FIS clock button
to access the FIS Clock Status Page.
(3) On the FIS Clock Status Page, press the RESET CLOCK button.
(4) Disconnect from the main power source for a minimum of 10 min-
utes and not more than a maximum of two hours.
(5) Turn the unit back on and verify that the system time indi-
cates the time duration since it was reset +/- 10%.
(6) Verify that on the FIS Clock Status Page that the STATIC MEM-
ORY BACKUP and CLOCK VALID have green ticks beside them.
AE. Subscription Management Processor (SMP) Test
(1) On the FIS Test and Status page, verify that the display shows
a non-zero value in the Terminal ID field.
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(2) Press the SMP STATUS key and verify that the display does not
show a warning message that the SMP is not working.
AF. Shutdown
(1) Verify there were no failures displayed on the screen during

any part of the test not explained.
(2) Press the "AUX" key.
(3) Deselect all Option Boards that were installed for test pur-
poses.
(4) Switch the unit power knob on the bezel to the ‘OFF’ position.
(5) Switch the power switch on the KMD540 Breakout Panel to the
Off position.
(6) Remove the side cover.
(7) Remove locking bar.
(8) Remove the Test Weather, EGPWS, Traffic, and FIS Boards that
were installed for test purposes.
(9) Reinstall locking bar.
(10) Reinstall side cover.
(11) Remove test data card.
(12) Install normal application data card
(13) Switch the power switch on the KMD540 Breakout Panel to the
On position
(15) Verify that all software loads properly.
(16) Verify that all self tests are passed.
(17) Switch unit power knob to the off position.
(18) Switch the power switch on the breakout panel to the off po-
sition.
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AG. Field Installation of the KMD 540 and Option Modules.
Refer to the KMD 550/850 System Installation Manual for field

installation and configuration procedures.
4. Troubleshooting Procedures
The KMD 540 self-test procedures are the primary means of

troubleshooting the unit and will aid in troubleshooting a failure.
The KMD 540 will perform a self-test upon power up. Self-test
procedures are also noted and verified in the Functional Test
Procedures detailed in Testing and Troubleshooting, Section 3.
Functional Test Procedures
5. Alignment Procedures
A. Display Alignment
(1) With a magnifying eyepiece, look at a vertical black line on

a white background.
(2) Focus the magnifying eyepiece on a black pixel.
(3) Rotate the “FOCUS” pot on the side of the display until the
screen moves completely left.
(4) Rotate the “FOCUS” pot back until there is no graying on ei-
ther side of the black pixel.
NOTE: The focus will cause the black pixel to move from
side to side. As the black slowly moves past the
pixel, it will cause the adjacent pixel to darken.
A properly focused display will have no graying on
either side.
NOTE: A pixel consists of green, red and blue segments.
(5) Rotate the “CLR”, “TNT”, and “BRT” potentiometers on the unit
fully counter-clockwise.
(6) Rotate the “CLR” potentiometer clockwise one revolution.
(7) Connect a coax cable from the BNC jack on the rear of the unit
to the NTSC generator’s COMPOSITE VIDEO jack.
(8) Press the “POWER” key on the NTSC generator to turn it On.
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(9) Press the “NTSC BARS” key on the NTSC generator.
(10) Ensure the “COLORS OFF” key is out to enable colors.
(11) Rotate the “COMPOSITE VIDEO” knob on the NTSC generator fully
counter-clockwise.
(12) Press the “AUX” key on the unit to get to the System Config-
uration screen.
(13) Press the “AUX” key again to enable the NTSC input.
(14) Rotate the “TNT” potentiometer on the unit until the colors
become clear in this order from left to right:
(a) White
(b) Yellow
(c) Cyan
(d) Green
(e) Magenta
(f) Red
(g) Blue
(15) Continue adjusting the “TNT” potentiometer until the vertical

bars are parallel and even.
B. Audio Adjustment
(1) Press the “AUX” key to get to the System Configuration page.
(2) Press the “TEST PORTS” key.
(3) Move the cursor down to highlight the “AUDIO ALARM” text.
(4) Move the cursor over to highlight the “OFF” status text.
(5) Connect the DMM test leads to the “AUDIO OUT” jacks on the
(6) Set the DMM for Volts AC.
(7) Move the cursor Up to enable the audio output.
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(8) Adjust the pot on the Interface board until the output is 2.5
± 0.25Vac.
(9) Set the DMM to measure frequency.
(a) Verify the output is 1.6 ± 0.08 KHz.
(10) Move the cursor up to disable the audio output.
6. Retest Procedure
After a fault has been isolated and repaired, the unit should be subjected
to the “Functional Test Procedure” to ensure that the repaired area is
operating correctly and that other areas have not been damaged during the
repair procedure.
7. Service Information
This manual has been written as a “level 2” or board level component

maintenance manual. Therefore, no service information relating to
components will be provided.
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SCHEMATIC DIAGRAMS
1. General
This section contains a unit summary of changes, a unit mechanical

installation drawing, and a unit end item (top level) assembly diagram.
As this is a level two manual, no information relating to circuit card

assemblies (CCAs), i.e. parts location diagrams and/or schematic diagrams,
will be included.
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SUMMARY OF UNIT CHANGES

PART NUMBER 066-04035-XXXX
MANUAL ASSEMBLY/ REVISION COMMENTS

REVISION
0 066-04035-0101 See ILLUSTRATED PARTS LIST Top Assembly - Black

0 066-04035-0201 See ILLUSTRATED PARTS LIST Top Assembly - Gray
0 066-04035-0301 See ILLUSTRATED PARTS LIST Top Assembly - Silver Crown
0 155-06053-0000 C KMD 540 Installation Drawing
0 155-01737-0000 A KAC 501 Installation Drawing
0 300-09735-0000 C End Item Assembly Drawing

1 155-06053-0000 C KMD 540 Installation Drawing
1 155-01738-0000 - KAC 504 Installation Drawing
1 300-09735-0000 D End Item Assembly Drawing

2 155-06053-0000 E KMD 540 Installation Drawing
2 300-09735-0000 E End Item Assembly Drawing

3 155-06053-0000 F KMD 540 Installation Drawing
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MANUAL ASSEMBLY/ REVISION COMMENTS

REVISION
3 300-09735-0000 F End Item Assembly Drawing

4 155-06053-0000 F KMD 540 Installation Drawing
4 300-09735-0000 J End Item Assembly Drawing
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Figure 2001 KMD 540 Installation Drawing

(Dwg No 155-06053-0000, Rev F, Sheet 1 of 1)
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Figure 2002 KMD 540 End Item Assembly Drawing

(Dwg No 300-09735-0000, Rev J, Sheet 1 of 2)
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Page 2009/2010
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Figure 2002A KMD 540 End Item Assembly Drawing

(Dwg No 300-09735-0000, Rev F, Sheet 1 of 2) (For Reference Only)
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(Dwg No 300-09735-0000, Rev F, Sheet 2 of 2 (For Reference Only))
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Figure 2003 KAC 501 Installation Drawing

(Dwg No 155-01737-0000, Rev A, Sheet 1 of 2)
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Page 2017/2018
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Page 2019/2020
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Page 2021/2022
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(Dwg No 155-01738-0000, Rev -, Sheet 1 of 2)
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DISASSEMBLY
1. General
This section provides information for disassembly of the KMD 540 Multi-
Function Display. Disassembly procedures are to be accomplished only when
repairs or modifications are required, and only to the extent that is
required by the repair, or as directed in the modification Service
Bulletin. This section contains the recommended procedures for removal of
all subassemblies.
Refer to the ILLUSTRATED PARTS LIST for aid in disassembly. Item numbers
are used in the IPL drawings to identify specific parts.
Complete disassembly should never be undertaken. Provisions have been

made in the design of the unit to make complete disassembly unnecessary
except to replace a damaged mechanical part that can not be reached
otherwise.
WARNING: REMOVE ALL POWER FROM THE UNIT BEFORE DISASSEMBLY OF ANY COM-
PONENT, PC BOARD, MODULE, OR SUBASSEMBLY. BESIDES BEING DAN-
GEROUS TO LIFE, VOLTAGE TRANSIENTS CAN CAUSE CONSIDERABLE DAM-
AGE TO THE EQUIPMENT.
CAUTION: EXERCISE EXTREME CARE WHEN DISCONNECTING AND RECONNECTING
MULTI-PIN CONNECTORS TO ENSURE THAT CONNECTORS ARE NOT DAMAGED
BY MISALIGNMENT OF PINS.

