(AA) MOTOROLA INC.

SABER" and SYSTEMS SABER"

Handie-Talkie Portable Radios
Universal, Submersible Models

wo

1. INTRODUCTION 2. GENERAL INFORMATION

SABER and SYSTEMS SABER submersible To ensure that the submersible radio is truly a
radio models meet the stringent requirements of watertight unit, special testing, test procedures,
U. S. MIL-STD-810C, Method 512.1, Procedure I, and specialized test equipment are required. The
and MIL-STD-810D, Method 512.2, Procedure I, special testing involves a vacuum check of the
which require the radio to maintain watertight radio and pressure testing (troubleshooting) for
integrity when immersed in three feet of water for water leaks if the vacuum check fails. The
two hours. Radios shipped from the Motorola specialized test equipment is needed to perform
factory have passed the water immersion test and the vacuum check and pressure testing, if
should not be disassembled. If disassembly is required.
necessary, refer to qualified service personnel and NOTE
service shops capable of restoring the watertight When ordering replacement batteries for a
integrity of the radio. submersible radio, either NTN4596 (Ni-Cd, FM
approved, Ultra-High-Capacity) or NTN4538
CAUTION (Ni-Cd, FM approved, Medium-Capacity)
It is recommended that should be ordered.
strongly
maintenance of the submersible radio be
deferred to qualified service personnel and
service shops. This is. of paramount 3. SPECIALIZED TEST EQUIPMENT
importance as irreparable damage to the a. Vacuum Pump Kit, NLN9839
radio can result from service by
unauthorized persons. If disassembly is The vacuum pump kit includes a vacuum
necessary, unauthorized attempts to repair pump with gauge, and a vacuum hose. An
the radio may void any existing warranties adapter with gasket (NTN4264), which must be
or extended performance agreements with ordered separately, connects the vacuum hose to
Motorola. it is also recommended that the radio's baseplate. The vacuum pump kit and
submersibility be checked annually by
qualified service personnel. adapter are also used on Motorola EXPO™
radios.

Submersible models can be identified by the b. Pressure Pump Kit, NTN4265

black escutcheon with white lettering on top of the The pressure pump kit includes a pressure
radio. lf the radio is accidentally dropped in water, pump with gauge, and a pressure hose; the
shake the radio to remove the excess water from pressure pump kit is also used on Motorola EXPO
the speaker grille area before operating; radios. As with the vacuum pump kit above, the
otherwise, the sound may be distorted until the NTN4264 adapter connects the pressure hose to
water has evaporated from this area. Also, the radio's baseplate.
remove the battery and dry the battery contacts c. Miscellaneous Hardware
on the bottom of the radio.
Other items needed for testing the
submersible radio include:
*
Large water container.
¢
Fresh water
* A supply of replacement seals, O-rings, and
gaskets (refer to the exploded view parts lists
in the applicable service manual for Motorola
®, Motoroia, SABER, SYSTEMS SABER, EXPO, SECURENET,
and Handie-Talkie are trademarks of Motorola Inc. part numbers).

Instruction Manual

© 1990 by Motorola Inc., Land Mobile Subscriber Group

8000 W. Sunrise Blvad., Ft. Lauderdale, FL 33322-9934
Printed in U.S.A. 8/90. All Rights Reserved.
68P81107C16-A
 Manual Scan
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[email protected]
4. DISASSEMBLY AND REASSEMBLY a properly sealed, watertight unit. Before starting
If disassembly and reassembly of the radio is the vacuum test:
required, refer to the "DISASSEMBLY/ * Remove the battery and check the battery
REASSEMBLY PROCEDURES" in the applicable contact mounting screws for correct torque.
service manual. * Check the two baseplate slotted-spanner nuts
a. Disassembly for correct torque.
Disassemble the radio according to the ¢
Check the antenna bushing spanner nut for
"DISASSEMBLY" section of the applicable service
correct torque.
manual; refer also to the "SERVICING MAJOR
*
SUBASSEMBLIES" section. Remove the universal connector cover to
b. Reassembly expose the universal connector.
¢
Reassemble the radio according to the If the radio has a belt clip (NTN4741 only),

