Garmin GPSMAP 60CSx Service Manual

The Garmin GPSMAP 60CSx is a rugged, waterproof handheld GPS receiver featuring a high-sensitivity GPS receiver, a color TFT display, a built-in basemap, expandable microSD card slot for detailed mapping, an electronic compass, barometric altimeter, and support for WAAS-enabled satellite signals. This service manual covers technical specifications, disassembly procedures, component replacement, troubleshooting, and maintenance guidelines for qualified service personnel.

Overview and Features

The GPSMAP 60CSx is designed for outdoor navigation with enhanced reception and mapping capabilities.

Feature	Description
High-Sensitivity Receiver	Uses SiRFstarIII chipset for improved reception under trees or near obstacles.
Color TFT Display	176 x 240 pixel, sunlight-readable, 256-color display.
Memory	64 MB internal, plus microSD card slot for optional MapSource detail maps.
Sensors	Electronic compass (requires calibration), barometric altimeter with trend recording.
Interface	USB and serial (RS-232) connectivity for data transfer and power.
Durability	IPX7 waterproof standard (submersible in 1 meter of water for 30 minutes).
Power	Operates on 2 AA batteries (alkaline or NiMH) or external DC input.
Waypoints/Tracks	1000 user waypoints, 20 reversible tracks with 10,000 points total.
Mapping	Includes a worldwide basemap; accepts detailed Garmin MapSource cartography.
Geocaching Mode	Supports paperless geocaching with hints and logs.

Technical Specifications

• Dimensions: 6.1 x 2.4 x 1.3 inches (15.5 x 6.1 x 3.3 cm).
• Weight: 7.5 ounces (213 grams) with batteries.
• Display: 2.6-inch diagonal, 176 x 240 pixels, 256-color TFT.
• GPS Receiver: High-sensitivity SiRFstarIII, WAAS/EGNOS enabled.
• Battery Life: Up to 20 hours typical use (varies with settings and battery type).
• Waterproof Rating: IEC 60529 IPX7.
• Operating Temperature: -15° to 70° C (5° to 158° F).
• Storage Temperature: -40° to 85° C (-40° to 185° F).
• Data Storage: 64 MB internal user memory, microSD card slot (supports up to 2 GB cards).
• Interface: USB 2.0 Full Speed, NMEA 0183, RTCM 104 differential input.

Disassembly Instructions

WARNING: Disassembly voids the user warranty. Perform only in a static-safe environment. Follow ESD precautions.

1. Remove Batteries: Open battery compartment cover and remove AA batteries.
2. Remove Screws: Using a T6 Torx screwdriver, remove the four screws on the back case.
3. Separate Halves: Carefully pry apart the front and rear case halves using a plastic opening tool. Start near the keypad area.
4. Disconnect Internal Connectors: Note the positions of the main flex cable, antenna connector, and any other ribbon cables. Gently disconnect them.
5. Access Mainboard: Remove additional screws securing the mainboard to the front housing. Lift the board out carefully.

CAUTION: The display and keypad are fragile. Avoid excessive force. Keep track of all screws and components.

Component Identification

Key internal components for service reference.

Ref. Designator	Component	Notes
U1	Main Processor	Central processing unit.
U2	GPS Receiver Module (SiRFstarIII)	High-sensitivity GPS chipset.
J1	Display Flex Connector	ZIF (Zero Insertion Force) connector for LCD.
J2	Keypad Flex Connector	Connector for membrane keypad.
J3	External Antenna Connector (MCX)	For optional external active antenna.
BATT+	Battery Contact Points	Positive and negative terminals.
S1	Power Button	Tactile switch on mainboard.
COMPASS	Fluxgate Sensor	For electronic compass function.

PCB Layout and Connectors

Mainboard overview and connector pinouts for testing.

1. USB/Serial Port (J4): 5-pin connector. Pins: 1-VBUS, 2-D-, 3-D+, 4-GND, 5-Serial TX.
2. Power Input (J5): For external 3-5V DC input. Observe polarity.
3. Test Points: TP1 (3.3V), TP2 (GND), TP3 (RESET). Use for voltage verification.
4. GPS Antenna Pad: Ceramic patch antenna connection point on board. Check for cracks.

Tip: Refer to the detailed schematic diagram (not included in this public manual) for full electrical details.

Battery System

Diagnosing and servicing power-related issues.

1. No Power: Check battery contacts for corrosion. Verify voltage >2.4V with two fresh AA batteries.
2. Short Runtime: Check for excessive current draw. In sleep mode, current should be <1mA.
3. External Power: Unit should operate from external 3-5V DC on the designated pins. Check internal fuse F1.
4. Battery Leakage: Clean contacts with isopropyl alcohol if corrosion is present. Severe damage may require mainboard replacement.