DS) DEVICES. ALL MODULES CONTAINING ESDS DEVICES ARE FLAGGED
OR IDENTIFIED ON SCHEMATICS AND ASSEMBLY ILLUSTRATIONS, AND ARE
INDIVIDUALLY IDENTIFIED IN THE PARTS LIST. ALL ESDS DEVICES
MUST BE HANDLED IN ACCORDANCE WITH PROCEDURES OUTLINED IN THE
REPAIR SECTION OF THIS MANUAL.
2. Recommended Disassembly Procedure
A. Unit Right Side Cover Removal
On unit case right side, Figure 10002 KMD 540 End Item Assembly
Drawing item 12, remove 4 screws, Figure 10002 KMD 540 End Item
Assembly Drawing item 15. These screws are indicated by "TO OPEN"
and arrows.
B. KAC 50X Interface Modules Removal
NOTE: KAC 50X refers to the option modules, i.e. KAC 501 Wx mod-
ule, KAC 502 EGPWS module, etc.
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NOTE: KAC 50X installation drawings have been provided in sec-

tion 2000 SCHEMATIC DIAGRAMS as reference.
(1) Remove right side cover per procedure detailed in paragraph

A. Unit Right Side Cover Removal.
(2) In the center of the case top assembly, Figure 10004A KMD 540
Chassis Drawing item 4, remove screw, Figure 10002 KMD 540 End
Item Assembly Drawing item 8, from PCB locking bar.
(3) Rotate 90° the PCB locking bar, Figure 10002 KMD 540 End Item
Assembly Drawing item 13, and remove outward.
(4) Extract KAC 50X interface module(s).
C. Front Panel Module Removal

(2) Remove 2 screws, Figure 10002 KMD 540 End Item Assembly Draw-
ing item 15, which attach the case left side to front panel,
Figure 10003A KMD 540 Front Panel Drawing (with Mod 2) or Fig-
ure 10003B KMD 540 Front Panel Drawing (pre Mod 2) item 6.
ing item 8, which attach the chassis to front panel, 3 top
side, 3 bottom side.
(4) Detach 1 ribbon cable and 2 coax cables from the front panel
module.
(5) Remove the front panel.
NOTE: There will be 2 loose RF protection filter screens.
(6) Disassembly of Front Panel Module
Further disassembly of the front panel module may be required

to service the following: 200-09706-xxxx, 200-09806-xxxx, and
200-09722-xxxx. Refer to the Front Panel Assembly drawing,
Figure 10003A KMD 540 Front Panel Drawing (with Mod 2) or Fig-
ure 10003B KMD 540 Front Panel Drawing (pre Mod 2) as re-
quired.
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D. Case Rear Plate Removal

(2) Remove KAC 50X Interface Module(s) per procedure detailed in

paragraph B. KAC 50X Interface Modules Removal.
(3) Remove 2 screws, Figure 10004A KMD 540 Chassis Drawing item
18, which attach the top cover to the case rear plate assem-
bly.
ing item 15, which attach the case left side to front panel
Figure 10004A KMD 540 Chassis Drawing item 6.
(5) Remove 2 screws Figure 10004A KMD 540 Chassis Drawing item 21
which attach the case left side to the rear plate.
19, which attach the bottom case to the rear plate.
21, which attach the interface board to the rear plate and
carrier assembly, Figure 10004A KMD 540 Chassis Drawing item
3.
(8) Slide case rear plate assembly out.
(9) Unplug fan power connector located right bottom side under
Distribution module.
(10) Remove case rear plate assembly.
(11) Disassembly of the Case Rear Plate Assembly
Further disassembly of the case rear plate assembly may be

required, i.e. replacement of the fan module. Refer to Figure
10005A KMD 540 Case Rear Plate Drawing.
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E. Nav Prog Module Removal


16, which attach the top case to the Nav Prog module.
(4) Pull Nav Prog module out the right side of unit.
F. Power Supply Module Removal


(3) Pull Power Supply Module out right side of unit.
G. Interface Board Removal

(2) Remove the case rear plate assembly per procedure detailed in
paragraph D. Case Rear Plate Removal.
(3) Remove power supply per procedure detailed in paragraph F.

Power Supply Module Removal.
(4) Remove 1 screw, Figure 10004A KMD 540 Chassis Drawing item 16,
which attaches the bottom cover to the interface board.
(5) Pull the interface board out the right side of the unit.
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H. Distribution Module Removal


(3) Remove Front Panel Module per procedure detailed in paragraph

C. Front Panel Module Removal.
(4) Remove Case Rear Plate per procedure detailed in paragraph D.

Case Rear Plate Removal.
(5) Remove Nav Module per procedure detailed in paragraph E. Nav

Prog Module Removal.
(6) Remove Power Supply Module per procedure detailed in paragraph

F. Power Supply Module Removal.
(7) Remove Interface Module per procedure detailed in paragraph

G. Interface Board Removal.
(8) Unplug the video clock coax cable, Figure 10004A KMD 540 Chas-
sis Drawing item 25, from the distribution board.
17, which attach the distribution module to left side cover.
(10) Remove distribution module.
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CLEANING
1. General
This section contains information pertaining to the cleaning of component

parts and subassemblies in the KMD 540.
WARNING: GOGGLES MUST BE WORN WHEN USING PRESSURIZED AIR TO BLOW DUST
AND DIRT FROM EQUIPMENT. ALL PERSONNEL SHOULD BE CLEARED FROM
THE IMMEDIATE AREA.
WARNING: OPERATIONS INVOLVING THE USE OF A CLEANING SOLVENT SHOULD BE
PERFORMED UNDER A VENTILATED HOOD. AVOID BREATHING SOLVENT VA-
POR AND FUMES; AVOID CONTINUOUS CONTACT WITH THE SOLVENT. WEAR
A SUITABLE MASK, GOGGLES, GLOVES, AND AN APRON WHEN NECESSARY.
CHANGE CLOTHING UPON WHICH SOLVENTS HAVE BEEN SPILLED.
WARNING: OBSERVE ALL FIRE PRECAUTIONS FOR FLAMMABLE MATERIALS. USE FLAM-
MABLE MATERIALS IN A HOOD PROVIDED WITH EXPLOSION-PROOF ELEC-
TRICAL EQUIPMENT AND AN EXHAUST FAN WITH SPARKPROOF BLADES
2. Recommended Cleaning Materials
Table 4001 Recommended Cleaning Materials lists the recommended cleaning

materials to be used during overhaul of the unit.
NOTE: Equivalent substitutes may be used for the listed cleaning

agents.
TYPE USED TO CLEAN
Denatured Alcohol Various, exterior and interior
DuPont Vertrel SMT Various, interior
PolaClear Cleaner (Polaroid Corp.) or Texwipe CRT display filter, LCD displays, and gen-
TX129 (Texwipe Co.) eral purpose lens/glass cleaner
KimWipes lint-free tissue (Kimberly Clark Various

Corp.)
Cloth, lint-free cotton Various
Brush, flat with fiber bristles Various
Brush, round with fiber bristles Various
Dishwashing liquid (mild) Nylon, Rubber Grommets
Table 4001 Recommended Cleaning Materials
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3. Recommended Cleaning Procedures
A. Exterior
(1) Wipe dust cover and front panel with a lint-free cloth damp-
ened with denatured alcohol.
(2) For cleaning connectors, use the following procedure.
CAUTION: Do not allow solvent to run into sleeves or conduit

that covers wires connected to insert terminals.
(a) Wipe dust and dirt from bodies, shells, and cable clamps
using a lint-free cloth moistened with denatured alco-
hol.
(b) Wipe parts dry with a clean, dry, lint-free cloth.
(c) Remove dirt and lubricant from connector inserts, insu-

lation, and terminals using a small soft bristled brush
moistened with denatured alcohol.
(d) Dry the inserts with an air jet.
(3) Remove cover.
(4) If necessary, open blocked ventilation holes by saturating the

clogged holes with denatured alcohol and blowing the loosened
material out with an air stream.
B. Interior
The following solvents are no longer recommended for bench top or

rework cleaning of printed circuit boards, modules, or
subassemblies.
Freon TF, IMC Propyl Alcohol

Trichloroethane Methyl Alcohol
Prelete (CFC-113) Ethyl Alcohol
Carbon Tetrachloride Butyl Alcohol
Chloroform Methylene Chloride
Trichloroethylene Xylene
Detergents (All™ and equivalents) Genesolv 2004/2010
Table 4002 Unsafe Solvents
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CAUTION: DO NOT USE SOLVENT TO CLEAN PARTS COMPOSED OF OR CONTAIN-

ING NYLON OR RUBBER GROMMETS. CLEAN THESE ITEMS WITH MILD
LIQUID DISHWASHING DETERGENT AND WATER. USE DETERGENT FOR
THIS PURPOSE ONLY.
CAUTION: DUPONT VERTREL SMT DOES HAVE GENERAL MATERIAL COMPATIBIL-

ITY PROBLEMS WITH POLYCARBONATE, POLYSTYRENE, AND RUBBER.
IT IS RECOMMENDED THAT THESE MATERIALS BE CLEANED WITH
DENATURED ALCOHOL.
CAUTION: DO NOT ALLOW EXCESS CLEANING SOLVENT TO ACCUMULATE IN ANY

OF THE ADJUSTMENT SCREW CREVICES AND THEREBY SOFTEN OR
DISSOLVE THE ADJUSTMENT SCREW EPOXY SEALANT.
CAUTION: AVOID AIR-BLASTING SMALL TUNING COILS AND OTHER DELICATE

PARTS BY HOLDING THE AIR JET NOZZLE TOO CLOSE. USE BRUSH-
ES CAREFULLY ON DELICATE PARTS.
CAUTION: IMPROPER CLEANING CAN RESULT IN SURFACE LEAKAGE AND CON-

