December 17, 2007

Procedure of exchanging the upper panel of JQE-103

This instruction manual describes procedure of exchanging the upper panel of JQE-103.

Disassemble and re-assemble the EPIRB in accordance with the order of item number on the following
table referring to the photos.

No. Contents of work Photo No. & Drawing No.

1 Disassemble the upper panel Photo No. 1∼6
2 Remove the bracket Drawing No.1&2, Photo No.7∼13
3 Exchange the upper panel Photo No. 14∼15
4 Re-assemble Photo No. 16∼27
5 Test after re-assembly Drawing No.3
6 Water tightness test Photo No. 28∼29
7 Operation test
8 Stick a label on the cover Drawing No.4

List of supplied items

No. Parts name Parts number Q’ty Remark

1 Upper panel (with parts assembled) 135906G01 1 For replacement
To use between
2 O-ring (large) 135708H01 1 bottom case and
upper panel
To apply on the
3 Silicone grease 1 O-ring(large)
4 Label (to show completion of repair) 14B382H02 1 To stick on the cover
5 O-ring (small) J2000058 3 To use for 3 screws
6 Instruction handbook 1 This manual

Caution

1. Never use solvents, such as a screw lock agent, alkali detergent, weak alkali detergent, neutral
detergent, IPA, alcohol, and thinner.

2. In order not to cause the erroneous transmission, perform this replacement work on the insulated
working table, and do not put upper panel assembly on a place which is easy to cause a short circuit
before pulling out the power supply connector on the upper panel assembly.

3. In order to prevent destroying a circuit component by static electricity during work, implement the
measure against static electricity removal of a human body, such as taking a ground.

1
1. Disassemble the upper panel

Photo 1. Remove the antenna Photo 2. Unfasten the three screws on the
bottom case using torque wrench.

Photo 3. Remove the upper panel assembly Photo 4. Pull out the power supply connector,
from the bottom case calmly. and remove the battery by unfastening
the screw knob on the bottom.

Photo 5. Remove the fixing tape (black) Photo 6. Pull out the connector on the harness
on the harness cable (white). cable (white) from the PCA-BEACON.

2
2. Remove the bracket

Screws on the PCA-BEACON (2 screws) and on the XENON ASSY (4 screws) should be unfastening before
unfastening the screws which fasten the upper panel and the bracket.

Since the screws on PCA

(PCA-BEACON and XENON
ASSY) are obstructive and
you cannot unfasten the
screws, which fasten the
Screw Screw upper panel and the bracket
(red arrow portion), please XENON ASSY
unfasten the screws on the Unfastening all
PCA (blue arrow portion) first. 4 screws on the
XENON ASSY
XENON ASSY in order to pull
out the antenna
PCA-BEACON connector.
Antenna connector
Bracket
Drawing 1. Position of screws for unfastening Drawing 2. Position of screws on the XENON
ASSY for unfastening

Since the screw lock is applied to the attachment screw of PCA-XENON and PCA-BEACON, when you loosen
those screws, be careful not to let a wrench slide. Never use a solvent at that time.

Photo 7. Unfasten 2 screws on the XENON Photo 8. Unfasten 2 screws on the

ASSY PCA-BEACON

Photo 9. Unfasten a screw which fasten the Photo 10. Unfasten a screw which fasten the
upper panel and the bracket (one of upper panel and the bracket (the other
PCA-BEACON side) one of PCA-BEACON side)
3
 Photo 11. Unfasten 2 screws which fasten the upper Photo 12. Unfasten 2 screws on the XENON ASSY
panel and the bracket (XENON ASSY side) (rest of 2 screws out of 4)

Photo 13. Pull out the connector of high-frequency cable.

Draw out the connector right-angled and do not apply power to the receptacle.

3. Exchange the upper panel

Photo 14. Disassembled EPIRB Photo 15. Prepare the new upper panel (with parts
assembled) for exchange

4
4. Re-assemble

Use torque wrench when you fix the PCA-BEACON and XENON ASSY to the bracket by M3mm SUS
screws. The tightening torque shall be 63.7cN･m (6.5 kgf-cm).

The tightening torque shall be 42.1cN･m (4.3 kgf-cm) when you fix the bracket to the upper panel by M3mm
SUS screws using torque wrench.

Photo 16. Connect the antenna cable connector to the antenna Photo 17. Fix the bracket to the upper panel by screws using
connector receptacle on the PCA-BEACON. Insert torque wrench with the tightening torque of 42.1
the antenna connector at right angles to the
connector receptacle.
cN･m (4.3 kgf-cm).

Photo 18. Fix the XENON ASSY to the bracket by Photo 19. Insert the connector on the harness cable (white)
screws using torque wrench with the tightening to the receptacle on the PCA-BEACON.
torque of 63.7cN･m(6.5 kgf-cm).
At that time, be careful to do not hook the
xenon lamp to the upper panel.