"REASSEMBLY" section of the applicable check the revision letter stamped on the
service manual; refer also to the "SERVICING underside of the metal bracket. Revision "O"
MAJOR SUBASSEMBLIES" section. Tighten all belt clips may cause leakage and should be
hardware which was loosened or removed per the replaced with a later version belt clip. Alf
Torque Specifications table. DO NOT RE- radios with belt clips should be vacuum tested
ASSEMBLE THE RADIO WITHOUT FIRST with the belt clip attached since the belt clip
PERFORMINGTHE FOLLOWING PRELIMINARY can affect the radios leak rate.
INSPECTION PROCEDURE:
b. Conducting the Test
(1) Remove the main seal O-ring from the control
(1) Attach the vacuum hose to the vacuum pump.
top panel. Check the pump and hose for leaks by
(2) Inspect the seal area around the control top blocking off the open end of the hose and
panel for foreign material that might prevent operating the pump a few times. The actual
the main seal O-ring from sealing properly. reading of the gauge at this point is not
(3) Instail new main seal O-ring; discard the old
Cca important; it is important that the gauge
O-ring. pointer remains steady, indicating no vacuum
leaks in the pump.
(4) Check to ensure that both frame stud seals
are in place and are not damaged in any way. (2) Ensure that a rubber gasket is attached to the
Replace both frame stud seals if any damage hose-to-baseplate adapter. Screw the adapter
or foreign material is visible. into the tapped hole in the baseplate.

(3) Attach the open end of the hose to the

CAUTION
adapter.
Fhe main seal O-ring should not be visible
when. looking at the top side of the radio. if (4) Operate the pump a few times until the gauge
theseal is visible, it is improperly installed. indicates 5 in. Hg; do not pull more than 10 in.
Hg of vacuum on the radio. The gauge should
indicate a leaking-down and should stabilize at
NOTE
When seating the main seal O-ring in the radio some lower value. The leak-down is normal
housing, use hand pressure to press the radio and important; it indicates that the pressure is
into the housing. Make sure that the baseplate equalizing across the port seal membrane.
slotted-spanner nuts are properly aligned NOTE
before tightening them.
Ifthis leak-down phenomenon does not occur,
the port seal is probably missing, damaged, or
5. VACUUM TEST wet. In this manual, refer to the "Baseplate
Elastomer Seal or Vacuum Port Seal"
Refer to the exploded view diagrams and paragraph of the "PRESSURE TEST" section.
parts lists in the applicable service manual.
a. General
Operate the pump again until the gauge
The vacuum test uses a vacuum pump and indicates 5 in. Hg. Some additional leak-down
gauge. The pump creates a vacuum condition will occur. After repeating this action two or
inside the radio, and the gauge monitors the radio three more times, the gauge should stabilize
for a stable vacuum reading; that is, checking for at 5 in. Hg.
(5) Observe the gauge for approximately two (5) Watch for any continuous series of bubbles. loosening the slotted-spanner nuts and 6. Gently remove the ground clip. If the clip
minutes. NOTE removing the center battery contact screw. is bent during removal, replace it.
Some air entrapment may cause the NOTE 7. Remove the power amplifier module
© Ifthe needie falls 2 in. Hg or less (for accumulation of bubbles, especially in the grille Before removing the baseplate, note the
example, from 5 in. Hg to 3 in. Hg), then area, but the bubbles should not be (U202).
location and orientation of the battery latch and
the radio has passed the vacuum test and continuous. 8. Grasping the main circuit board at the
battery latch spring.
is approved for submersibility. No bottom connector end, lift the board and
additional testing will be required. (6) Note all of the seal areas that show signs of carefully slide it out from under the control
(b) Inspect the elastomer seal for damage or
eakage. Pinpoint the problem(s) to one (or top panel.
© Ifthe needle falls more than 2 in. Hg (for
more) of the following areas: foreign material; replace or clean as
example, from 5 in. Hg to less than 3 in. necessary. Remove the old vacuum port seal,
(a) housing and inspect the sealing surfaces of the CAUTION
Hg), then the radio has failed the vacuum When the main circuit board is
(b) baseplate elastomer seal or vacuum port housing and baseplate for damage; replace
test and the radio might leak if seal removed, fragile wireform and ground
submersed. Additional troubleshooting of any faulty items, and install a new vacuum contacts are exposed. Handle gently to
(c) antenna bushing seal or port seal. avoid damage.
the radio will be required; complete this
lightpipe seal
procedure, then go to the "PRESSURE (c) Ensure that the center O-ring portion of the
(d) frequency switch and on/off/volume
TEST" section of this manual. control elastomer seal is fully seated around the (b) The control top panel must now be removed
threaded bushing in the housing. Reassemble from the frame assembly. Remove the two
(6) Remove the vacuum hose and adapter from (e) rf connector
the radio. dual-function switch and actuator the baseplate with the convex surface of the screws that hold the panel to the side of the
(f)
latch spring toward the baseplate. Tighten the radio frame.
assembly
(g) frame stud seals battery contact screws and slotted-spanner (c) Remove the on/off/volume control and
6. PRESSURE TEST nuts to the correct torque.
(h) main seal frequency switch knobs by grasping the tip of
Refer to the exploded view diagrams and (3) Antenna Bushing Seal or Lightpipe Seal each knob with pliers and pulling the knob off
(7) Remove the radio from the water container
parts lists in the applicable service manual. the shaft of the switch. Open the insert by
and dry it thoroughly. Be especially careful to (a) Check the antenna bushing spanner nut for
a. General
dry the area around the main seal to prevent correct torque. If the nut is loose, tighten it to inserting a screwdriver blade into the insert's
Pressure testing the radio is necessary only if contamination of the internal electronics while the correct value and run the pressure test slot, then pull the nsert off the shaft. Remove
the torque washer from the volume control, if
the radio has failed the vacuum test. Do not the unit is open. Also, to keep the area around again. If the nut is not loose, the antenna
perform the pressure test until the vacuum test the port seal dry, make sure that there is no bushing must be replaced. This will require necessary.
has been completed. Pressure testing involves water around the baseplate vacuum port. the removal of the main circuit board from the (d) Remove the detent washer from around the
creating a pressure condition inside the radio, (8) Remove the adapter and pressure hose frame assembly according to the following frequency switch, noting the orientation of the
submersing the radio in water, and observing the added in steps (1) and (2). procedure: washer, relative to the switch, prior to removal.
radio for a stream of bubbles (leak). Since all c. Troubleshooting Leak Areas 1. Referring to the "DISASSEMBLY" section Then, remove the spanner nut from each
areas of the radio are being checked, observe the switch.
Before repairing any leak, read all applicable
in the applicable service manual,
entire unit carefully for the possibility of multiple disassemble the radio until the speaker (e) Noting the location of the lightpipe, which will
leaks before completing this test. area repair paragraphs. This will help to eliminate
bracket assembly is disconnected and be loose, lift the control top panel off the
unnecessary disassembly and reassembly of a removed from the frame assembly. frame.
b. Conducting the Test radio with multiple leaks. Troubleshoot only the
(1) Screw the adapter (with gasket) into the faulty seal areas listed in the "PRESSURE TEST" (f) Remove the antenna bushing spanner nut and
section, and, when multiple leaks exist, in the CAUTION the antenna bushing from the control top
tapped hole in the baseplate. Ensure that all static electricity
(2) Attach one end of the pressure hose to the
order listed. panel. inspect the sealing surfaces on the
safeguards are in place prior to control top panel and bushing; replace faulty
adapter and the other end to the pressure NOTE beginning radio disassembly.
Before reassembling the radio, always install a items as required. Remove and discard the
pump. new main seal O-ring, and new O-rings in the 2. Read the precautions outlined in the old antenna bushing O-ring, and install newcea