DUCTIVE PARTICULATES, SUCH AS SOLDER BALLS OR METALLIC
CHIPS, WHICH CAN CAUSE ELECTRICAL SHORTS. SEVERE IONIC
CONTAMINATION FROM HANDLING AND FROM ENVIRONMENTAL CON-
DITIONS CAN RESULT IN HIGH RESISTANCE OR OPEN CIRCUITS.
CAUTION: ULTRASONIC CLEANING CAN DAMAGE CERTAIN PARTS AND SHOULD

GENERALLY BE AVOIDED.
NOTE: References to "air jet" refer to a hand-operated air noz-

zle supplied with clean, dry, compressed air at a maximum
of 28 pounds force per square inch gauge (psig).
NOTE: Solvents may be physically applied in several ways in-

cluding agitation, spraying, brushing, and vapor degreas-
ing. The cleaning solvents and methods used shall have
no deleterious effect on the parts, connections, and ma-
terials being used. If sensitive components are being
used, spray is recommended. Uniformity of solvent spray
flow should be maximized and wait-time between soldering
and cleaning should be minimized.
NOTE: Clean miscellaneous metal parts i.e. fasteners, handles,

mounting hardware, etc. with a suitable cleaning machine.
Remove each module subassembly. Then remove any foreign matter from
the casting.
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(1) Casting covers and shields should be cleaned as follows:
(a) Remove surface grease with a lint-free cloth.
(b) Blow dust from surfaces, holes, and recesses using an

air stream.
(c) If necessary, use a solvent and scrub until clean, work-

ing over all surfaces and into all holes and recesses
with a suitable non-metallic brush.
(d) Position the part to dry so that solvent is not trapped

in holes or recesses. Use an air stream to blow out any
trapped solvent.
(e) When thoroughly clean, touch up any minor damage to the

finish.
(2) Modules (circuit card assemblies) containing resistors, ca-

pacitors, rf coils, inductors, transformers, and other wired
parts should be cleaned as follows:
(a) Remove dust and dirt from all surfaces, including all
parts and wiring, using soft-bristled brushes in con-
junction with an air stream.
(b) Any dirt that cannot be removed in this way should be

removed with a brush (not synthetic) saturated with an
approved solvent listed above. Use of a clean, dry,
compressed air stream (25 to 28 psi) is recommended to
remove any excess solvent.
(c) Remove flux residue, metallic chips, and/or solder

balls with an approved solvent.
(3) Wired chassis devices containing terminal boards, resistor

and capacitor assemblies, rf coils, switches, sockets, induc-
tors, transformers, and other wired parts should be cleaned
as follows:
NOTE: When necessary to disturb the dress of wires and

cables, note the positions before disturbing and
restore them to proper dress after cleaning.
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(a) Blow dust from surfaces, holes, and recesses using an

air jet.
(b) Finish cleaning chassis by wiping finished surfaces

with a lint-free cloth moistened with solvent.
(c) Dry with a clean, dry, lint-free cloth.
(d) When thoroughly clean, touch-up any minor damage to the

finish.
(e) Protect the chassis from dust, moisture, and damage

pending inspection.
(4) Ceramic and plastic parts should be cleaned as follows:
(a) Blow dust from surfaces, holes, and recesses using an

air jet.
(b) Finish cleaning chassis by wiping finished surfaces

with a lint-free cloth moistened with solvent.
(c) Dry with a clean, dry, lint-free cloth.
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CHECK
1. General
This section provides procedures to perform a visual inspection of the

unit.
2. Inspection Procedures
A. Cover
Inspect the cover for dents, deformation, or damage to the finish

that should be repaired.
B. Front Panel
Check that name, serial number, and plates or stickers are secure
and hardware is tight.
C. Chassis
Inspect chassis for loose or missing mounting hardware, deformation,

dents, damaged fasteners, or damaged connectors. Check for
corrosion or damage to the finish that should be repaired.
D. Hardware, Covers and Shields
Inspect for bent, warped, stripped, dented or corroded parts. Check

for damaged fasteners. Check plating, painting, and identification
stencils for worn, exposed, or scratched surfaces.
E. Circuit Boards
Inspect for loose, broken or corroded terminal connections and

damage; such as cracks, burns, or charred track. Check for
insufficient solder, proper bonding, fungus, mold or other deposits
that should be repaired.
F. Connectors
Inspect connector bodies for broken parts, check insulation for

cracks, and check contacts for damage, misalignment, corrosion, or
bad plating. Check for broken, loose, or poorly soldered
connections to connector terminals. Inspect connector hoods and
cable clamps for crimped wires.
G. Terminal Connections
Inspect for corrosion or loose connections.
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H. Terminal Connections, Soldered
(1) Inspect for cold soldered or rosin joints. Bad joints can be
recognized by a dull porous appearance.
(2) Check for excessive solder, insufficient solder, or solder

splashes resulting from previous repair.
(3) Check for corrosion at the terminal connections.
I. Wiring
Inspect wiring of the chassis and subassemblies for any signs of

physical damage or charring.
J. Capacitors
Inspect capacitors for case or body damage and for loose, broken,
or corroded terminal connections.
K. Resistors and Diodes
Inspect for blistered, charred, or cracked bodies. Check for loose,

broken, or corroded terminal connections.
L. Filters and Inductors
Inspect for damage to body or casting and for loose, broken, or

corroded terminal connections. Check for secure mounting to
chassis.
M. Transformers
Inspect for damage to case and for signs of excessive heating. Check
for loose, broken, or corroded terminal connections.
N. Transistors and Integrated Circuits
Inspect for damage to body or casing. Check for proper and secure
attachment to sockets.
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O. Rotary Switches
Check for proper mechanical operation: no binding or looseness

should be evidenced.
P. Insulators
Inspect for looseness and/or evidence of damage such as burned

areas, cracks, and broken or chipped edges.
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REPAIR
1. General
This section contains information for repair of the unit. The repair or
replacement of damaged parts usually involves standard service techniques
suggested by examination of drawings and equipment. Some repairs,
however, demand an exact repair sequence to ensure proper operation of the
equipment.
After correcting a malfunction in any section of the unit, the functional

test in paragraph 3. Functional Test Procedures should be performed.

DS) DEVICES. ALL MODULES CONTAINING ESDS DEVICES ARE FLAGGED
OR IDENTIFIED ON SCHEMATICS AND ASSEMBLY ILLUSTRATIONS, AND ARE
INDIVIDUALLY IDENTIFIED IN THE PARTS LIST. ALL ESDS DEVICES
MUST BE HANDLED IN ACCORDANCE WITH PROCEDURES OUTLINED IN THIS
SECTION OF THIS MANUAL.
ESDS DEVICES INCLUDE, BUT ARE NOT LIMITED TO, C-MOS, J-MOS,
PMOS, NMOS, SOCMOS, HMOS, MOS/FET, MICROWAVE MIXER DIODES, SOME
BIPOLAR DEVICES, AND SOME METAL FILM RESISTORS.
MOST DAMAGE TO ESDS DEVICES RESULTS IN DEGRADED PERFORMANCE OR

PREMATURE FAILURE, NOT IN CATASTROPHIC FAILURE AT THE TIME EX-
PERIENCED.
2. Repair Procedures
A. Repair Precautions
(1) Refer to paragraph 2. B. Electrostatic Discharge Sensitive

(ESDS) Devices for special ESDS and MOS handling precautions.
(2) Perform repairs and replace components with power disconnect-

ed from equipment.
(3) Use a conductive table top for repairs. Connect table to

ground conductors of 60Hz and 400Hz power lines.
(4) Replace connectors, shield conductors, and twisted pairs ONLY

with identical items.
(5) Observe cable routing within unit prior to disassembly, to en-

able proper routing of cables during reassembly.
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B. Electrostatic Discharge Sensitive (ESDS) Devices
Devices sensitive to electrostatic discharge are used in this

equipment. These devices, including metal oxide semiconductors,
some metal film resistors, and other devices, are susceptible to
damage by electrostatic charges and high-voltage fields. Because
of the very high resistance in ESDS devices, they can be damaged by
low current electrical sources that would not damage standard
semiconductors. Special precautions must be taken during handling
and repair procedures to prevent damage.
The human body is the most common low-energy source causing damage
to ESDS devices. The body generates and retains static electricity,
in conjunction with non-conductive garments and floor covering. An
individual can easily develop several thousand volts of
electrostatic charge while simply walking across the floor or moving
around in a chair. Electrostatic charges of 20 kV can develop on
personnel, and 35 kV on their garments.
The capacitive elements in all MOS devices, and in linear integrated

circuits, hybrids, and bipolar integrated circuits can be destroyed
by a voltage field, even when installed in their circuits.
Not all electrostatic damage will result in immediate catastrophic

failure. Damaged devices may operate within their minimum limits
but can experience early field failure or erratic performance later.
The following precautions are recommended for ESDS circuits, and are
especially important in low humidity, high static conditions.
CAUTION: ESDS DEVICES INCLUDE, BUT ARE NOT LIMITED TO, C-MOS, J-
MOS, PMOS, NMOS, SOCMOS, HMOS, MOS/FET, MICROWAVE MIXER
DIODES, SOME BIPOLAR DEVICES, AND SOME METAL FILM RESIS-
TORS.
CAUTION: MOST DAMAGE TO ESDS DEVICES RESULTS IN DEGRADED PERFOR-

MANCE OR PREMATURE FAILURE, NOT IN CATASTROPHIC FAILURE
AT THE TIME EXPERIENCED.
(1) Storage
Store and transport all ESDS devices in conductive material.

