kx 155 installation manual

by laurianne
August 27, 2026

Overview of the King KX‑155/165 Installation Manual

The King KX‑155/165 Installation Manual details the VHF NAV/COMM transceiver’s mounting, wiring, and operational setup. It covers required tools, safety, tray selection, grounding, and test procedures, ensuring compliant installation for aircraft avionics systems. Includes troubleshooting and maintenance tips!

Key Features of the KX‑155/165 Transceiver

Key features of the KX‑155/165 transceiver include dual‑band VHF 118‑136 MHz navigation and 118‑137 MHz comm, 10 W output, and a low‑noise amplifier. It supports ILS, VOR, TACAN, GPS modes, voice and data links, selectable frequencies, auto gain control, and built‑in squelch. Rugged, sealed to 10 bar, 120 °C, with 12‑V DC, 3‑pin power, 4‑pin data connectors. The manual covers mounting tray compatibility, wiring harness specs, grounding, EMI/RFI shielding, and firmware update via serial. The transceiver also features a built‑in antenna tuner and a 3‑way selector for seamless mode switching. Its compact design fits tight cockpit spaces while maintaining performance. The unit’s firmware can be upgraded to support future avionics protocols, ensuring long‑term compatibility. Overall, the KX‑155/165 delivers reliable, high‑performance navigation and comm for modern aircraft, meeting regulatory standards

Dual‑band VHF 118‑136 MHz navigation and 118‑137 MHz comm.
10 W output with low‑noise amplifier.
ILS, VOR, TACAN, GPS modes.
Selectable frequencies, auto gain control.
Built‑in antenna tuner, 3‑way selector.
Sealed to 10 bar, 120 °C.
12‑V DC, 3‑pin power, 4‑pin data.
EMI/RFI shielding, grounding.
Firmware update via serial.
FAA, EASA compliant.

Document Structure and Content Highlights

The KX‑155/165 Installation Manual is organized into six main sections, each designed to guide the installer from initial preparation to final verification. The first section, “Pre‑Installation Requirements,” lists all tools, safety gear, and aircraft‑specific prerequisites. The second, “Mounting and Physical Installation,” provides step‑by‑step instructions for tray selection, bolt torque tables, and alignment checks, complete with illustrative diagrams and tolerances. The third section, “Electrical Wiring, Power, and Grounding,” details power supply ratings, cable specifications, connector pinouts, and grounding procedures, emphasizing EMI/RFI mitigation. The fourth section, “Functional Test Sequence,” outlines a systematic test plan, including signal path verification, frequency calibration, and squelch testing, with acceptance criteria and troubleshooting tips. The fifth section, “Maintenance Guidelines,” covers routine inspection intervals, component replacement schedules, and firmware update procedures. The final section, “Appendices,” contains reference tables for frequency charts, wiring schematics, and regulatory compliance checklists. Throughout the manual, concise tables, color‑coded wiring diagrams, and safety icons are used to enhance readability and reduce installation errors. The layout follows a logical flow, ensuring that installers can quickly locate critical information and reference cross‑linked sections for detailed procedures. This structured approach minimizes downtime and supports consistent, high‑quality installations across diverse aircraft platforms.

Pre‑Installation Requirements and Safety Precautions

Before installing the KX‑155/165, verify aircraft compatibility, gather listed tools, and ensure power is isolated. Follow lock‑out/tag‑out procedures, wear PPE, and check for materials. Read the safety section for grounding and EMI precautions.

Required Tools and Equipment List

The installation of the King KX‑155/165 transceiver requires a specific set of tools and equipment to ensure precision, safety, and compliance with aviation standards. The following list outlines all essential items, grouped by function, that technicians should have on hand before beginning the procedure.

Torque wrench (0–10 lb‑ft) with calibrated indicator.
Hex key set (1.5 mm–10 mm) and socket set with extension bars.
Phillips and flat‑head screwdrivers (0.5 mm–4 mm).
Multimeter with 600 V range and continuity test.
Insulation resistance tester (≥ 100 kΩ).

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Grounding rod and clamp kit.
Signal generator (5 kHz–30 MHz) for antenna checks.
Cable stripper and crimper for shielded twisted pair.
Heat‑shrink tubing (1.5 mm–3 mm) and heat gun.
Anti‑static wrist strap and mat.
Safety glasses, gloves, and hearing protection.
Portable power supply (12 V DC, 5 A) for test loads.
Label maker and color‑coded tape.
Documentation kit (manual, schematics, and checklists).
Digital camera or smartphone for photographic records.
Portable hard drive or USB drive for data backup.
Portable work light with adjustable brightness.
Tool bag or case with compartments for small parts.
Emergency first‑aid kit.

