MT400 Technical Service Manual
Contents
1. To re assemble and or replace components each step is to be completed in numerical order as follows Step Action 1 Push the switch slider onto a slider track appropriate to the beacon model type x ss MT400 type has OFF p lt T MT401 type has READY UL Leave this hole exposed when fitting switch slider 2 Locate the switch and switch slider track so that tongue provided on that track engages into the slot provided at the front of the beacon cap Place then hold in position a switch cover of the type appropriate to the beacon model type as shown Commercial in Confidence 42772 5 Doc Page 7 of 28 Document 42772 Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Step Action B 9 4 Yellow switch covers are fitted to yellow chassis beacons Orange covers to orange coloured beacons 4 Close the switch cover 5 3 3 Chassis Disassembly Assembly This operation is carried out when Internal access to the beacon is required A mechanical repair requires the EPIRB cap and chassis to be separated Disassembly For disassembly each step is to be completed in numerical order as follows Step Action 1 Using a Philips screwdriver Size 1 remove all four screws that retain the EPIRB cap to the lower chassis Retain the screws for later reuse Commercial in Confidence 42772 5 Doc Page 8 of 28 Document 427722. 406MHz COSPAS SARSAT Emergency Beacon MT400 Series EPIRB Technical Service Manual Order Part Number Drawing Number Issue Status Date Change History Standard Communications Pty Ltd 6 Frank St Gladesville NSW 2111 Australia ABN 93 000 346 814 42772 5 doc 310433 42772 5 Released 04 FEB 2009 5649 This document and the information contained herein is the property of Standard Communications Pty Ltd It may not be copied used or disclosed in whole or in part except with prior permission of Standard Communications Pty Ltd It is supplied without liability for errors or omissions f Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 1 APPLICABILITY This document applies to the following models e MT400 manually activated EPIRB LiSO gt batteries e MT401 manually amp water activated EPIRB LiSO batteries e MT403 manually amp water activated EPIRB LiMnO batteries e MT403G manually amp water activated EPIRB integral GPS LiMnO batteries e MT401FF float free EPIRB LiSO gt batteries e MT403FF float free EPIRB LiMnO gt batteries e MTA403FG float free EPIRB integral GPS LiMnO batteries 2 SCOPE Service Department level maintenance is outlined within this document A suitable skill level is assumed as 1s access to common electronic and mechanical tools The scope of this document 1s li
3. 5 Doc Page 9 of 28 Document 42772 Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Notes Action Fully seat the new o ring in the groove A blunt instrument may be of assistance in this matter Whichever tool is used ensure that it does not damage the face of the o ring seal 3 There is only one correct orientation with which the cap and lower chassis will correctly mate Ensure that the guides provided around the lip of the lower chassis mate with the corresponding ridges provided on the cap 2 on one long side one on the other 4 When mating the cap and lower chassis together ensure that the 2 tongues provided on the lower edge of the PCB module engage centrally within the respective guides provided on the top face of the battery pack Failure to do so will result in the PCB unacceptably flexing when the cap and lower chassis are assembled together A PCB so flexed should be i 9 Tighten all 4 screws securing the cap to the chassis evenly before finally Commercial in Confidence 42772 5 Doc Page 10 of 28 Document 42772 Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Notes Action torquing each screw to 50cNm 5 3 4 Cap Disassembly Assembly This operation is carried out when The external antenna and or seal need to be replaced It is necessary to remove the ele
4. Department Issue Date 04 02 2009 Nature of service inspection Replacement Internal Repair External Repair Produce Beacon Record Transmission Test and Report Packing for Return to Customer This operation must be carried out May be required depending on circumstances refer to test criteria Not required Table 5 1 5 3 Servicing Operations 5 3 1 Inspection This operation is carried out to determine if the beacon has suffered from physical or environmental abuse that will require rectification prior to its return into service Correct electrical operation of the EPIRB is assessed Step Action 1 Carry out the inspections as outlined with the Emergency Beacon Inspection Proforma Drawing No 42341 2 Complete the form noting all failures 5 3 2 External Switch Mechanism This operation is carried out when Access to the leak seal screw is required The switch mechanism or switch cover needs to be replaced DISASSEMBLY For disassembly each step is to be completed in numerical order as follows Step Action 1 Move the beacon activation switch to the ON position Note IMMEDIATELY move onto and complete the next step 2 Remove the screw then the slider track completely from the beacon Commercial in Confidence 42772 5 Doc Page 6 of 28 Document 42772 Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Step Action Assembly
