COMPONENT MAINTENANCE MANUAL

FOR
SANDEL SN3500 EHSI Navigation Display

Document No. 82005-0133

Revision D, February 1, 2010

SANDEL AVIONICS, INC.

2401 Dogwood Way
Vista, CA 92081
Telephone: (760) 727-4900
Facsimile: (760) 727-4899
www.sandel.com

PROPRIETARY DATA
SANDEL AVIONICS proprietary rights are included in the information disclosed herein. Recipient by
accepting this document agrees that neither this document nor the information disclosed herein nor any
part thereof shall be reproduced or transferred to other documents or used or disclosed to others for
manufacturing or for any other purpose except as specifically authorized in writing by SANDEL
AVIONICS.
 REVISION SHEET

REV Date Pages Para. DESCRIPTION OF CHANGES

D February 1, 2010 9-11 All A/R 1108 Added Section 5. Field replacement of
Diffuser Window
C June 24, 2009 7-8 All A/R 1077 Added section 4. Field u-joint
replacement.
B Nov 20, 2007 4 3 A/R 941; Added Lamp Kit part number; updated
for Mod 1 LED backlight;
4-6 All Updated lamp housing figures for better clarity.

A Sep 14, 2006 All All A/R 855; Initial Release

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 TABLE OF CONTENTS

1. APPLICABLITY .................................................................................................................. 4
2. UPLOADING SYSTEM SOFTWARE AND DATABASES ............................................ 4
3. LAMP REPLACEMENT PROCEDURE .......................................................................... 4
4. U-JOINT REPLACEMENT PROCEDURE...................................................................... 7
5. DIFFUSER WINDOW REPLACEMENT PROCEDURE............................................... 9

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 1. APPLICABLITY

This document is applicable to maintenance for continued airworthiness of Sandel SN3500

EHSI Navigation display:

Unit part number: SN3500-xxx, Software revision 1.00 or later

2. UPLOADING SYSTEM SOFTWARE AND DATABASES

System software is released via SIL (Service Information Letter) posted on the Sandel
website. The SIL contains links to the software and the related software installation files
necessary to load the software. Database updates are available for purchase via the Sandel
website. The database information site also contains up-to-date links to database download
instructions.

The SIL's and Database update information can be found at: www.sandel.com under
"Support".

3. LAMP REPLACEMENT PROCEDURE

Field lamp replacement applies to part number SN3500-xxx, serial numbers less than 2000
without Mod Level 1 LED light source [the Mod level is shown on the lower portion of the TSO
label]. Use the following eleven step procedure to replace the lamp using Sandel Lamp Kit
part number 90130-LK. SN3500-xxx Mod Level 1 LED light source is not field serviceable.

Step 1 Step 2
4 Screws
2 Screw
holes

Fig. 2: Remove Lamp Module and carefully disconnect

Fig. 1: Place SN3500 unit onto a grounded bench lamp terminals. Either of the 2 screw holes can be used
area. Remove 4 flat head screws that hold the lamp to aide module removal. Insert a 4-40 screw as a handle
module. and pull module out.

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 Step 3 Step 4

Save

Discard

Fig. 4: Remove screw, lamp bracket, lamp and spacer.

Fig. 3: Place lamp module onto flat surface. Discard lamp and spacer. Lamp Contains Mercury,
Dispose According to Local, State or Federal Laws.
Save bracket and screw for replacement lamp set.

Step 5 Step 6 Step 7

Lamp Assy Red stripe

84015 wire

Fig. 5: Remove lamp and shim

from protective packaging. Do not
touch lamp glass with bare skin!
This can significantly reduce lamp
life. Ensure lamp is clean and free
from dirt or dust. If cleaning is Fig. 7: Ensure lamp is fully
required, use isopropyl alcohol and Fig. 6: Orient the lamp wire with red seated into lamp housing. Torque
a clean cotton swab. stripe as shown. Assemble new lamp, pan head screw until snug.
spacer, existing bracket and screw into
lamp module as shown.

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 Wires
Step 8 Terminal Step 9 Step 10
inside
Covers
box

Fig. 8: Reconnect the lamp Fig. 10: Fully seat lamp module
terminals to mating terminals inside into unit lamp pocket. Fasten and
unit lamp pocket. Ensure terminal Fig. 9: Ensure the lamp wires are torque flat head screws until
covers are completely engaged securely seated inside the plastic snug.
and completely cover the wire box. Ensure the lamp wires are
connected terminals. These not touching the circuit cards or rear
covers prevent high voltage fan surface.
shorting inside the unit.

Step 11 SOFTWARE RESET:

Reset the lamp-hours counter in the SN3500 by

entering the BRT/AUDIO maintenance page, in Edit
Mode. Select “Lamp Hours/Cycles” using the
arrow buttons. Press the “Reset” softkey to reset.