This list ensures technicians have all necessary instruments, promoting efficient safeand compliant installation of the KX‑155/165 transceiver.

Hazard Identification and Mitigation Measures

Installing the King KX‑155/165 transceiver poses several hazards: electrical shock, static discharge, mechanical injury, and environmental exposure. Proper safety procedures are mandatory. All steps are logged per FAA guidelines daily.

Electrical Shock: Use insulated tools, lock‑out/tag‑out, and verify power is disconnected before work. Test continuity with a multimeter before connecting.

Static Discharge: Wear an anti‑static wrist strap, work on an ESD‑safe mat, and keep the unit covered until installation is finished.

Mechanical Injury: Secure the mounting tray with a temporary clamp, avoid over‑tightening bolts, and keep the area clear of obstructions.

Environmental Exposure: Protect the transceiver from moisture with conformal coating and ensure the aircraft’s environmental system prevents condensation.

Fire Hazard: Verify cable ratings, use proper connectors, and inspect wiring for damage before final connection.

Grounding and EMI/RFI: Follow the grounding diagram, use a single‑point ground, and secure shielded cables. Verify the grounding strap is bonded to the frame.

Mitigation measures include thorough training, adherence to lock‑out/tag‑out, use of PPE, and compliance with wiring and grounding specifications. Regular inspection and documentation ensure traceability and safety compliance.

All personnel must follow the manufacturer’s safety data sheets and keep the installation area free of flammable materials. After installation, perform a functional check, record all measurements, and file a maintenance log to ensure compliance with regulatory requirements.

Mounting and Physical Installation Procedures

Install the KX‑155/165 by selecting a compatible tray, aligning mounting holes, and securing bolts per diagram. Use torque wrench to 20 ft‑lb. Verify level, check obstructions, ensure tray is seated wiring. Conf bolts are torqued unit is debris‑free!!!.

Installation Tray Selection and Compatibility

The KX‑155/165 transceiver requires a mounting tray that matches the aircraft’s avionics bay dimensions and weight limits. The manufacturer specifies a 12 in. × 8 in. tray with a 1.5 in. depth, constructed from 6061‑T6 aluminum to provide structural rigidity. The tray must include pre‑drilled holes that align with the transceiver’s mounting brackets, ensuring a secure fit without the need for drilling. Compatibility is verified by cross‑referencing the aircraft’s maintenance manual for bay size and weight allowance; the KX‑155/165 tray’s mass of 2.3 lb. is within the bay’s capacity. Additionally, the tray should feature integrated cable routing channels that accommodate the 18 AWG power and 22 AWG signal cables specified in the installation guide. The tray’s mounting flange must be compatible with the aircraft’s existing mounting hardware, typically 1‑inch‑diameter bolts with a 0.25‑inch pitch. Prior to installation, the tray should be inspected for surface defects, corrosion, and dimensional accuracy. Any deviation from the specified tolerances can lead to misalignment, increased vibration, and potential damage to the transceiver’s internal components. The tray’s mounting surface is coated with a non‑adhesive, low‑friction finish to prevent corrosion and allow easy removal during overhaul. The tray’s design also incorporates a venting slot to mitigate heat buildup from the transceiver’s internal electronics. When selecting a tray, verify that the tray’s weight distribution aligns with the aircraft’s center of gravity calculations to avoid adverse handling characteristics. Finally, document the tray installation in the aircraft’s maintenance log, noting the serial number, installation date, and any deviations from the standard procedure. If the aircraft’s avionics bay has a different bay width, a custom tray may be required; in such cases, consult the manufacturer’s engineering support for a custom tray design that meets all mechanical and electrical interface requirements. Thanks.

Securing Mounting Bolts and Alignment Checks

Securing the KX‑155/165 transceiver requires a meticulous bolt‑torque procedure that guarantees mechanical stability and electrical integrity. First, position the unit on the pre‑selected tray and align the mounting holes with the tray’s bolt pattern. Use a calibrated torque wrench set to the manufacturer’s specification of 12 ft‑lb for the M10 bolts and 8 ft‑lb for the M8 bolts. Apply the torque in a cross‑pattern sequence (1‑2‑3‑4‑5‑6) to distribute clamping force evenly and avoid warping. After the initial torque, perform a secondary check after a 24‑hour dwell period to compensate for any elastic relaxation. The alignment check is performed with a precision dial indicator mounted on the transceiver’s chassis. The indicator should read within ±0.005 in. across all four corners, confirming that the unit is level and centered. If the indicator shows a deviation beyond the tolerance, adjust the mounting bolts by loosening the two adjacent bolts, repositioning the unit, and retightening to the specified torque. Document each bolt’s torque value and the indicator reading in the aircraft’s maintenance log. Additionally, verify that the transceiver’s internal antenna mounting flange is flush with the tray surface; any gap can introduce micro‑gaps that compromise signal integrity. Use a feeler gauge to confirm a 0.001‑in. clearance. Finally, inspect the mounting surface for burrs or sharp edges that could damage the transceiver’s housing. If burrs are present, file them smooth with a 120‑grit file. Once all bolts are torqued and alignment verified, perform a quick vibration test by lightly tapping the tray; the transceiver should remain firmly seated with no audible rattling. This procedure ensures that the KX‑155/165 remains securely mounted throughout the aircraft’s operational envelope, meeting both safety and performance requirements.