5. Oo OO 015767 MT400ant MT400 series antenna service kit kit services 1 o oo o o 08 015774 MTA00bat MT400 series battery service kit c w TT lower chassis 019395 MT40 bat MISI cones DAEN SENICE KIEG kit services 1 e o lower chassis 018451 MT403bat eae eves pellet SERIES kit services 1 e o o lower chassis MT400exPCB MT400 Exchange Circuit Module o MT401exPCB MT401 Exchange Circuit Module o MT403exPCB MT403 Exchange Circuit Module o o MT403GexPC2 MT403G Exchange Circuit Module o o 015766 MT401FFblt HRU bolt c w SS nuts kit services 1 o o 002106 74A4G16PEM Screws cap retention single o o o o Oo OO OO 013654 74A6G25PEM Screws battery retention single o oo o o Oo OO OO 014011 74A4G10CEM Screws switch ext switch assy single e o o o o 009768 7442G10PEM Screws leak test hole singe e e o o o 015173 61A0504 FF Adapter Plate only single o o 013366 97MT400WND MT400 lower chassis c w lanyard single o 014126 97MT401WND MT401 lower chassis c w lanyard single o o o oO OO 013333 280018 Lanyard Retention heat shrink tubing mult of 75mm o o o o o oO OO 014289 61A0399 MT400 401 Cap only with reflective tape single o o Oo e 017904 61A0694 MT403G Cap only with reflective tape single o o 013337 400563 Security Label single o o o o o oO OO 013739 46A0441 Ballast Weight single o 8 Table 7 3 Schedule of Misc Replacement Components by EPIRB model These items not presently availa
6. Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Step Action 2 Firmly grasp the cap in one hand not by the antenna and with the other hand the lower chassis to fully separate The fit is reasonably tight and it may sometimes be necessary to rock the two components in respect to each other to initiate the separation process In extreme cases apply air pressure to the leak test hole to separate the cap from the lower chassis For water activation models the water sensor interface on the circuit board may momentarily touch the metallic paint on the lower chassis during withdrawal causing a beacon self test operation to occur WARNING Water Activated Models If the cap and lower chassis are left only partially separated sensor interface contact with the lower chassis may cause the beacon to activate after 50s 3 Disconnect the batteries fly lead from the PCB by first squeezing the latch release lever on the connector then withdrawing the connector housing vertically away from the printed circuit board Assembly Assembly can be carried out by following the disassembly operations in reverse sequence also noting Notes Action 1 Inspect all components for damage and replace as necessary 2 Itis always necessary to replace the o ring seal located in the groove around the cap with a new one prior to re assembly of the chassis Commercial in Confidence 42772
7. cell pairs ballast and a circuit board This battery pack assembly is for use ONLY on MT403 based beacons Under no circumstances attempt to fit this pack to MT400 401 beacons For the MT400 401 types only verify that the base ballast weight loose is present below where the battery will be fitted Note This ballast weight must NOT be fitted to MT403 based units Note MT400 401 series only Insert a new battery pack orientated as shown in the figure below MT400 401 series 42772 5 Doc Commercial in Confidence Page 15 of 28 Document 42772 5 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Step Action single rib on chassis flying lead exit side MT403 series iL single rib on chassis flying lead exit side double rib 5 Apply firm pressure on the pack to seat it squarely and fully with the base of the EPIRB 6 Use the two 2 Philips screws previously removed to retain the battery pack in place Tighten both screws evenly but firmly before torquing both screws tight to 85cNm 7 Fully discharge the old battery pack and dispose of it in accordance with local regulations 8 Note down the expiry date month and year marked on the top face of the newly installed battery pack Note Depending on model and or build date of the EPIRB this information is either ink stamped directly onto the battery pack assembly housing or provided as a
8. sticker You will need this later when marking the battery expiry on the exterior of the beacon Commercial in Confidence 42772 5 Doc Page 16 of 28 Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Step Action Battery expiry date ink stamping Battery expiry date sticker lt 5 3 6 Replacement of Desiccant Sachet The desiccant sachet must be replaced whenever the beacon has been opened if the integrity of the case has been compromised All steps are to be completed in numerical order as follows Step Action 1 Remove the existing desiccant sachet from the PCB exercising care not to tear it messy Carefully remove any remnants of the double sided tape that had previously retained the sachet in place WARNING The sachet s eventual capacity to absorb moisture within the beacon is compromised if prior to fitment it is exposed to open air for any longer than a few minutes Remove the desiccant sachet from the sealed bag in which it was provided 3 From the rear on the sachet carefully remove the cover strip from the double sided adhesive strip provided 4 Atthe location shown firmly press the desiccant against the metal screening can ensuring it makes good contact and is securely retained Commercial in Confidence 42772 5 Doc Page 17 of 28 Document 42772 Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Release