Do not insert ESDS devices into conventional plastic trays
used for storing and transporting standard semiconductor de-
vices. Special bags or containers must have a maximum resis-
tivity of 104 ohms/cm, or the leads of the device must be
shorted together through a conductive material (special foam)
having a maximum resistivity of 104 ohms/cm.
Page 6002
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Modules, circuit boards, or assemblies containing ESDS devic-

es must be stored in static shielding bags with a maximum re-
sistivity of 104 ohms/cm in the outer layer of the bag, and
1012 ohms/cm resistivity in the inner layer.
A caution label shall be attached to the outside of all con-

tainers containing ESDS devices. The ESDS labels are identi-
fied in the advisory information located in the front of this
manual. Do not remove device from container until actually
used or tested.
(2) Work Station
All equipment, tools, materials, and personnel at the work

station must be maintained at the same electrical potential.
All grounding connections shall have a common point, and that
point shall be connected to electrical ground.
Soldering irons shall be isolated from the power line by

transformer, or shall be direct current isolated. The sol-
dering iron must be grounded and have a resistance of less
than 0.2 ohm from the tip to ground when the iron is hot.
Test equipment shall have all exposed metallic surfaces elec-

trically connected to the test equipment power system ground
(through 200 ohms or less).
Do not use rubber mats, carpets, and rugs in the work station
area. Use grounded conductive mats.
Do not allow non-conductive items on the workbench. This in-

cludes such items as plastic ash trays, cellophane wrappers,
plastic tools, Styrofoam coffee cups, etc.
Maintain the relative humidity higher than 40 percent (mini-

mum) in the work area.
Keep all material and work surfaces CLEAN in the work area.
Wash with damp cloth when necessary.
Keep the work station static-safe. Periodically check the

area with a static meter. When a dangerous reading is ob-
served, remove the nonconductor or take precautions to prevent
contact with ESDS devices.
Page 6003
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(3) Personnel
When handling electrostatic discharge sensitive devices or

assemblies, wear a skin-contact wrist strap connected to the
work station common ground.
WARNING: DO NOT CONNECT PERSONNEL DIRECTLY TO EARTH OR

BUILDING GROUND. USE A COMMERCIAL GROUNDING STRAP
WITH 1 MEGOHM IN THE CORD TO PROTECT PERSONNEL FROM
ELECTRICAL SHOCK.
WARNING: DO NOT WEAR GROUND STRAP WHEN TROUBLESHOOTING OR

TESTING HIGH VOLTAGE CIRCUITS WITH POWER APPLIED.
Do not wear smocks, gloves, finger cots, or sleeve protectors

made of plastic, nylon, or rubber in the area where ESDS de-
vices are handled.
When the operator is properly grounded, contact with the op-

erator's hand will provide sufficient ground for hand tools
or other tools that may be electrically isolated from ground.
(4) Special Troubleshooting Precautions
In addition to the above considerations, the following spe-

cific precautions should be observed when troubleshooting or
repairing modules containing ESDS devices.
Do not use high velocity dry air for applying heat during
troubleshooting. Special infrared heat devices should be
used.
Do not use Freon spray during troubleshooting. To cool com-

ponents, use antistatic quick-chill sprays.
Remember, even when the ESDS device is installed on a printed

circuit board it can STILL be damaged by electrostatic dis-
charge.
C. Replacement of Printed Circuit Board Protective Coating
WARNING: CONFORMAL COATING CONTAINS TOXIC VAPORS! USE ONLY WITH

ADEQUATE VENTILATION!
(1) Clean repaired area of printed circuit board per instructions

in the CLEANING section of this manual.
Page 6004
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(2) Apply Conformal Coating Humiseal #1B-31 HYSOL PC20-35M-01

(Humiseal Division, Columbia Chase Corp., 24-60 Brooklyn
Queens Expressway West, Woodside, N.Y., 11377) Honeywell p/n
016-01040-0000.
(3) Shake container well before using.
(4) Spray or brush surfaces with smooth, even strokes: if spray-

ing hold nozzle 10-15 inches from work surface.
(5) Cure time is ten minutes at room temperature.
D. Programmable Read Only Memory (PROM) Replacement
The read only memory packages are specially programmed devices to

provide specific logic outputs required for the operation in the
control unit. The manufacturer's part (type) number is for the
unprogrammed device and cannot be used. The Honeywell part number
must be used to obtain the correctly programmed device. Refer to
the ILLUSTRATED PARTS LIST.
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ASSEMBLY
1. General
This section provides procedures for assembly of the KMD 540, 550, and 850
Multi-Function Display. Assembly procedure are to be followed after the
unit has been disassembled for repair, cleaning, inspection, or
modification by service bulletin.
WARNING: REMOVE ALL POWER FROM UNIT BEFORE ASSEMBLY OF ANY MODULE. VOLT-
AGE TRANSIENTS ARE DANGEROUS TO LIFE. VOLTAGE TRANSIENTS CAN
DAMAGE THE EQUIPMENT.
CAUTION: EXERCISE EXTREME CARE WHEN DISCONNECTING AND RECONNECTING MUL-
TIPLE PIN CONNECTORS. ENSURE THAT CONNECTORS ARE NOT DAMAGED
BY MISALIGNMENT OF THE PINS.

DS) DEVICES. EQUIPMENT MODULES AND ESDS DEVICES MUST BE HANDLED
IN ACCORDANCE WITH SPECIAL ESDS HANDLING PROCEDURES.
2. Materials Required For Assembly
Table 7001 Sealants and Staking Compounds lists materials used in assembly
of the unit. Equivalent substitutes may be used for listed sealants,
staking compounds, and thermal compounds.
NOTE: The following are general use compounds. Where applicable, use
the specific assembly compounds called out in the parts list.
REPRESENTATIVE TYPE QUANTITY USED
Loctite 425 Thin coat to threads of screws and retaining

nuts
Conformal Coating Humiseal #1B-31 Thin coats on all components, not on connec-
HYSOL PC20-35M-01 tors
Adhesive-Sealant RTV 3145 Thin coat for adhesion
Thermal Compound Thin coat on power transistor insulator (both

sides)
Nylon Cable Tie As required to secure wiring
Solder, 60% Tin 40% Lead As required for connections
Table 7001 Sealants and Staking Compounds
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3. Recommended Reassembly Procedures
A. Unit Right Side Cover Reassembly
On the unit case right side, Figure 10002 KMD 540 End Item Assembly
Drawing item 12, install 4 screws, Figure 10002 KMD 540 End Item
Assembly Drawing item 15. These screws are indicated by "TO OPEN"
and arrows.
B. KAC 50X Interface Modules Reassembly
NOTE: KAC 50X refers to the option modules, i.e. KAC 501 We mod-
ule, KAC 502 EGPWS module, etc.
NOTE: KAC 50X installation drawings have been provided in SCHE-

MATIC DIAGRAMS section as reference.
(1) Install KAC 50X interface module(s).
(2) Install PCB locking bar, Figure 10002 KMD 540 End Item Assem-
bly Drawing item 13, and rotate 90°.
(3) In the center of the case top assembly, Figure 10004A KMD 540
Chassis Drawing item 4, install screw, Figure 10002 KMD 540
End Item Assembly Drawing item 8, which attaches PCB locking
bar to top side cover.
(4) Install right side cover per procedure detailed in paragraph

A. Unit Right Side Cover Reassembly.
C. Front Panel Module Reassembly
NOTE: If additional disassembly of the front panel module has

occurred, reassembly must occur before the module can be
reinstalled. Refer to the Front Panel Assembly drawing,
Figure 10003A KMD 540 Front Panel Drawing (with Mod 2) or
Figure 10003B KMD 540 Front Panel Drawing (pre Mod 2) as
required.
(1) Install 2 loose RF protection filters, P/N 187-011903-000X,

front panel module and chassis, top & bottom.
(2) Reconnect 1 ribbon cable and 2 coax cables.
(3) Install 6 screws, Figure 10002 KMD 540 End Item Assembly Draw-
ing item 8, which attach the chassis to front panel, 3 top
side, 3 bottom side.
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ing item 15, which attach the case left side to front panel,
Figure 10004A KMD 540 Chassis Drawing item 6.

D. Case Rear Plate Reassembly
NOTE: If additional disassembly of the case rear plate

assembly has occurred, reassembly must occur be-
fore the module can be reinstalled. Refer to Figure
10005A KMD 540 Case Rear Plate Drawing.
(1) Install case rear plate assembly.
(2) Connect fan power connector located right bottom side under
Distribution module.
(3) Slide the case rear plate assembly in.
(4) Install 5 screws, Figure 10004A KMD 540 Chassis Drawing item
21, which attaches the interface board to the rear plate and
carrier assembly, Figure 10004A KMD 540 Chassis Drawing item
3.
19, which attaches the bottom case to the rear plate.
21, which attach the case left side to the rear plate.
ing item 15, which attach the case left side to the front pan-
el, Figure 10004A KMD 540 Chassis Drawing item 16.
18, which attach the top cover to the case rear plate assem-
bly.

(10) Install KAC 50X Interface Module(s) per procedure detailed in

paragraph B. KAC 50X Interface Modules Reassembly.
E. Nav Prog Module Reassembly
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(1) Install Nav Prog module.
16, which attach the top case to the Nav Prog module.