(3) Operate the pump until the gauge reads defective area.
"SERVICING MAJOR SUBASSEMBLIES" one.
approximately 1 psig. Some leak-down is section of the service manual before
normal as the pressure equalizes across the (g) Before reassembling the radio, inspect the O-
(1) Housing performing steps 3 through 8, below. rings on the lightpipe, on/off/volume control,
port seal membrane.
lf a leak occurs in any portion of the housing 3. Disconnect the PTT/controls flexible and frequency switch for damage and foreign
CAUTION assembly (monitor, push-to-talk, or RAT switches, circuit from the radio circuit board. material. Also, ensure that the lightpipe and
Pressure any greater than 1 psig may push speaker grille, or universal connector), replace the the antenna bushing's hex head are properly
4. Remove the back shield.
air around the main seal and may damage housing. seated in the control top panel.
the grille area. 5. Remove the two bottom connector screws
(2) Baseplate Elastomer Seal or Vacuum and three power amplifier module (U202) (h) Reassemble the radio in reverse order of
Port Seal screws (one through the PC board, and disassembly, using new frequency switch and
(4) Maintain the pressure at 1 psig and submerse onoff/volume control knobs and inserts.
(a) These seals can, and should, be repaired two through the frame), securing the main
the radio into a water-filled container. without removing the radio chassis from the circuit board.
housing assembly. Remove the baseplate by
(4) Frequency Switch and On/Off/Volume Control (d) Reassemble the radio in reverse order of (c) Remove the antenna before installing a new
(a) Remove the suspect knob by grasping it with disassembly. main seal O-ring. Install the main seal O-ring
pliers and pulling it off the shaft of the switch. (6) Dual-Function Switch and Actuator Assembly by first placing it in the groove on the antenna
Then, grasp the insert with the pliers and pull side of the radio, then by slowly stretching the
(a) Remove the knob assembly by gently O-ring around and over the frequency switch
it off the shaft. If you are working on the
separating the two arms of the switch bracket and on/off/volume control, and finally by
frequency switch, remove the detent washer {located between the switch and the main O-
from around the switch as well, noting the dropping it into the groove on the push-to-talk
ting seal) and pulling the knob up and away switch side of the radio.
orientation of the washer, relative to the from the control top.
switch, prior to removal. If you are working on (d) Inspect again for proper seating of the main
the volume control, remove the torque washer (bo) Remove the O-ring from the knob's shaft and
seal all around the control top panel, and for
as well, if necessary. replace it with a new, prelubricated O-ring.
foreign material. Observe carefully to ensure
NOTE that the main seal O-ring is not pinched
(b) Check the switch's spanner nut for correct The switch bracket should hold the switch
torque. If the nut is loose, tighten it to the between the radio housing and the control top
firmly against the inside of the control top
correct value and rerun the pressure test. If panel. If this is not the case, replace the panel during insertion of the radio chassis into
the nut is not loose, determine if the leak is switch bracket. the housing assembly. Pinched main seal O-
internal (from within the switch) or external rings are one of the most common causes of
(from around the switch) by pressurizing the vacuum test failures.
(c) Before reinserting the knob into the switch
radio to 1 psig, submersing the unit in water,
bracket, ensure that the slot in the switch is
and observing the flow of bubbles.
properly aligned with the blade on the knob's
(c) Following the procedures detailed in "(3) shaft. RELATED PUBLICATIONS AVAILABLE SEPARATELY
Antenna Bushing Seal or Lightpipe Seal,"
(d) Reinsert the knob into the switch bracket; the SABER OPERATING INSTRUCTIONS 68P81065C60
above, disassemble the radio until the control arms of the switch bracket will snap into
|