9. the hole in the triangular retention plate 4 Tighten the 3 screws that hold the retention plate in place to a torque of o0cNm 9 The o ring fitted externally beneath the base of the antenna must be replaced with a new one 6 Ensure that the spring washer is in place beneath the antenna retention nut before tightening to 95cNm using a 7mm socket driver 7 During reassembly of GPS equipped models carefully align the Helix Commercial in Confidence 42772 5 Doc Page 12 of 28 f Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Notes Action antenna protruding from the leading edge of the module with the corresponding cavity provided in the cap 5 3 9 Battery Pack Replacement The EPIRB battery should be replaced when any of the following is evident or has occurred The Battery has reached or exceeded it expiry date or would otherwise reach its expiry in the near term The beacon has been activated or is suspected of having been activated and or The battery pack has failed or is considered suspect Two battery pack configurations containing cells of different chemistries are used within this range of EPIRB they are not interchangeable between model types however The preferred method of replacement is through use of the applicable battery service kit these are a complete assembly including battery pack lower chassis ballast and misc i
10. to be completed in numerical order as follows Commercial in Confidence 42772 5 Doc Page 22 of 28 f Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Step Action 1 Using a portable beacon tester or equivalent verify that the self test transmission and its content are as expected and details correspond with the external labelling on the beacon and the beacon record produced by the Programming Kit 5 3 11 2 Verify the presence and correct operation of the 121 5MHz homing signal and strobe 3 For water activated models and with the beacon removed from it s mounting bracket momentarily place a load of approximately 1MQ across the water activation contacts Verify that this initiates a self test operation 4 Repeat as for 3 above but with the beacon returned to its mounting bracket Verify that a self test does NOT occur 5 For GPS equipped models take the EPIRB outdoors into a clear open space with good sky visibility Perform a single GPS self test according to the instructions given within the user instruction manual 6 Complete an Emergency Beacon Inspection Proforma 5 3 13 Packing for Return to Customer All steps are to be completed in numerical order as follows Notes Description 1 Water activated models should be returned to the customer within the sealable plastic bag included as part the MT400 series battery service kit if b
11. 1 MT403 manual release mounting bracket these brackets are identical Note that float free EPIRB models will need to have their black base plate temporarily removed to be compatible with these mounting brackets removal and replacement is the same as when programming these types 3 Alternatively instead of defeating the water activation circuitry testing could be completed within an RF screened room Commercial in Confidence 42772 5 Doc Page 18 of 28 Document 42772 5 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 All steps are to be completed in numerical order as follows and assume that a MT400DPK is available Step Action 1 Using the dealer leak test fixture remove activation cover slide switch and sealing screw then apply dry air at a pressure of 1 0 bar 0 1 bar to the leak test hole For operation of the Dealer Leak Test Kit operation refer to the included instructions Part 310463 2 WARNING if NOT using Dealer Leak Test Kit It is necessary that the water activation feature of the UUT first be defeated for all models so equipped prior to immersion Refer to beginning of this section for further advice Completely submerse the UUT in fresh water and allow for any externally trapped air to surface 3 Observe for a minimum period of 30s and verify that no air bubbles emanate from the UUT 4 Completely remove the UUT from the wa