F. Power Supply Module Reassembly
(1) Install Power Supply Module in right side of unit.
(2) Install the case rear plate assembly, ensure that the connec-
tor is connected.


G. Interface Prog Module Reassembly
(1) Install interface prog modules.
(2) Install large ribbon cable under interface prog module. In-
stall interface prog module.
(3) Install the case rear plate per procedure detailed in para-
graph D. Case Rear Plate Reassembly.
(4) Install 1 screw, Figure 10004A KMD 540 Chassis Drawing item
16, which attaches the bottom cover to the interface board.


H. Distribution Module Reassembly
(1) Install distribution module.
Page 7004
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17, which attach the distribution module to left side cover.
(3) Reconnect Video clock coax cable, Figure 10004A KMD 540 Chas-
sis Drawing item 25, to distribution module.
(4) Reconnect Video clock coax cable, Figure 10005A KMD 540 Case
Rear Plate Drawing item 7, to rear of the front panel module.
(5) Install Interface Prog Module per procedure detailed in para-

graph G. Interface Prog Module Reassembly.
(6) Install Power Supply Module per procedure detailed in para-

graph F. Power Supply Module Reassembly.
(7) Install Nav Prog Module per procedure detailed in paragraph

E. Nav Prog Module Reassembly.
(8) Install Case Plate per procedure detailed in paragraph D. Case

Rear Plate Reassembly.
(9) Install Front Panel Module per procedure detailed in paragraph

C. Front Panel Module Reassembly.
(10) Reconnect large ribbon cable to rear of front panel module

from the distribution board.


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SPECIAL TOOLS, FIXTURES, AND EQUIPMENT

1. General
This section contains information on special tools. fixtures, and test

equipment used to test, troubleshoot, and repair the unit.
Refer to Figure 9001 KMD 540 Breakout Test Panel Assembly Drawing, Figure
9002 KMD 540 Test Equipment Interconnect Drawing, and Figure 9003 KMD 540
Breakout Test Panel Schematic as required.
2. Equipment Required to Test
Table 9001 Required Test Equipment is a listing of the test equipment

required to perform the testing and troubleshooting procedures described
in this manual. Except where noted by an asterisk (*), equipment other
than that listed may be substituted if it is technically equal or better.
Item Description Representative Type

1 KMD 540 Breakout Panel Honeywell 071-00168-0000*
2 Diagnostic Test Software Honeywell 222-00471-00XX
(where 00XX = latest revision)*
3 Power Supply (2 required) HP E3632A
4 Power Cable Honeywell 200-09830-0000*
5 Test Panel Cables (P1) Honeywell 200-09828-0000*
6 Test Panel Cables (P2) Honeywell 200-09827-0000*
7 453 Simulator Honeywell 071-00167-0000*
8 DMV HP 34401A
9 Heading Simulator Honeywell 120-0126-0000
10 NTSC Signal Generator BK Precision 1249B
Table 9001 Required Test Equipment
Page 9001
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Page 9002
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Figure 9001 KMD 540 Breakout Test Panel Assembly Drawing

(Sheet 1 of 2)
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N
Figure 9001 KMD 540 Breakout Test Panel Assembly Drawing

(Sheet 2 of 2)
Page 9005/9006
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Figure 9002 KMD 540 Test Equipment Interconnect Drawing
Page 9007/9008
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N
Figure 9003 KMD 540 Breakout Test Panel Schematic

(Sheet 1 of 3)
Page 9009/9010
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(Sheet 2 of 3)
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(Sheet 3 of 3)
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ILLUSTRATED PARTS LIST

1. General
The Illustrated Parts List (IPL) is a list of assemblies and parts required
for the unit. The IPL also provides for the proper identification of
replacement parts. Individual parts lists within this IPL are arranged
in numerical sequence starting with the top assembly and continuing with
the mechanical sub-assemblies. Each parts list is followed by a component
location drawing.
NOTE: This manual is a level two manual; therefore, the IPL will not
show circuit card assemblies (CCAs). Only mechanical assem-
blies are included.
Parts identified in this IPL by Honeywell part number meet design

specifications for this equipment and are the recommended replacement
parts. Warranty information concerning Honeywell replacement parts is
contained in Service Memo #1, P/N 600-08001-00XX.
Some part numbers may not be currently available. Consult the current
Honeywell catalog or contact a Honeywell representative for equipment
availability.
2. Revision Service
The manual will be revised as necessary to reflect current information.
3. List of Abbreviations
Abbreviation Name
B Motor or Synchro
C Capacitor
CJ Circuit Jumper
CR Diode
DS Lamp
E Voltage or Signal Connect Point
F Fuse
FL Filter
FT Feedthru
Table 10001 Abbreviations
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Abbreviation Name
I Integrated Circuit
J Jack or Fixed Connector
L Inductor
M Meter
P Plug
Q Transistor
R Resistor
RT Thermistor
S Switch
T Transformer
TP Test Point
U Component Network, Integrated Circuit,
Circuit Assembly
V Photocell/Vacuum Tube
W, WG Waveguide
Y Crystal
Table 10001 Abbreviations
4. Typical Parts List
Refer to Figure 10001 Typical Parts List for a typical parts list which
accompanies each assembly drawing.
NOTE: The typical parts list is only a sample. The actual format and
style may vary slightly. A ‘Find Number’ column, when shown,
references selected items on the assembly drawing’s accompany-
ing parts list. This information does not apply to every parts
list. Therefore, a lack of information in this column, or a
lack of this column, should not be interpreted as an omission.
Page 10002
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Figure 10001 Typical Parts List
Page 10003
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Page 10004
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Page 10005/10006
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Page 10007/10008
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(Dwg No 300-09735-0000, Rev F, Sheet 1 of 2) (For Reference Only)
Page 10009/10010
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(Dwg No 300-09735-0000, Rev F, Sheet 2 of 2 (For Reference Only))
Page 10011/10012
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PN DESCRIPTION REV
-----------------------------------------------------------------------
066-04035-0101 KMD 540 MFD G
066-04035-0201 KMD 540 MFD ( GREY) G
066-04035-0301 KMD 540 MFD (BLACK W/SILVER RIM) G
----------------------------------------------------------------------------------------
SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0101 -0201 -0301
----------------------------------------------------------------------------------------
000-01040-0112 PRODUCT STRUCTURE KMD 540 MFD RF .00 .00 .00
004-02195-4000 KMD 540 MULTI-FUNCTION DISPLA RF .00 .00 .00
035-01007-0020 4 CONN CVR NAS820-8 EA 1.00 1.00 1.00
047-12493-0003 12 CASE, SIDE, RIGHT, W/HARDWARE EA 1.00 1.00 1.00
057-03186-0101 18 FLAVOR TAG EA 1.00 . .
057-03186-0201 18 FLAVOR TAG EA . 1.00 .
057-03186-0301 18 FLAVOR TAG EA . . 1.00
057-03511-0001 5 DECAL, CAUTION EA 1.00 1.00 1.00
057-05988-0001 7 KMD 540 SERIAL TAG EA 1.00 1.00 1.00
057-06098-0001 19 US PATENT LABEL EA 1.00 1.00 1.00
088-03444-0001 13 PCB LOCKING BAR EA 1.00 1.00 1.00
089-05222-0004 15 SCR FHP 4-40X1/4 EA 5.00 5.00 5.00
089-05903-0003 8 SCR PHP 4-40X3/16 EA 7.00 7.00 7.00
090-00990-0007 17 PROTECTIVE CAP, SUB-D, 37P EA 2.00 2.00 2.00
187-01902-0001 10 RF PROTECTION FILTER (BOTTOM) EA 1.00 1.00 1.00
200-09734-0010 3 KMD 540 FRONT PANEL ASSY/ BLA EA 1.00 . .
200-09734-0011 3 KMD 540 FRONT PANEL ASSY/ GRA EA . 1.00 .
200-09734-0012 3 KMD 540 FRONT PANEL ASSY / 5G EA . . 1.00
200-09736-0000 2 CHASSIS ASSY KMD 540 EA 1.00 1.00 1.00
206-00405-0112 KMD 540 BASE PROG BRD SET EA 1.00 1.00 1.00
300-09735-0000 KMD 540 FINAL ASSY RF .00 .00 .00
Page 10013
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PN DESCRIPTION REV
-----------------------------------------------------------------------
066-04035-1101 KMD 540 MFD -
066-04035-1201 KMD 540 MFD (GREY) -
066-04035-1301 KMD 540 MFD (BLACK W/SILVER RIM) -
----------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------
000-01040-0112 PRODUCT STRUCTURE KMD 540 MFD RF .00 .00 .00
004-02195-4000 KMD 540 MULTI-FUNCTION DISPLA RF .00 .00 .00
035-01007-0020 4 CONN CVR NAS820-8 EA 1.00 1.00 1.00
047-12493-0003 12 CASE, SIDE, RIGHT, W/HARDWARE EA 1.00 1.00 1.00
057-03186-1101 18 FLAVOR TAG EA 1.00 . .
057-03186-1201 18 FLAVOR TAG EA . 1.00 .
057-03186-1301 18 FLAVOR TAG EA . . 1.00
057-03511-0001 5 DECAL, CAUTION EA 1.00 1.00 1.00
057-05988-0001 7 KMD 540 SERIAL TAG EA 1.00 1.00 1.00
057-06098-0001 19 US PATENT LABEL EA 1.00 1.00 1.00
089-05222-0004 15 SCR FHP 4-40X1/4 EA 5.00 5.00 5.00
089-05903-0003 8 SCR PHP 4-40X3/16 EA 7.00 7.00 7.00
090-00990-0007 17 PROTECTIVE CAP, SUB-D, 37P EA 2.00 2.00 2.00
187-01902-0001 10 RF PROTECTION FILTER (BOTTOM) EA 1.00 1.00 1.00
200-09734-0010 3 KMD 540 FRONT PANEL ASSY/ BLA EA 1.00 . .
200-09734-0011 3 KMD 540 FRONT PANEL ASSY/ GRA EA . 1.00 .
200-09734-0012 3 KMD 540 FRONT PANEL ASSY / 5G EA . . 1.00
206-00405-0112 KMD 540 BASE PROG BRD SET EA 1.00 1.00 1.00
300-09735-0000 KMD 540 FINAL ASSY RF .00 .00 .00
Page 10014
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The following is the parts list from the previous manual revision and is provided for reference
only.
066-04035-0101 KMD 540 MFD Rev. F