Photo 20. Stick the fixing tape (black) on the harness Photo 21. Insert the set-pin on the bottom of bracket to the
cable (white) to fix the herness cable again. hole on the battery. Then, fix the battery by
fastening the screw knob on the bottom.
5
Photo 22. Connect the power supply cable to the Photo 23. Put the O-ring (large) and grease into a new bag, and rubs
connector on the PCA-BEACON. with fingers from over the bag so that the O-ring is well
covered by grease. At that time, be careful so that dust
does not adhere to O-ring.

Photo 24. Match the top part of triangular O-ring (large) Photo 25. Please check carefully that any dust has not
with the top part of a bottom case. adhered to the O-ring. (Even a hair that
adhered on the O-ring would cause a leakage,
so please check carefully.)

Photo 26. Exchange the O-ring (small) on the screw. Photo 27. Put the new upper panel assembly into the
Tweezer may be used when removing old bottom case. Match the ▼mark on the upper
O-ring, however, be sure to insert the new panel and ▲mark on the bottom case when
O-ring into the screw by hand in order to do insert.
not damage the O-ring. Use a torque wrench to tighten the three screws.
Caution: 1. Do not damage the O-ring. The tightening torque shall be 68.6cN-m
2. Check that any dust has not adhered to the (7.0kgf-cm).
O-ring.
Lastly, install the antenna on the upper panel.

6
5. Test after re-assembly

After completion of re-assembly, perform test utilizing the test function as follows.

Turn the selector switch to "TEST" position, and confirm lighting of LED by holding the switch knob by
hand during the test. The selector switch can be turned to “TEST” without releasing the stopper.

Indicator lamp

Orange LED(lights at power ON)

Yellow LED(lights at TEST activation)

Red LED(lights at transmission of 406.028MHz)

Selector switch

Drawing 6. Lamp and LED on the panel

① Yellow LED and orange LED light for 4 seconds when turning selector switch to TEST.

② Then, Red LED and Yellow LED light a moment, and the light is put out immediately.

③ Then, the indicator lamp flashes at 2.6 sec. Interval.

④ The selector switch automatically returns to "READY" position by releasing the hand from the
switch knob.( In this test, permitted distress signal for the test purpose is transmitted only by one burst.
Do not execute the test repeatedly.)

If you confirmed lighting of LED as above ①∼③、the EPIRB is normal. If you find any faulty, please
request repair promptly.

7
6. Water tightness test.

(1) Prepare a plastic container with a capacity of 40-50 liter, and pour warm water (room temperature +30℃∼
35℃) into it.

(2) Clean the body of EPIRB by cotton cloth.

(3) Carefully cover the two conductive switch terminal (water sensor terminal) by vinyl tape as shown below
Photo 28.
This procedure is necessary to avoid erroneous transmission by activation of water sensor.

Before taping Taping

Photo 28. Taping on water sensor terminal

(4) Please put EPIRB into warm water and remove the air bubbles which are attached outside by shaking
EPIRB underwater.

Photo 29. Water tightness test

(5) Sinks the EPIRB so that the upper panel surface shall be set to 10cm or more from the water surface,
and watch 10 minutes or more, and confirm whether there is any leakage of air bubbles from inside
of the EPIRB.

8
 Caution!
Confirm that the indicator lamp does not flash.

If the indicator lamp flashes, it shows that the EPIRB is activating due to insufficient taping. In that
case, take out the EPIRB from the water immediately, remove the tapes, and dry out the body by
cotton cloth.

If the indicator lamp stop flashing within 50 seconds, distress signal is not transmitted. If you
could not stop it in 50 seconds, please take proper action referring instruction manual page 7
“CAUTION BEFORE OPERATION” article (4) “Please take the following measures at once when
you notice the transmission of distress signal other than emergency disaster”.

(6) Judgement of the result of the water tightness test

When there’s no leakage of air bubbles from inside of the EPIRB, then the EPIRB is good.
If there’s leakage of air bubbles, then please perform following procedure.

① Check if there’s any dust between the upper panel assembly and the bottom case, and perform the
water tightness test again.

② If there’s leakage of air bubbles again, request repair to manufacturer.

(7) Caution for performing the test.

① When using warm water, protect your hand with thick latex gloves etc. to avoid from scald.

② Do not use more than 60 degree C of warm water for the test.

9
7. Operation test

Measure the transmitting electric power using GMDSS measuring instrument, EPIRB tester and spectrum
analyzer.

① Remove the stopper pin by a wrench.

② Remove the antenna, and connect the antenna receptacle and measuring instrument by coaxial cable.
(Insert a attenuator between antenna receptacle and measuring instrument if necessary.)

③ Turn the selector switch to ON, measure the transmitting electric power and confirm that its value is within
the standard criteria.

④ Return the selector switch to READY position.

⑤ Remove the coaxial cable, and install the antenna.

⑥ Fix the stopper pin using a torque wrench. The tightening torque shall be 42.1cN･m (4.3 kgf-cm).

8. Stick a label on the cover

Stick the attached label on the cover after re-installing of the EPIRB on the vessel referring to
following Drawing 4.

Stick the attached label (to show completion of repair) on this

position

Drawing 4. Label position

10