12. FF battery amp EPIRB service kit MT403G FG battery amp EPIRB service kit Table 7 1 Service and Conversion Kits Name Description Mounting bracket common base MT400 mounting bracket collar MT401 mounting bracket collar c w magnets for defeat mechanism Replacement Float Free Housing cover only assembly use with existing base Replacement Float Free Housing base only assembly use with existing cover Placard 400 401 403 403G Placard 401FF 403FF 403FG Instruction manual 400 401 Instruction manual 401FF Instruction Manual MT403 403G Instruction Manual MT403FF FG NOAA 406MHz Registration Label for beacon chassis USA models only Supply Quantity kit services 1 kit services 1 kit services 1 kit services 1 kit services 1 kit services 1 Supply Quantity single single single single single single single single single single single single Table 7 2 User Serviceable Items Specify if Orange or Yellow latch type 42772 5 Doc Commercial in Confidence 9 MT401FF e MT403FF e MT403FG Page 26 of 28 Document 42772 Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 ce Supply Product Sales Order Name Description Quantity S No Code I 015770 MT400extsw MT400 external switch service kit kit services 1 o 015768 MT401extsw MT401 3 external switch service kit kit services 1 o o o o
13. at Free C Float Free 5 3 10 Ext Labelling Replacement Update New external labelling will need to generated If the beacon message programming has changed The beacons PCB has been exchanged Damaged or weathered labels require replacement New batteries have been fitted and the expiry date needs to be updated to reflect this The following specialist items are required to complete this operation Dealer Programming kit P N MT400DPK brother P touch 2420 PC or equivalent laminated label printer and laminated label stock as applicable to the labels printed Follow the operating instructions contained within the kit NOTE for USA only e fa new chassis is being used it is necessary to apply a NOAA registration label P N 400732 over the heat shrink retaining the lanyard beacon front activation instruction side Verify FCC ID applicable to model is present on the side of the chassis under the area APPROVED BY COSPAS SARSAT If the FCC ID is not present use the laminated label printer to produce a label of no less than 10pt character height with the FCC ID details Apply firmly to the rear of the beacon on the unused area between WARNING and manufacturer details 5 3 11 Produce Beacon Record A Dealer Programming kit P N MT400DPK 1s required for this operation refer Table 7 4 Follow the operating instructions contained within the kit 5 3 12 Transmission Test and Report All steps are
14. ble PCB Issue and firmware revision constraints apply Commercial in Confidence 42772 5 Doc Page 27 of 28 Document 42772 Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Supply Product Sales Order Name Description Quantity No Code 014484 MT400DPK Dealer Programming Kit MT400 series c w software 019160 MI400DIK MT400 Dealer Leak Test Kit Table 7 4 Test and Programming Tools Commercial in Confidence 42772 5 Doc Page 28 of 28
15. ce operations contained here in Access to a range of service tools is assumed however please note some service operations also require access to specialised tools refer Table 7 4 A dry pressurised air source is required for leak testing 5 1 1 Model Variants Please be aware the pictorial representations shown in a particular service operation step may not always precisely depict all model variants or build revisions In situations where this detail discrepancy is important to the actions being described it shall be addressed by a note alternate picture or both 5 2 Repair Matrix The sequence of operations for each service type 1s given within Table 5 1 Multiple service types may be combined provided the sequence of operations 1s maintained Nature of service Internal Repair External Repair Replacement c o o eo e o e Battery 9 3 1 Inspection e e e e 9 912 External Switch Mechanism X X X e Dio Chassis Disassembly Assembly X 9 e X 5 3 4 Cap Disassembly Assembly X X O X 0 3 0 Battery Pack Replacement X e O 5 3 6 Replacement of Desiccant X e X 9 9 9 Chassis Disassembly Assembly X e e X D050 Leak Test O e e e 5 3 0 security Seal Replacement oO 9 e O 9 3 9 Reprogramming User Information X O X X 5 3 10 Ext Labelling Replacement Update O e O O Commercial in Confidence 42772 5 Doc Page 5 of 28 f Document 42772 GME Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering
16. ctronic module from the cap Access to the internal switch assembly including the sealing membrane is required Disassembly For disassembly each step is to be completed in numerical order as follows Step Action 1 Use a mm hex driver to undo the antenna retention nut Remove the nut and spring washer 2 Separate the antenna from the cap Discard the o ring seal that is present at the interface between the two CAUTION This equipment contains static sensitive componentry Handling precautions required Carefully withdraw the PCB from the cap and place it on an antistatic surface 4 Undo all three screws from the plate which retains the internal switch mechanism Commercial in Confidence 42772 5 Doc Page 11 of 28 Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Step Action 5 Remove the retention plate sealing gasket and plastic plunger from the cap Discard the sealing gasket Antenna o ring seal RN e i j Ooch sealing gasket Assembly Assembly can be carried out by following the disassembly operations in reverse sequence also noting Notes Action 1 Inspect all components for damage and replace as necessary 2 Where the switch mechanism has been disassembled it is necessary to fit a new sealing gasket 3 The sealing gasket is installed facing such that the round button protrudes through