066-04035-0201 KMD 540 MFD (GREY) Rev. F
066-04035-0301 KMD 540 MFD (BLACK W/SILVER RIM) Rev. F
-----------------------------------------------------------------------------
-----------------------------------------------------------------------------
000-01040-0112 PRODUCT STRUCTURE RF .00 .00 .00
004-02195-4000 KMD 540 MULTI-FUNC RF .00 .00 .00
035-01007-0020 4 CONN CVR NAS820-8 EA 1.00 1.00 1.00
047-12493-0003 12 CASE, SIDE, RIGHT, EA 1.00 1.00 1.00
057-03186-0101 18 FLAVOR TAG EA 1.00 . .
057-03186-0201 18 FLAVOR TAG EA . 1.00 .
057-03186-0301 18 FLAVOR TAG EA . . 1.00
057-03511-0001 5 DECAL, CAUTION EA 1.00 1.00 1.00
057-05988-0001 7 KMD 540 SERIAL TAG EA 1.00 1.00 1.00
089-05222-0004 15 SCR FHP 4-40X1/4 EA 5.00 5.00 5.00
089-05903-0003 8 SCR PHP 4-40X3/16 EA 7.00 7.00 7.00
090-00990-0007 17 PROTECTIVE CAP, SU EA 2.00 2.00 2.00
187-01902-0001 10 RF PROTECTION FILT EA 1.00 1.00 1.00
200-09734-0010 3 KMD 540 FRONT PANE EA 1.00 . .
200-09734-0011 3 KMD 540 FRONT PANE EA . 1.00 .
200-09734-0012 3 KMD 540 FRONT PANE EA . . 1.00
206-00405-0112 KMD 540 BASE PROG EA 1.00 1.00 1.00
300-09735-0000 KMD 540 FINAL ASSY RF .00 .00 .00
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Page 10016
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Figure 10003 KMD 540 Front Panel Drawing (with Mod 2)

(Dwg No 300-09734-0000, Rev N, Sheet 1 of 3)
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Figure 10003A KMD 540 Front Panel Drawing (with Mod 2)

(Dwg No 300-09734-0000, Rev M, Sheet 1 of 3) (For Reference Only)
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Figure 10003B KMD 540 Front Panel Drawing (pre Mod 2)

(Dwg No 300-09734-0000, Rev J, Sheet 1 of 3) (For Reference Only)
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Configurations with Mod 2:
200-09734-0010 KMD 540 FRONT PANEL ASSY/ BLACK Rev. -

200-09734-0011 KMD 540 FRONT PANEL ASSY/ GRAY Rev. -
200-09734-0012 KMD 540 FRONT PANEL ASSY / 5G Rev. -
-----------------------------------------------------------------------------
-----------------------------------------------------------------------------
073-01034-0008 1 FRONT PANEL, BLACK EA 1.00 . .
073-01034-0010 1 FRONT PANEL, GRAY EA . 1.00 .
073-01045-0006 1 FRONT PANEL, S.C. EA . . 1.00
200-09734-0098 COMMON BOM EA 1.00 1.00 1.00
205-00949-0000 FRONT PANEL PROG A RF .00 .00 .00
PN DESCRIPTION REV
-----------------------------------------------------------------------
200-09734-0098 COMMON BOM E
--------------------------------------------------------------------------
SYMBOL PART NUMBER FIND NO DESCRIPTION UM -0098
--------------------------------------------------------------------------
012-05160-0001 4 DISPLAY WINDOW EA 1.00
016-01013-0000 VAC GREASE DC 976 AR 1.00
016-01016-0000 79 MOLYKOTE G-N PASTE AR 1.00
016-01082-0000 68 DC RTV 3145 AR 1.00
043-05019-0002 5 LCD DISPLAY EA 1.00
047-12498-0006 6 FRONT PANEL CHASSIS EA 1.00
047-12540-0002 7 JOYSTICK DISK W/FINISH EA 1.00
047-12615-0001 72 ROTARY GROUND TAG EA 1.00
047-12650-0001 77 DISPLAY RETAINER EA 1.00
057-05971-0001 10 FRONT PANEL LABEL (SUL) EA 1.00
073-00550-0002 11 SHAFT W/F EA 1.00
073-00554-0003 12 KNOB W/PNT EA 1.00
073-00923-0004 13 HOUSING, W/FIN, KLN 90B EA 1.00
073-00924-0001 14 HOUSING BACK MACH EA 1.00
073-00991-0005 15 KNOB W/DECORATION EA 1.00
073-00991-0007 16 PLAIN KNOB W / WASHER EA 1.00
073-01042-0002 17 SUL LIGHTING SHROUD EA 1.00
076-02883-0005 18 SHAFT W/FINISH EA 1.00
076-03074-0002 19 SHAFT, W/FINISH EA 1.00
076-03076-0002 20 JOYSTICK W/ FIN EA 1.00
076-03091-0002 21 SHAFT W/ FINISH EA 1.00
078-02110-0001 22 JOYSTICK SPRING EA 1.00
088-00769-0000 23 SLEEVE LOCKING EA 1.00
088-03029-0001 24 INC/DEC REFLECTOR EA 2.00
088-03030-0000 25 INC/DEC RTR BROWN EA 1.00
088-03030-0001 26 INC/DEC RTR WHITE EA 1.00
088-03172-0002 27 KNOB W/LGT BUSHING EA 1.00
088-03283-0001 28 KLN 90B BUSHING EA 1.00
088-03418-0002 29 KEYCAP, WX EA 1.00
Page 10035
006-15608-0004 Rev. 4 31-60-01 July/2004
N
--------------------------------------------------------------------------
--------------------------------------------------------------------------
088-03418-0003 30 KEYCAP, TRFC EA 1.00
088-03418-0004 31 KEYCAP, TERR EA 1.00
088-03418-0005 32 KEYCAP, ’-------’ EA 5.00
088-03419-0001 33 LED LENS MOULDING EA 5.00
088-03420-0001 34 HORIZONTAL RUBBER KEYPAD EA 10.00
088-03422-0004 35 ON/OFF LIGHT BLOCK EA 1.00
088-03423-0001 36 LIGHTING BLOCK FOR 2-STAGE CO EA 1.00
088-03424-0001 37 SUL LIGHTING BLOCK EA 5.00
088-03428-0001 38 WINDOW SEAL EA 1.00
088-03433-0001 39 JOYSTICK GAITER EA 1.00
088-03434-0002 40 JOYSTICK LIGHTING RING W/FIN EA 1.00
088-03435-0004 41 BRT LIGHT BLOCK EA 1.00
088-03436-0002 42 KEYCAP, AUX EA 1.00
088-03437-0002 43 KEYCAP, MAP EA 1.00
088-03438-0001 44 DISPLAY MOUNTING BRACKET EA 1.00
088-03439-0001 45 2 STAGE LIGHT BLOCK SPACER EA 1.00
089-05899-0003 46 SCR PHP 2-56X3/16 EA 2.00
089-05899-0004 75 SCR PHP 2-56X1/4 EA 8.00
089-05899-0008 49 SCR PHP 2-56X1/2 EA 2.00
089-06004-0003 80 SCR FHP 2-56X3/16 EA 1.00
089-06004-0004 51 SCR FHP 2-56X1/4 EA 5.00
089-06163-0003 53 SCR FHP 4-40X3/16 EA 4.00
089-06200-0003 55 SCR SET 2-56X3/32 EA 5.00
089-06415-0004 78 SCR PHP 4-20X1/4 EA 1.00
090-00019-0005 57 RING RTNR .188 EA 2.00
090-00074-0001 59 RETNG RING .125 EA 1.00
091-00633-0001 61 DISPLAY RETAINER SPACER PAD EA 1.00
155-02948-0002 63 CABLE ASSY, RIBBON, FLEX, 14 EA 1.00
155-02948-0003 62 CABLE ASSY, RIBBON, FLEX, KMD EA 1.00
187-01905-0001 64 SUL SEAL EA 1.00
187-01911-0001 76 PAD, URETHANE FOAM EA 1.00
200-09722-0001 66 JOYSTICK/KNOB BOARD EA 1.00
200-09806-0001 65 KMD 540 SWITCH BOARD EA 1.00
205-00949-0000 67 FRONT PANEL PROG ASSY, KMD 54 RF .00
300-09734-0000 KMD 540 FRONT PANEL ASSY RF .00
Page 10036
006-15608-0004 Rev. 4 31-60-01 July/2004
N
only.
200-09734-0098 COMMON BOM Rev. C