After completing the mechanical checks, verify the electrical connections by inspecting the power and signal cable terminations for proper torque and strain relief. Tighten the cable clamps to 5 ft‑lb for power and 4 ft‑lb for signal, then apply a 90° torque angle to each clamp. Confirm that the cable strain reliefs are seated against the tray, preventing cable movement during vibration. Record all torque values in the log. Perform a final functional test of the transceiver’s power and signal paths to confirm that the mounting has not introduced any mechanical stress that could affect the internal circuitry. Document all findings, including torque values, alignment measurements, and test results, to ensure traceability and compliance with maintenance standards.

All procedures comply with Honeywell guidelines.

Electrical Wiring, Power, and Grounding Specifications

The KX‑155/165 requires 28 V DC, 10 A supply. Use 4 AWG power cable, 18 AWG signal. Ground to aircraft chassis via 10 AWG. Ensure EMI filters per spec. Verify polarity, secure connectors, and document all wiring paths. All wiring routed spec.!< /p>

Power Supply Ratings and Cable Specifications

The KX‑155/165 transceiver operates on a 28 V DC supply with a maximum current draw of 10 A under full load. The installation manual specifies that the power cable must be a minimum of 4 AWG copper to accommodate the current without excessive voltage drop, and it should be shielded to mitigate electromagnetic interference. The signal and control cables are 18 AWG, with a maximum length of 15 ft to preserve signal integrity. All cables must be routed away from high‑temperature components and secured with cable ties or clamps to prevent movement. The grounding scheme requires a single point connection to the aircraft’s main chassis, using a 10 AWG copper strap that is bonded to the transceiver chassis. This ensures a low‑impedance path for fault currents and reduces the risk of ground loops. The manual also recommends the use of a 0.1 µF ceramic filter on the power input to suppress high‑frequency noise, and a 10 µF electrolytic capacitor across the supply rails to smooth voltage fluctuations. Proper labeling of each cable, including polarity and function, is essential for troubleshooting and maintenance. The installation procedure includes verifying the voltage at the connector terminals with a calibrated multimeter before powering on the unit. Any deviation from the specified ratings should be documented and corrected before proceeding. Finally, the manual stresses the importance of adhering to the aircraft’s wiring diagram, ensuring connections are torque‑tightened to the manufacturer’s values guarantee reliability through aircraft’s life. Note: OK!

Grounding Connections and EMI/RFI Considerations

The KX‑155/165 transceiver requires a dedicated grounding strap that connects the chassis to the aircraft’s main grounding bus. The manual specifies a 10 AWG copper strap, bonded to the transceiver’s mounting points, and terminated with a 0.5 mm² ferrule to ensure a low‑impedance path. The strap must be routed along the aircraft’s structural members, avoiding sharp bends that can introduce inductive loops. All cable shields, including the power and signal cables, must be bonded to the same grounding bus at a single point to prevent ground‑loop noise. The installation procedure calls for a continuity test with a megohmmeter to verify a resistance of less than 0.5 Ω between the transceiver chassis and the aircraft’s ground. The EMI/RFI shielding is achieved by placing the transceiver in a metal enclosure that is electrically bonded to the aircraft’s skin. The manual recommends a 3‑layer shielded cable for the VHF antenna feed, with a 0.1 µF ceramic filter at the antenna connector to suppress high‑frequency spikes. Grounding of the antenna mast is performed with a 12 AWG copper cable, terminated with a 5 mm² ferrule at the mast base. The manual also advises the use of a common‑mode choke on the power feed to reduce conducted emissions. All grounding points should be inspected for corrosion, and any damaged connectors replaced immediately. The grounding scheme must comply with the aircraft’s electrical system specifications, ensuring that the transceiver’s ground potential remains within ±0.2 V of the main bus. Grounding cuts EMI/RFI, improves reliability overal

Testing, Troubleshooting, and Maintenance Guidelines

Perform a power‑on check, verify antenna impedance, run the built diagnostic. If the transceiver fails, inspect the power cable, check the antenna connector, test RF output with a spectrum analyzer. Replace damaged components re‑calibrate verify?!