top panel is removed from the frame SABER II/IIl OPERATING INSTRUCTIONS 68P81065C65
position (approximately 0.2 inches apart).
assembly.
NOTE SYSTEMS SABER OPERATING INSTRUCTIONS 68P81060C10
(d) If the leak is from the internal switch seal, The knob should not be loose in the switch SABER VHF SERVICE MANUAL 68P81043C90
replace the switch; follow the unsoldering and bracket; if the knob is loose, replace the switch
SABER UHF SERVICE MANUAL 68P81043C95
replacement instructions contained in the new bracket.
switch's instruction sheet. If the leak is from SABER SECURENET VHF SERVICE MANUAL 68P81045C70
the external switch seal, replace the switch's
(7) Frame Stud Seals SABER SECURENET MID-BAND SERVICE MANUAL 68P81063C30
O-ring.
(a) Remove the seals by pulling them off the SABER SECURENET UHF SERVICE MANUAL 68P81045C75
(e) Before reassembling the radio, inspect the frame studs. SYSTEMS SABER SECURENET VHF SERVICE MANUAL 68P81067C10
light pipe seal and both switch seals for SYSTEMS SABER SECURENET UHF SERVICE MANUAL 68P81066C95
(b) Inspect sealing areas on the radio housing for
damage and foreign material. Repair or clean
as necessary. foreign material, scratches, and nicks. Clean SABER THEORY/MAINTENANCE MANUAL 68P81044C05
off foreign material as required; replace the
(f) Reassembie the radio in reverse order of housing assembly if it is damaged in any way.
disassembly, using new frequency switch and
on/off/volume control knobs and inserts. (c) Install the new seals, ensuring that they are
fully seated against the radio frame before
(5) RF Connector reassembling the radio.
(a) To replace the rf connector seal, disassemble (8) Main Seal
the radio until the main circuit board is
removed from the frame assembly, following (a) Remove and discard the old main seal O-ring
around the control top panel. Inspect the
the procedures detailed in "(3) Antenna
sealing surfaces on the housing and control
Bushing Seal or Lightpipe Seal," above.
top panel, replacing faulty items and cleaning
(b) While applying light pressure on the rf off any foreign material.
connector, pull and disconnect the rf ground
(b) Inspect the speaker bracket assembly to
clip. If the bubbles in the pressure test come ensure that the two tabs protruding from the
through the rf connector (as opposed to
around the connector), then replace the top of the speaker bracket are properly seated
between the frame and the control top panel.
connector. Lift out the rf connector and replace
An improperly located speaker bracket will
the O-ring. Inspect the rf connector hole in the
distort the housing in the seal area, causing
control top panel for foreign material, and
clean as required. leakage.

(c) Reassemble the rf connector, snapping the rf

ground clip in place while applying pressure to
the connector. Ensure that the ground clip is
fully seated within the groove in the connector.