---------------------------------------------------------------
---------------------------------------------------------------
016-01013-0000 VAC GREASE DC 976 AR 1.00
016-01082-0000 68 DC RTV 3145 AR 1.00
016-01139-0000 9 SUPERBONDER 414 AR 1.00
016-01144-0001 8 ACCELERATOR 11525 AR 1.00
043-05019-0001 5 13 CM FULL COLOR T EA 1.00
047-12498-0006 6 FRONT PANEL CHASSI EA 1.00
047-12540-0002 7 JOYSTICK DISK W/FI EA 1.00
057-05971-0001 10 FRONT PANEL LABEL EA 1.00
073-00550-0002 11 SHAFT W/F EA 1.00
073-00554-0003 12 KNOB W/PNT EA 1.00
073-00923-0004 13 HOUSING, W/FIN, KL EA 1.00
073-00991-0007 16 PLAIN KNOB W / WAS EA 1.00
073-01042-0002 17 SUL LIGHTING SHROU EA 1.00
076-02883-0005 18 SHAFT W/FINISH EA 1.00
076-03074-0002 19 SHAFT, W/FINISH EA 1.00
076-03076-0002 20 JOYSTICK W/ FIN EA 1.00
076-03091-0002 21 SHAFT W/ FINISH EA 1.00
088-03283-0001 28 KLN 90B BUSHING EA 1.00
088-03418-0002 29 KEYCAP, WX EA 1.00
088-03418-0003 30 KEYCAP, TRFC EA 1.00
088-03418-0004 31 KEYCAP, TERR EA 1.00
088-03418-0005 32 KEYCAP, ’-------’ EA 5.00
088-03420-0001 34 HORIZONTAL RUBBER EA 10.00
088-03423-0001 36 LIGHTING BLOCK FOR EA 1.00
088-03428-0001 38 WINDOW SEAL EA 1.00
088-03434-0002 40 JOYSTICK LIGHTING EA 1.00
088-03436-0002 42 KEYCAP, AUX EA 1.00
088-03437-0002 43 KEYCAP, MAP EA 1.00
Page 10037
006-15608-0004 Rev. 4 31-60-01 July/2004
N
---------------------------------------------------------------
---------------------------------------------------------------
088-03438-0001 44 DISPLAY MOUNTING B EA 1.00
088-03439-0001 45 2 STAGE LIGHT BLOC EA 1.00
089-05899-0003 46 SCR PHP 2-56X3/16 EA 2.00
089-05899-0004 75 SCR PHP 2-56X1/4 EA 8.00
089-05899-0008 49 SCR PHP 2-56X1/2 EA 2.00
089-06004-0003 80 SCR FHP 2-56X3/16 EA 1.00
089-06004-0004 51 SCR FHP 2-56X1/4 EA 5.00
089-06163-0003 53 SCR FHP 4-40X3/16 EA 4.00
089-06200-0003 55 SCR SET 2-56X3/32 EA 5.00
089-06415-0004 78 SCR PHP 4-20X1/4 EA 1.00
090-00019-0005 57 RING RTNR .188 EA 2.00
090-00074-0001 59 RETNG RING .125 EA 1.00
091-00633-0001 61 DISPLAY RETAINER S EA 1.00
155-02948-0002 63 CABLE ASSY, RIBBON EA 1.00
187-01905-0001 64 SUL SEAL EA 1.00
200-09722-0001 66 JOYSTICK/KNOB BOAR EA 1.00
200-09806-0001 65 KMD 540 SWITCH BOA EA 1.00
205-00949-0000 67 FRONT PANEL PROG A RF .00
300-09734-0000 KMD 540 FRONT PANE RF .00
Page 10038
006-15608-0004 Rev. 4 31-60-01 July/2004
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Configurations without Mod 2:
200-09734-0000 KMD 540 FRONT PANEL ASSY/ BLACK Rev. C

200-09734-0001 KMD 540 FRONT PANEL ASSY/ GRAY Rev. C
200-09734-0002 KMD 540 FRONT PANEL ASSY / 5G Rev. C
-----------------------------------------------------------------------------
-----------------------------------------------------------------------------
073-01034-0008 1 FRONT PANEL, BLACK EA 1.00 . .
073-01034-0010 1 FRONT PANEL, GRAY EA . 1.00 .
073-01045-0006 1 FRONT PANEL, S.C. EA . . 1.00
200-09734-0099 COMMON BOM EA 1.00 1.00 1.00
205-00934-0002 FRONT PANEL PROG A RF .00 .00 .00
200-09734-0099 COMMON BOM Rev. N

---------------------------------------------------------------
---------------------------------------------------------------
016-01013-0000 VAC GREASE DC 976 AR 1.00
016-01082-0000 68 DC RTV 3145 AR 1.00
016-01139-0000 9 SUPERBONDER 414 AR 1.00
016-01144-0001 8 ACCELERATOR 11525 AR 1.00
043-05016-0001 5 COLOR LCD MODULE EA 1.00
047-12498-0006 6 FRONT PANEL CHASSI EA 1.00
047-12540-0002 7 JOYSTICK DISK W/FI EA 1.00
057-05971-0001 10 FRONT PANEL LABEL EA 1.00
073-00550-0002 11 SHAFT W/F EA 1.00
073-00554-0003 12 KNOB W/PNT EA 1.00
073-00923-0004 13 HOUSING, W/FIN, KL EA 1.00
073-00991-0007 16 PLAIN KNOB W / WAS EA 1.00
073-01042-0002 17 SUL LIGHTING SHROU EA 1.00
076-02883-0005 18 SHAFT W/FINISH EA 1.00
076-03074-0002 19 SHAFT, W/FINISH EA 1.00
076-03076-0002 20 JOYSTICK W/ FIN EA 1.00
076-03091-0002 21 SHAFT W/ FINISH EA 1.00
088-03283-0001 28 KLN 90B BUSHING EA 1.00
088-03418-0002 29 KEYCAP, WX EA 1.00
088-03418-0003 30 KEYCAP, TRFC EA 1.00
088-03418-0004 31 KEYCAP, TERR EA 1.00
Page 10039
006-15608-0004 Rev. 4 31-60-01 July/2004
N
---------------------------------------------------------------
---------------------------------------------------------------
088-03418-0005 32 KEYCAP, ’-------’ EA 5.00
088-03420-0001 34 HORIZONTAL RUBBER EA 10.00
088-03423-0001 36 LIGHTING BLOCK FOR EA 1.00
088-03428-0001 38 WINDOW SEAL EA 1.00
088-03434-0002 40 JOYSTICK LIGHTING EA 1.00
088-03436-0002 42 KEYCAP, AUX EA 1.00
088-03437-0002 43 KEYCAP, MAP EA 1.00
088-03438-0001 44 DISPLAY MOUNTING B EA 1.00
088-03439-0001 45 2 STAGE LIGHT BLOC EA 1.00
089-05899-0003 46 SCR PHP 2-56X3/16 EA 2.00
089-05899-0004 75 SCR PHP 2-56X1/4 EA 8.00
089-05899-0008 49 SCR PHP 2-56X1/2 EA 2.00
089-06004-0004 51 SCR FHP 2-56X1/4 EA 6.00
089-06163-0003 53 SCR FHP 4-40X3/16 EA 4.00
089-06200-0003 55 SCR SET 2-56X3/32 EA 5.00
089-06415-0004 78 SCR PHP 4-20X1/4 EA 1.00
090-00019-0005 57 RING RTNR .188 EA 2.00
090-00074-0001 59 RETNG RING .125 EA 1.00
187-01905-0001 64 SUL SEAL EA 1.00
200-09722-0001 66 JOYSTICK/KNOB BOAR EA 1.00
200-09806-0001 65 KMD 540 SWITCH BOA EA 1.00
205-00934-0002 67 FRONT PANEL PROG A RF .00
300-09734-0000 KMD 540 FRONT PANE RF .00
Page 10040
006-15608-0004 Rev. 4 31-60-01 July/2004
N
Figure 10004 KMD 540 Chassis Drawing

(Dwg No 300-09736-0000, Rev L, Sheet 1 of 3)
Page 10041/10042
006-15608-0004 Rev. 4 31-60-01 July/2004
N

Page 10043/10044
006-15608-0004 Rev. 4 31-60-01 July/2004
N

Page 10045/10046
006-15608-0004 Rev. 4 31-60-01 July/2004
N
Figure 10004A KMD 540 Chassis Drawing

Page 10047/10048
006-15608-0004 Rev. 4 31-60-01 July/2004
N

(Dwg No 300-09736-0000, Rev J, Sheet 2 of 3 (For Reference Only))
Page 10049/10050
006-15608-0004 Rev. 4 31-60-01 July/2004
N

Page 10051/10052
006-15608-0004 Rev. 4 31-60-01 July/2004
N
200-09736-0000 CHASSIS ASSY KMD 540 Rev. K