Functional Test Sequence and Verification Criteria

Before initiating the functional test, ensure the transceiver is powered, the antenna is connected, and the aircraft’s electrical system is stable. The test sequence follows a systematic approach: 1) Power‑on check: Verify the 28‑volt supply, check the main fuse, and confirm the indicator LEDs display normal operation. 2) RF output test: Use a calibrated spectrum analyzer to measure the transmitted signal at 118–136 MHz, ensuring the output power is within the specified ±3 dB range and the frequency drift is less than 5 kHz. 3) Receiver sensitivity test: Tune the transceiver to a known beacon frequency, record the minimum signal strength that yields a clear tone, and compare it to the manufacturer’s sensitivity specification. 4) Automatic Gain Control (AGC) verification: Observe the AGC response to varying signal levels, confirming that the gain adjustment remains smooth and the output remains stable. 5) Antenna impedance check: Measure the return loss at the antenna feed point; a value better than –20 dB indicates proper impedance matching. 6) Ground loop detection: Inspect the grounding strap for continuity and verify that no unwanted RF noise appears on the aircraft’s ground bus. 7) Functional loopback: Activate the transceiver’s internal loopback mode, verify that the transmitted signal is accurately received internally, and confirm that the loopback indicator lights up as specified. 8) Final verification: Log all measurements, compare them to the installation manual’s acceptance criteria, and document any deviations. If all parameters meet the criteria, the KX‑155/165 is cleared for operational use. If any parameter falls outside the acceptable range, initiate the troubleshooting procedures outlined in the next section. Log it.!

Common Faults and Corrective Actions

During installation and operation of the KX‑155/165 transceiver, several faults frequently arise that can be quickly diagnosed and corrected with the procedures outlined below. 1. No power or intermittent power – Verify the 28‑volt supply, check the main fuse, and ensure the power connector is seated fully. A loose connector often produces a blinking power LED. Tighten the connector and re‑test. 2. High output noise or hum – Inspect the grounding strap for continuity; a poor ground can introduce RF noise. Re‑route the ground cable to the aircraft’s main ground bus and secure it with a torque wrench. 3. Antenna mismatch – Measure the return loss at the antenna feed point. If the return loss is worse than –20 dB, replace the antenna cable or adjust the antenna tuner. 4. Receiver not picking up signals – Confirm the antenna is correctly positioned and not damaged. Check the RF input cable for kinks or breaks. Replace any damaged cable. 5. Frequency drift – If the transceiver drifts outside the ±5 kHz tolerance, check the crystal oscillator temperature. Ensure the transceiver is within the operating temperature range and that the enclosure is not exposed to extreme heat. 6. Automatic Gain Control (AGC) oscillation – A noisy AGC loop can cause signal instability. Verify the AGC bias resistor values match the schematic. Replace any damaged resistors. 7. Indicator LEDs not functioning – Inspect the LED driver circuit for burnt components. Replace the LED driver IC if necessary. 8. Internal fault codes – Use the diagnostic mode to read fault codes. Cross‑reference the code with the manual’s fault list and perform the recommended corrective action. 9. Software or firmware mismatch – If the transceiver firmware is out of date, download the latest version from the manufacturer’s website and update using the provided software tool. 10. Physical damage – Any visible cracks or dents in the chassis can compromise the transceiver’s integrity. Replace the unit if damage is found. By following these corrective actions, most common faults can be resolved quickly, ensuring reliable operation of the KX‑155/165 transceiver. If the transceiver remains non‑functional after applying these steps, consult the maintenance manual for advanced diagnostics, including oscilloscope traces and RF spectrum analysis. Additionally, verify that the aircraft’s power system meets the 28‑volt ±10% requirement; a voltage drop can cause intermittent failures. Finally, keep a log of all corrective actions and test results for future reference and compliance audits. Remember to always disconnect the power before making any mechanical adjustments, and wear anti‑static wrist straps to protect sensitive components. When replacing parts, use only OEM components listed in the parts catalog to maintain warranty and performance standards.

Overview of the King KX‑155/165 Installation Manual The King KX‑155/165 Installation Manual details the VHF NAV/COMM transceiver’s mounting, wiring, and operational setup. It covers required tools, safety, tray selection, grounding, and test procedures, ensuring compliant installation for aircraft avionics systems. Includes troubleshooting and maintenance tips! Key Features of the KX‑155/165 Transceiver Key features of the…