17. d Engineering Department Issue Date 04 02 2009 Step Action Sachet location 9 IMMEDIATELY reseal the EPIRB 5 3 3 and Leak test 5 3 7 including insertion of the sealing screw 5 3 7 Leak Test It is vitally important that the integrity of all environmental seals remains in tact This test is performed where e The EPIRB chassis has been opened for access or repair purposes or A beacon s continued performance in this respect is to be verified prior to placing it back into service WARNING All water activated models such as MT401 and MT403 series including float free variants will automatically activate and transmit a distress message if placed in water Please refer to the necessary precautions detailed below It will not normally be possible to complete this test within 60 seconds of first UUT immersion and thereby on water activated models reliably avoid the transmission of a false distress alert In normal use the manual release and float free housings for these models contain magnet s which interact with beacon circuitry to disable water activation when stowed This feature must be mimicked during the leak test operation Suggest approaches in order of decreasing preference are 1 Use a leak test fixture such as that provided within the Dealer Leak Test Kit P N MT400DTK refer to refer Table 7 4 which is equipped with an appropriately positioned defeat magnet 2 Test the EPIRB in a spare MT40
18. e users installation Instructions for replacement of the HRU and Bolt are contained within the Float Free Housing Refurbishment Kit It is generally possible to carry out this service in situ without removing the housing from the structure to which it is mounted Servicing does not require any particular skills or training and can be completed by the owner within 5 minutes The Refurbishment Kit and other replacement items are identified within the Schedule of Items for Service amp Repair 5 5 Float Free Product Conversion MT401 403 403G YELLOW beacons sold with a manual release bracket can be easily adapted to fully automatic float free operation The Float Free MT401 Conversion Kit contains all the necessary items and full instructions for this operation NOTE Provision is made within the COSPAS SARSAT protocols to include beacon activation type Especially where the owner s vessel is under survey it is advisable to reprogram and relabel the EPIRB accordingly ATTENTION MT400 l ORANGE beacons CANNOT be converted for automatic float free operation as they are not equipped with a water activation sensor NEVER attempt to fit a MT400 into a float free housing During an emergency it may automatically release and be lost without activating NOTE A very limited number of early MT401 beacons do not possess the keyways necessary to mate with the FF Adapter Plate To adapt these models for float free operation it is necessary t
19. eal DO NOT use cleaning products that may attack the plastics 2 Carefully place the replacement seal ensuring that the two tabs on the switch mechanism fall within the cut out slot 3 Press down on the seal to ensure good and complete contact with the beacon 4 Inspect the seal if it has torn during installation a new seal must be placed 5 3 9 Reprogramming User Information Where the printed circuit board has been replaced it is necessary to re enter user preferences and requirements relating to the selected C S Protocol A Dealer Programming kit P N MT400DPK is required for this operation refer Table 7 4 NOTE The serial number S N reported by the programming software directly relates to the S N of the PCB By changing the PCB the EPIRB S N has also changed If the customer wishes to use the Serial User Protocol with the Manufacturer Serial Number and TAC then the beacon fitted with a replacement PCB must be re registered with the applicable authority Commercial in Confidence 42772 5 Doc Page 21 of 28 n Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 MESSAGE INFORMATION This number is uniquely serial user protocol m determined by the P telea Manufacturer Serial Humber Hational Authority Issued Mo EPIRB TAC Number National Use Field 1 National Use Field 2 Beacon Deployment Type f Hon Fla