---------------------------------------------------------------
---------------------------------------------------------------
047-12490-0004 4 CASE TOP ASSEMBLY EA 1.00
047-12491-0004 5 CASE BOTTOM ASS’Y EA 1.00
047-12492-0003 6 CASE SIDE, LEFT, W EA 1.00
049-00057-0003 9 RACK STRIP, W/ FIN EA 2.00
049-00067-0003 10 LOCKING ASSEMBLY S EA 1.00
049-00073-0002 14 STRENGTHENER PLATE EA 1.00
057-06000-0001 26 MODULE SLOT ASSIGN EA 2.00
073-00869-0002 13 HOLD DOWN UNIT EA 1.00
076-03111-0002 22 SCREW, W/ FINISH EA 1.00
089-05899-0003 16 SCR PHP 2-56X3/16 EA 7.00
089-05899-0005 17 SCR PHP 2-56X5/16 EA 8.00
089-05903-0004 18 SCR PHP 4-40X1/4 EA 8.00
089-06008-0002 19 SCR FHP 4-40X1/8 EA 2.00
089-06008-0004 21 SCR FHP 4-40X1/4 EA 10.00
089-08231-0000 23 WASHER FLAT EA 1.00
090-00265-0000 24 GROOVE PIN .046 X EA 1.00
155-02949-0001 25 CABLE ASSY, COAX, EA 1.00
187-01903-0001 28 RF PROTECTION FILT EA 1.00
200-09702-0001 1 POWER SUPPLY EA 1.00
200-09704-0001 2 DISTRIBUTION BOARD EA 1.00
200-09766-0002 3 CASE REAR PLATE AS EA 1.00
205-00932-0001 11 NAV PROG ASSY KMD RF .00
205-00933-0001 12 INTERFACE PROG ASS RF .00
300-09736-0000 KMD 540 CHASSIS AS RF .00
Page 10053
006-15608-0004 Rev. 4 31-60-01 July/2004
N
Page 10054
006-15608-0004 Rev. 4 31-60-01 July/2004
N
Figure 10005 KMD 540 Case Rear Plate Drawing

(Dwg No 300-09766-0000, Rev F, Sheet 1 of 1)
Page 10055/10056
006-15608-0004 Rev. 4 31-60-01 July/2004
N
Figure 10005A KMD 540 Case Rear Plate Drawing

(Dwg No 300-09766-0000, Rev B, Sheet 1 of 1) (For Reference Only)
Page 10057/10058
006-15608-0004 Rev. 4 31-60-01 July/2004
N
PN DESCRIPTION REV
-----------------------------------------------------------------------
200-09766-0002 CASE REAR PLATE ASSEMBLY C
--------------------------------------------------------------------------
--------------------------------------------------------------------------
047-12561-0003 2 BLANKING PLATE W/ HARDWARE EA 1.00
047-12913-0001 1 BACKPLATE EA 1.00
089-05907-0014 3 SCR PHP 6-32X7/8 EA 4.00
089-06004-0003 4 SCR FHP 2-56X3/16 EA 2.00
148-05195-0001 6 FAN 12VDC, 62X62 MM EA 1.00
155-02943-0001 7 CABLE ASSY, COAX, COMPOSITE V EA 1.00
300-09766-0000 CASE REAR PLATE ASSEMBLY K RF .00
only.
200-09766-0002 Case Rear Assembly KMD 540 Rev. -

---------------------------------------------------------------
SYMBOL PART NUMBER FIND NO DESCRIPTION UM 0002
---------------------------------------------------------------
047-12561-0003 2 BLANKING PLATE W/ EA 1.00
047-12660-0003 1 BACK PLATE W/HDW EA 1.00
089-05907-0016 3 SCR PHP 6-32X1 EA 4.00
089-06004-0003 4 SCR FHP 2-56X3/16 EA 2.00
090-01035-0001 5 FAN GUARD, EMI SHI EA 1.00
148-05195-0001 6 FAN 12VDC, 62X62 M EA 1.00
187-01901-0001 8 RF MESH (FAN) EA 1.00
300-09766-0000 CASE REAR PLATE AS RF .00
45043-3407 9 HEX NUT EA 4.00
only.
200-09766-0001 Case Rear Assembly KMD 540 Rev. A

---------------------------------------------------------------
SYMBOL PART NUMBER FIND NO DESCRIPTION UM 0001
---------------------------------------------------------------
047-12494-0003 1 CASE REAR PANEL W/ EA 1.00
047-12561-0003 2 BLANKING PLATE W/ EA 1.00
089-05907-0016 3 SCR PHP 6-32X1 EA 4.00
089-06004-0003 4 SCR FHP 2-56X3/16 EA 2.00
090-01035-0001 5 FAN GUARD, EMI SHI EA 1.00
148-05195-0001 6 FAN 12VDC, 62X62 M EA 1.00
187-01901-0001 8 RF MESH (FAN) EA 1.00
300-09766-0000 CASE REAR PLATE AS RF .00
45043-3407 9 HEX NUT EA 4.00
Page 10059
006-15608-0004 Rev. 4 31-60-01 July/2004
N
Page 10060
006-15608-0004 Rev. 4 31-60-01 July/2004
N
STORAGE
1. General
This section provides procedures for the storage of the unit.
2. Storage Procedures
A. Short-Term Storage
The unit can be temporarily stored on the shelf but should not be
exposed to extremes of temperature, humidity, or other environmental
conditions without additional protection. The use of plug covers
is recommended.
B. Long-Term Storage
For long-term or unlimited storage, it is recommended that the unit

be packaged as for shipment and that a suitable desiccant be placed
within the container. Mark the packing date plainly on the contain-
er. An alternate method is to store the unit in a location having
a carefully controlled, low-humidity environment. Units which have
been in long-term storage must be visually inspected, cleaned, and
must pass the 3. Functional Test Procedures in the Testing and Fault
Isolation section of this book before returning to service.
Page 15001
006-15608-0004 Rev. 4 31-60-01 July/2004
N
Page 15002
006-15608-0004 Rev. 4 31-60-01 July/2004

KMD 540 Manual de Mantenimiento

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KMD 540 Manual de Mantenimiento

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COMPONENT MAINTENANCE

MANUAL NUMBER 006-15608-0004

©2000-2001, 2003, 2004 Honeywell International Inc.

REPRODUCTION OF THIS PUBLICATION OR ANY PORTION THEREOF BY ANY MEANS

Component Maintenance Manual

IF ANY UNUSUAL OR SPECIFIC SERVICE PROBLEMS ARISE, CONTACT HONEYWELL,

This document contains proprietary information and

• Added 066-04035-1101, -1201, -1301 and applicable Environmental Qualifica-

• Updated to add changes per Application SW version 01/13.

• Added cross-referencing for electronic copy (PDF).

• Added ETSO information.

THIS PAGE IS RESERVED

REV. REVISION DATE DATE

RECORD OF REVISIONS (cont.)

REV. REVISION DATE DATE

SERVICE/SOFTWARE MANUAL MANUAL

KMD 540-1 3 Jan/2003 S/N 3300, Mod 1

KMD 540-2 3 Jan/2003 S/N 4203, Mod 2

KAC 501-1 3 Jan/2003 S/N 2197, Mod 1

KAC 502-1 3 Jan/2003 S/N 1928, Mod 1

KAC 503-1 3 Jan/2003 S/N 1644, Mod 1

KAC 504-1 3 Jan/2003 S/N 1912, Mod 1

THIS PAGE IS RESERVED

Title Page * T-1 July/2004

Revision Highlights * RH-1 July/2004

Record of Revisions * RR-1 July/2004

Service Bulletin List * SB-1 July/2004

List of Effective Pages * LEP-1 July/2004

Table of Contents * TC-1 July/2004

Introduction * INTRO-1 July/2004

Description and Operation * 0 July/2004

Description and Operation * 11 July/2004

Description and Operation F * 55 July/2004

Testing and Fault Isolation * 1001 July/2004

Schematics * 2001 July/2004

Disassembly * 3001 July/2004

Cleaning * 4001 July/2004

Check * 5001 July/2004

Repair * 6001 July/2004

Assembly * 7001 July/2004

Special Tools, Fixtures and * 9001 July/2004

Illustrated Parts List * 10001 July/2004

Illustrated Parts List (cont). F * 10011 July/2004

Storage * 15001 July/2004

THIS PAGE IS RESERVED

DESCRIPTION AND OPERATION

2. Configurations Available ..............................................5

3. Leading Particulars ...................................................5

4. Brief Description of Equipment .......................................25

5. Theory of Operation ..................................................26

TESTING AND TROUBLESHOOTING

2. Test Equipment .....................................................1001

3. Functional Test Procedures .........................................1013

C. 28VDC Lighting Bus ...........................................1018

4. Troubleshooting Procedures .........................................1032

5. Alignment Procedures ...............................................1032

6. Retest Procedure ...................................................1034

7. Service Information ................................................1034

2. Recommended Disassembly Procedure ..................................3001

2. Recommended Cleaning Materials .....................................4001

3. Recommended Cleaning Procedures ....................................4002

2. Inspection Procedures ..............................................5001

2. Repair Procedures ..................................................6001

2. Materials Required For Assembly ....................................7001