WARNING! Do not short-circuit battery terminals. Use correct battery polarity.

Display Module Replacement

Procedure for replacing the color TFT display.

1. Disassemble unit to access mainboard (see Section 4).
2. Open the ZIF connector (J1) latch by lifting the brown tab.
3. Gently pull the display flex cable out of the connector.
4. Remove any adhesive or screws securing the display to the front bezel.
5. Install the new display module, ensuring the flex cable is seated fully in J1 and the latch is closed securely.
6. Reassemble and power on to test display functionality.

CAUTION: The display is sensitive to ESD. Handle by the edges only.

Keypad and Seal Service

Maintaining waterproof integrity and keypad responsiveness.

1. Keypad Non-Responsive: Check the membrane keypad flex cable connection at J2. Clean contacts if needed.
2. Seal Replacement: The main O-ring/gasket between case halves is critical for waterproofing. Replace if torn, nicked, or flattened.
3. Button Feel: Ensure the silicone rubber keypad dome is correctly positioned over the mainboard tactile switches.
4. Seal Lubrication: Apply a thin film of silicone grease to the main O-ring during reassembly to ensure a proper seal.

Tip: After reassembly, perform a waterproof test without electronics installed if possible.

GPS Antenna Module

The internal ceramic patch antenna and related circuitry.

• Poor Satellite Fix: Verify the antenna is not cracked. Check solder joints from antenna pad to RF input.
• External Antenna Port (J3): Test continuity. If using an external antenna, ensure it is active (powered) for the 60CSx.
• Receiver Performance: Use the satellite status page to check signal strength. Weak signals across all satellites may indicate a failed SiRFstarIII module (U2).

Note: The GPS receiver requires a clear view of the sky for initial acquisition. Allow several minutes outdoors.

Reassembly and Testing

Final steps to ensure proper operation after service.

1. Ensure all flex cables are connected and latched.
2. Place the main O-ring correctly in its channel in the case.
3. Align case halves carefully and press together evenly.
4. Insert and tighten the four T6 screws in a cross pattern to avoid stress.
5. Functional Test:
   • Power on with fresh batteries.
   • Check all keypad buttons for response.
   • Verify display is clear with no lines or artifacts.
   • Acquire GPS satellites outdoors.
   • Test USB connectivity with a PC.
   • Calibrate compass and altimeter (see Section 12).

Troubleshooting Flowcharts

Symptom	Possible Cause	Corrective Action
Unit will not power on	Dead batteries, corroded contacts, faulty power switch, mainboard failure.	1. Install new batteries. 2. Clean battery contacts. 3. Check voltage at test point TP1. 4. Check switch S1 continuity.
No GPS signal acquisition	Obstructed view, faulty antenna, failed GPS module.	1. Test outdoors with clear sky view. 2. Inspect antenna for damage. 3. Check for cold solder joints at RF path.
Display is blank or garbled	Loose display cable, faulty display, mainboard issue.	1. Re-seat display flex cable at J1. 2. Replace display module. 3. Verify 3.3V at display power pin.
Buttons not working	Dirty keypad contacts, torn flex cable, mainboard connector issue.	1. Clean keypad membrane contacts. 2. Re-seat keypad flex at J2. 3. Check for continuity on keypad matrix.
Not recognized by PC via USB	Faulty cable, incorrect driver, damaged USB port on unit.	1. Try a different USB cable. 2. Check Device Manager for unknown device. 3. Inspect USB connector solder joints.
Compass/Altimeter inaccurate	Requires calibration, sensor failure.	1. Perform sensor calibration (see Section 13). 2. Ensure unit is held level during compass use.

Calibration Procedures

Steps to calibrate the built-in sensors.

1. Electronic Compass:
   • Go to Menu > Setup > Heading.
   • Select 'Calibrate Compass'.
   • Follow on-screen prompts: hold unit level and rotate slowly two full rotations (usually 360° twice).
   • Perform in an area away from metal objects and strong magnetic fields.
2. Barometric Altimeter:
   • Go to Menu > Setup > Altimeter.
   • Select 'Calibrate Altimeter'.
   • Enter the known correct elevation or barometric pressure if available.
   • For best accuracy, calibrate using a known elevation point.

Note: Calibration should be performed after any internal repair that might affect sensor placement.

Parts List and Ordering

Common service parts for the GPSMAP 60CSx. Contact Garmin Parts Department or authorized distributors.

Part Number	Description	Notes
010-00421-00	Display Assembly (Color TFT)	Includes flex cable.
010-00422-00	Keypad Membrane	Front panel button overlay.
010-00423-00	Main O-Ring Seal Kit	Waterproofing gasket.