20. eing returned out of bracket Where this bag is not available another similar sealable bag should be sourced 2 The MT400 amp MT401 series EPIRB contains lithium battery cells and are classified as Miscellaneous Hazardous Cargo Class 9 for transport purposes The nature of the goods must be declared to the organisation responsible for transport freighting do not send these EPIRBS through the normal postal service 5 4 Float Free Housing Service The Float free housing shipped with some MT401 based EPIRB is expected to remain installed upon the vessel and not usually returned for routine service other than repair Routine service is generally limited to inspection for physical deterioration or damage and may involve the replacement of the Hydrostatic Release Unit HRU and bolt If the expiry date of the installed HRU has lapsed then a Float Free Housing Service will need to be performed This date should be visible on both the housing cover and the HRU itself and both instances should be verified Typically legislation requires that the HRU be replaced within two 2 years of entering service not from the actual date of HRU manufacture It Commercial in Confidence 42772 5 Doc Page 23 of 28 Document 42772 Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 may be necessary to verify this period with local or other relevant Authorities that have jurisdiction over th
21. ment is given in Table 3 1 Rev Date Rev ECO General Description of Change 17 Aug 2005 A Create Document for initial comment review 29 Aug 2005 B Further develop detail 09 Sep 2005 C Preliminary Issued for Comment 19 OCT 2005 1 4669 Released for information 29 JUN 2006 2 4827 Minor amendments full release 14 AUG 2006 3 4827 Apply to GPS models 3 Add GPS equipped module assembly note Correct typographical error 09 JAN 2008 4 9338 Amend to include new model types Add note on leak testing Q2 FEB 2009 5 5649 Amended to include replacement battery chassis assemblies amp reference to leak test fixture Table 3 1 Commercial in Confidence 42772 5 Doc Page 3 of 28 f Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 4 ASSOCIATED DOCUMENTS Reference to the additional material identified within Table 4 1 and Table 4 2 may be required to complete some of the operations detailed within this manual Furthermore from time to time Technical Service Bulletins TSBs may also be released These bulletins contain information which may be important to the continued service of specific beacons and the instructions contained therein must be followed It is possible to regularly verify the Issue status and download as necessary new document releases including TSBs via the support area on the company s website Always work with the latest versions of thi
22. mited to servicing and repair as follows Inspection and performance check e Battery replacement typically due to use or life expiry Replacement of physical piece parts which may have been damaged or has deteriorated to a point of no longer being serviceable and or Exchange of a printed circuit card assembly that has failed in a manner not covered by the product warranty i e a non electrical failure due to leakage or physical damage only NOTE1 Repair of the printed circuit card assembly is not possible at the distributor level replacement of components is likely to affect module calibration Specialist fixtures and facilities only available at the factory are required to perform a module alignment after any repair operation Additional servicing requirements may be imposed by other Organisations and Authorities on particular users and installations e g IMO Circ 1039 Such requirements are outside the scope of this document and it 1s the responsibility of the Agent carrying out the inspection and or service to determine which if any may apply These requirements where applicable are always in addition to and do not replace any of the requirements specified within this document Commercial in Confidence 42772 5 Doc Page 2 of 28 f Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 3 DOCUMENT REVISION HISTORY The change history of this docu
23. o carefully remove the two 2 corresponding ridges on the FF Adapter Plate This may be successfully carried out using a scalpel or small side cutters Under no circumstances attempt to add keyways to the yellow EPIRB housing Commercial in Confidence 42772 5 Doc Page 24 of 28 f Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 6 EXPLODED VIEW OF CONSTRUCTION 6 1 MT400 401 403 IN z lt V V gt mM Note MT400 401 battery pack shown Not present on MT403 model types Commercial in Confidence 42772 5 Doc Page 25 of 28 STANDARD COMMUNICATIONS PTY LTD Engineering Department f Product No 015773 015772 019391 019392 019393 019394 Product No 013357 013358 014617 015466 015467 014135 015442 014610 015472 018407 017796 016593 Document Revision Status Issue Date 42772 5 Released 04 02 2009 SCHEDULE OF ITEMS FOR SERVICE amp REPAIR Sales Orde r Code MTA401FFsvc MT401con MT400svc MT401svc MT403svc MT403Gsve Sales Order Code 61A0355 61A0356 97MT401MTG 97CVR401FF 97BSE401FF 310209 310336 310221 310337 310424 310406 400732 Name Description Float Free housing service kit Float Free MT401 conversion kit MT400 battery and EPIRB service kit MT401 FF battery amp EPIRB service kit MT403