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 4. U-JOINT REPLACEMENT PROCEDURE
Field U joint replacement applies to part number SN3500-xxx. Replacement U-joints, Sandel
part number 90253-01 may be ordered from Sandel.

Step 1 Step 2

Fig. 2: Rotate Heading and Course knobs to expose U-

Joint retaining setscrews. Using 0.050” hex wrench,
Fig. 1: Place SN3500 unit onto a grounded bench loosen U-Joint retaining setscrews. (left and right hand
area. Remove 12 ea 4-40 X .25 flat head machine sides are symmetric)
screws securing side covers to unit. Remove side
covers

Step 3 Step 4

Fig. 4:
1. Apply Thread Locker (Loctite 222, or eq.) to
Fig. 3: Remove Heading and Course Knobs thru threads of replacement U-Joint retaining
front of bezel, disengage U-Joints from Encoder setscrews.
Shafts and remove from unit. 2. Align U-Joints to Encoder Shafts and install into
unit, leaving ~.10” gap between rear of U-Joint
and face of Encoder (see Fig. 6).
3. Reinstall Heading and Course Knobs (ensuring
proper orientation, see Fig. 5), thru bezel, into
sockets of replacement U-Joints. Space knobs
to leave .06” gap between Knobs and face of
bezel (see Fig. 6).
4. Align U-Joint setscrews to flats on Encoder and
Knob Shafts and tighten firmly

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 Step 4 (cont.) Step 4 (cont.)

Fig. 5: Ensure correct orientation of Heading and

Course Knobs. Fig. 6: Space knobs to leave .06 gap between face of
bezel and knobs, ~.10” gap between rear of U-Joints
and faces of Encoders.

Step 5 Step 6

Verify Encoder operation:

1. Rotate Heading and Course Knobs through
360º, ensuring that mechanism does not
bind.
2. At each detent position, push and release
knob, ensuring that encoder push button
function operates smoothly, without
sticking.
3. If improper function is noted at any position,
loosen setscrews and reposition U-Joint
slightly to alleviate condition. Maintain .06
gap between knob and bezel.

Fig. 7: Reinstall Side Covers to SN3500. Install 12 X 4-

40 Flat Head Machine Screws. Torques screws to5-7
inch-lbs.

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 5. DIFFUSER WINDOW REPLACEMENT PROCEDURE

Field replacement of Diffuser Window applies to part number SN3500-xxx. Replacement display
windows, Sandel part number 63034 may be ordered from Sandel.

Step 1 Step 2

Fig. 1: Place SN3500 unit onto a grounded

bench area. Carefully pry heading and course Fig. 2 Remove 6 ea flat head machine screws, 2-56
knob caps from encoder knobs using a small, X .125 retaining bezel to actuator housing. Hold
flat blade screw driver or similar. Loosen bezel in place to prevent shifting of retained
encoder knob collets using a flat blade screw components.
driver and remove encoder knobs from encoder
shafts.

Step 3 Step 4

Fig. 4: Align replacement window to switch actuators

and place onto Fresnel lens on face of unit. Ensure that
Diffuser Window and Fresnel Lens are properly located
Fig. 3: Carefully lift Bezel and Diffuser Window and have not shifted during procedure.
from unit. Do not remove or shift Fresnel lens.
Remove existing window from unit.

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 Step 5 Step 6

Fig. 5: Carefully reinstall Bezel onto Actuator Fig. 6: Place encoder knobs over encoder shafts.
Housing. Ensure that the machined lip in Diffuser Leave approximately 0.06” (1.5mm) gap between
Window engages Bezel opening and that Bezel back of encoder knob and face of bezel. Tighten
fully seats. If necessary, loosen (but do not encoder knob collets using flat blade screw driver.
remove) screws at bottom corners of unit to allow
Menu Actuator and USB socket to “float” to facilitate Verify knob operation by rotating knob and pushing
installation. Secure Bezel using 6 Ea Flat Head in knob. Detent in knob push should be detectable
Machine Screws, 2-56 X .125. Re-torque corner and knob should not contact bezel. When
screws, if loosened. depressed, verify gap dimension by slipping a piece
of paper between the knob and the bezel (paper is
approximately 0.005” [0.1mm]). The paper should
fit easily.
Reinstall encoder knob caps into encoder knobs.
Ensure proper location of heading and course caps.

Step 7

Verify installation:
1. Ensure that all affected components are
installed.
2. Ensure that Bezel is fully seated.
3. Ensure that Bezel retaining screws are
securely installed.
4. Ensure that all Switch Actuators operate
freely, without binding.
5. Ensure that Encoder Knobs are properly
installed, with .060 gap between back of
knob and face of Bezel and that encoder
switches actuate freely.

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