24. or of the beacon Note Depending on model and or build date of the EPIRB this information is either ink stamped directly onto the battery pack assembly housing or provided as a sticker Battery expiry date ink stamping Battery expiry date sticker a 3 Fully discharge the old battery pack and dispose of it in accordance with local regulations METHOD 2 Alternate Two different battery types exist one for the MT400 MT401 orange pack and another for the MT403 yellow pack refer to Table 7 3 Schedule of Misc Replacement Components by EPIRB for ordering details Ensure that the replacement is of an identical type All steps are to be completed in numerical order as follows Commercial in Confidence 42772 5 Doc Page 14 of 28 Document 42772 Revision 5 STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Step 1 Action Using a Philips driver Size No 2 undo and remove the two screws which retain the BATTERY PACK in the base of the EPIRB 2 Remove the fresh battery pack from the plastic shipping bag Retain this 4 bag for later use WARNING Is imperative that the correct battery pack be fitted to the model under service 97MT400bat is an orange battery pack comprised of 2 large D cells and is suitable for MT400 and MT401 based beacons 97MT403bat is a yellow battery pack assembly that is comprised of housing 5 battery
25. s and other documentation The company s home page web address 1s Wwww gme net au As information access is limited to approved organisations distributors and dealers it is first necessary to apply for an account login Such applications can be made online from the SUPPORT page Item Part Drawing No Title No 1 as PDF 42341 Emergency Beacon Inspection Proforma 2 as PDF Vei MT400 series Material Safety Data Sheet MSDS 3 310345 42773 MT401 Float Free HRU Replacement Instruction Leaflet 4 310346 42774 MT401 Float Free Conversion Instruction Leaflet 9 310218 42155 MT400 series Dealer Programming kit Instruction Leaflet 6 310463 44669 Dealer Leak Test Kit Instructions Table 4 1 Internal Documents Item Ref Identification Title 1 T2 6 01 MSC Circ 1039 Guidelines for Shore based Maintenance of Satellite or as amended EPIRBs Table 4 2 External Documents Commercial in Confidence 42772 5 Doc Page 4 of 28 f Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 9 PRODUCT MAINTENANCE amp SERVICE 5 1 Introduction A number of service actions are identified within this manual more than one may be applicable at any beacon service Please familiarise yourself with all available service actions to ensure that a complete service is carried out Only manufacturer authorised spares and components are approved for use in carrying out the servi
26. tems Alternatively per the second method an individual battery pack can be sourced and fitted in place of the original NOTE The yellow battery pack P N 97MT403BAT provided within the MT403BAT Service Kit or as a separate item is suitable for MT403 based models only Due to electrical and mechanical incompatibility any attempt to fit this item into a MT400 or MT401 will result in diminished operational performance and probable physical damage to that EPIRBs circuit board METHOD 1 Preferred Separate kits exist for the MT400 MT401 and MT403 EPIRB refer to Table 7 3 for ordering details Step Action 1 Verify the model type shown on the original chassis Only the first five 5 characters are significant for the purposes of determining which service kit type is to be used i e MT400 MT401 or MT403 MEME i x This example is MT403 Commercial in Confidence 42772 5 Doc Page 13 of 28 Document 42772 5 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Step Action WARNING Is imperative that the correct battery service kit be used e MT400BAT is for use only with MT400 e MT401BAT is for use only with MT401 e MT403BAT is for use only with MT403 2 Note down the expiry date month and year marked on the top face of the replacement battery pack You will need this later when marking the battery expiry on the exteri
27. ter and using compressed air blow clear any water in proximity to the leak test hole Commercial in Confidence 42772 5 Doc Page 19 of 28 Revision STANDARD COMMUNICATIONS PTY LTD Status Engineering Department Issue Date Document 42772 5 Released 04 02 2009 Step Action Use only a neutral cure silicon sealant Apply sufficient but not excessive silicon sealer into the leak test hole to promote a good seal Immediately insert then tighten the test hole sealing screw to 30cNm torque before the sealant begins to cure Fully dry the exterior of the UUT using an absorbent cloth and or air gun as required e Re install slide switch and activation cover 5 3 8 Security Seal Replacement A failed or torn Security Seal may lead the owner to question the operational status of the EPIRB Some repair operations result in destruction of the original seal thereby necessitating it replacement Commercial in Confidence 42772 5 Doc Page 20 of 28 Document 42772 Revision STANDARD COMMUNICATIONS PTY LTD Status Released Engineering Department Issue Date 04 02 2009 Where an EPIRB is returned for assessment and it seal is intact but in deteriorated condition it is recommended that a replacement seal be provided to extend its life through to the next inspection All steps are to be completed in numerical order as follows Step Action 1 Clear away all remnants of the previous s
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