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Motorola Dp3400 3401 3600 3601 Mototrbo Basic 6866574d29 E Manual
Motorola Dp3400 3401 3600 3601 Mototrbo Basic 6866574d29 E Manual
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Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-19 5.8.3 Specialized Test Equipment This section summarizes the specialized test equipment necessary for testing the integrity of the series radios. To ensure that the radio is truly a watertight unit , special testing, test procedures, and specialized test equipment are required. The special testing involves a vacuum check of the radio and pressure testing (troubleshooting) for water leaks if the vacuum check fails. The specialized test equipment/ instrument (Table 2-2 on page 2-2) is authorized by Motorola and needed to perform the vacuum check and pressure testing, if required. Any equipment/tools/instruments not mentioned in the table must not be used to perform these test. 5.8.4 Vacuum Pump Kit NLN9839 The vacuum pump kit includes a vacuum pump with gauge, and a vacuum hose. A connector fitting (part number 5871134M01) and fitting seal (part number 3271133M01) pump connector, which must be ordered separately, connects the vacuum hose to the radio’s chassis. Figure 5-20. Connector Fitting - Fitting Seal Pump Connector 5.8.5 Pressure Pump Kit NTN4265 The pressure pump kit includes a pressure pump with gauge, and a pressure hose. As with the vacuum pump kit above, the connec tor fitting - fitting seal pair connects the pressure hose to the radio’s chassis. 5.8.6 Miscellaneous Hardware Other items needed for testing the immersibility radio include: • Large water container • Deionized (DI) water • A supply of replacement parts: Main seal O-ri ng, Battery Contact Seal, Breathing Vent Label and Breathing Vent Membrane. (Refer to Section 5.9.1 Display Model Exploded View and Parts List on page 5-27 or Section 5.9.2 Non-Display Model Exploded View and Parts List on page 5-30.) 5.8.7 Vacuum Test The vacuum test uses a vacuum pump and gauge. The pump creates a vacuum condition inside the radio, and the gauge monitors the radio for a stable vacuum reading; that is, checking for a properly sealed, watertight unit. Before starting the vacuum test: • Remove the battery. Fitting Seal (part number 3271133M01) Connector Fitting (part number 5871134M01)
5-20Disassembly/Reassembly Procedures: Ensuring Radio Immersibility • Remove the universal connector dustcover to expose the universal connector. • Remove the breathing vent label and breathing vent membrane. To conduct the vacuum test: 1. Attach antenna firmly to the radio. 2. Attach the vacuum hose to the vacuum pump. Check the pump and hose for leaks by block- ing off the open end of the hose and operating th e pump a few times. The actual reading of the gauge at this point is not important; it is important that the gauge pointer remained steady, indicating no vacuum leaks in the pump. 3. Ensure that the fitting seal is attached to the hose-to-chassis pump connector. Screw the pump connector into the tapped hole in the chassis. 4. Attach the open end of the hose to t he pointed end of the pump connector. 5. Place the radio on a flat surface with the chassis facing upward. 6. Operate the pump until the gauge indicates 6 in . Hg of vacuum on the radio.Observe the gauge for approximately 1 minute. • If the needle falls 0.5 in. Hg or less (one scale interval, for example, from 6 in. Hg to 5.5 in. Hg), then the radio has passed the vacuum test and is approved for immersibility. No additional testing will be required. • If the needle falls more than 0.5 in. Hg (one scale interval, for example, from 6 in. Hg to less than 5.5 in. Hg), then the radio has failed the vacuum test and the radio might leak if immersed. Additional troubleshooting of the radio will be required; comple te this procedure, then go to Section 5.8.8 Pressure Test. 7. Remove the vacuum hose and pump connector from the radio. 5.8.8 Pressure Test Pressure testing the radio is necessary only if th e radio has failed the vacuum test. Do not perform the pressure test until th e vacuum test has been completed. Pressure testing involves creating a positive pressure condition inside the radio, imme rsing the radio in water, and observing the radio for a stream of bubbles (leak). Since all areas of th e radio are being checked, observe the entire unit carefully for the possibility of multiple leaks before completing this test. To conduct the pressure test: 1. Screw the pump connector (with fitting seal) into the tapped hole in the chassis. 2. Attach one end of the pressure hose to the pump connector and the other end to the pressure pump. 3. Attach antenna firmly to the radio. 4. Operate the pump until the gauge reads approximately 1 psig. 5. Maintain the pressure at 1 psig and immerse the radio in to a water-filled container. 6. Watch for any continuous series of bubbles. A stream of bubbles indicates a sign of leakage. CAUTION: Pressure any greater than 1 psig might push air around the main seal. NOTE Some air entrapment may cause the accumulati on of bubbles, especially in the grille area, but the bubbles should not be continuous.
Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-21 7.Note all of the seal areas that show signs of leakage. Pinpoint the problem(s) to one (or more) of the following areas: • Front Housing • Chassis (Main Seal O-ring) • Battery Contact Seal 8. Remove the radio from the water container, and dry the radio thoroughly. Be especially care- ful to dry the area around the main seal to prevent contamination of the internal electronics while the unit is open. 9. Remove the pump connector from the chassis. 10. Radio after performing Pressure Test must undergo baking process in a temperature chamber for constant temperature soaking at 60°C for 1 hour. This is to ensure no moisture is trapped inside the radio and prevent c ontamination of the internal electronics after reassembling the radio. 5.8.9 Troubleshooting Leak Areas Before repairing any leak, first read all of the step s within the applicable section. This will help to eliminate unnecessary disassembly and reassembly of a radio with multiple leaks. Troubleshoot only the faulty seal areas listed in Section 5.8. 8 Pressure Test on page 5-20, and when multiple leaks exist, in the order listed. 5.8.9.1 Front Housing Do one or both of the following: 1. If a leak occurs at the Lens (Display Model s only), Universal Connector, chassis/Housing interface, PTT button area of the housing, repl ace the housing. Refer to Section 5.6 Radio Disassembly – Detailed on page 5-5. a. Remove the housing assembly from the radio. b. Discard the housing assembly and main seal O-ring. c. Install a new main seal O-ring around the chassis assembly according to Section 5.7.2 Chassis Reassembly on page 5-14. d. Install a new housing assembly to the radio. e. Inspect the main seal for proper seating. f. Observe carefully to ensure that the main seal O-ring is not pinched between the housing and the chassis interface. 2. If the leak occurs at the control top area, remove the knobs in order to determine the leak location: a. Conduct the Pressure Test. b. Identify the leak location. CAUTION: Keep the area around the chassis’s vacuum port dry by ensuring that there is no water around it. NOTE Before reassembling the radio, always install a new Main seal O-ring, Battery Contact Seal in the defective area.
5-22Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5.8.9.2 Chassis (Main Seal O-ring) To replace the main seal O-ring: 1. Refer to Section 5.6.1 Front Cover from Chassis Disassembly on page 5-5, remove the chassis assembly from the radio. 2. Refer to Section 5.6.2 Chassis Disassembly on page 5-8, remove the Main Board from chassis. 3. Remove the main seal O-ring. 4. Inspect the seal area around the chassis for fore ign material that might prevent the main seal O-ring from sealing properly. 5. Assemble a new O-ring; discard the old O-ring. 6. For detailed O-ring assembly sequence , refer to clause 2, step i. to step viii. of Section 5.7.2 Chassis Reassembly on page 5-14. 7. Reassemble the chassis assembly followed by in stalling into Front Cover. (Refer to Section 5.7 Radio Reassembly – Detailed on page 5-12). 8. Inspect the main seal O-ring fo r proper seating. Observe carefully to ensure that the main seal O-ring is not pinched betwe en the housing and the chassis. 5.8.9.3 Battery Contact Seal To replace the Battery Contact Seal: 1. Refer to Section 5.6 Radio Disassembly – Detailed on page 5-5 to remove the Battery Con- tact Seal. 2. Remove the Battery Contac t Seal from the Chassis. 3. Inspect the Battery Contact Seal, Chassis and surrounding areas for foreign material that might prevent the Battery Contact Seal from sealing properly. 4. Install a new Battery Contact Seal; discard the old Seal. 5. Replace a new main seal O-ring; discard the old O-ring. 6. Reassemble the chassis assembly followed by in stalling into Front Cover. (Refer to Section 5.7 Radio Reassembly – Detailed on page 5-12). 7. Inspect the main seal O-ring fo r proper seating. Observe carefully to ensure that the main seal O-ring is not pinched betwe en the housing and the chassis. IMPORTANT: Both Breathing Vent Label (3371478L01) and Breathing Vent Membrane (3271570L01) need to be replaced after vacuum test, pressure test or water leakage troubleshooting. NOTEWhen installing the assembled cha ssis to the Front Cover, ensure the O-ring at the top two corners are not dislodged from the chassis groove.
Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-23 5.8.9.4 Breathing Vent Membrane and Breathing Vent Label To replace the Breathing Vent Membrane and Breathing Vent Label: 1. Remove the Breathing Vent Label that covers the Breathing Vent Membrane from the chas- sis. 2. Remove the Breathing Vent Membrane. 3. Ensure that the chassis’s surface (at the Br eathing Vent Label & Breathing Vent Membrane recessed) is clean, no/minimum scratches and free from any adhesive or other foreign mate- rials. 4. Install a new Breathing Vent Membrane, covering the vent port hole, in the small recessed area in the chassis. Ensure that no oily substance come in contact with the seal. 5. Install a new Breathing Vent Label over the Breathing Vent Membrane in the larger recessed area in the chassis. Press down evenly over the label’s surface to ensure good adhesion.
5-24Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5.8.10 Troubleshooting Charts Troubleshooting Flow Chart for Va cuum Test (Sheet 1 of 2) Start 1 . Remove Battery 2 . Remove Universal Connector Dustcover 3 . Remove breathing vent label and membrane 1 . Attach antenna firmly to the radio. 2 . Attach vacuum hose to vacuum pump 3 . Ensure fitting seal is attached to hose-to-chassis pump connector 4 . Screw pump connector into chas- sis’ s tapped hol e 5 . Attach vacuum hose to pu mp con nector 6 . P lace radio on flat surface 7 . Operate pump (gauge = 6 in. Hg) Gauge does not fall bel ow 0 .5 in. Hg NO Y ES Run Pressure Te s t 1 .Repl ace Breath- ing Ve n t labe l and Breathing Ve n t Membrane 2 . Radio approved for immersibil ity Full e quipment for pressure test procedure avail able Y ES NO B End A
Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-25 Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2) StartB 1 Remove pump and connectors from radio 2. Remove antenna 3. Separate front housing kit Examine and reassembl e main O-ring Repl ace front housing kit with new unitReplace main O-ring with new unit Repl ace new chassis kit without PCBs Y ES NO NONONO Changed front housing kitY ESChanged back chassis kitY ESChanged main O-ringExamined main O-ring fitting YES Send radio to Motorola Depot or Motorola Service Center End A
5-26Disassembly/Reassembly Procedures: Ensuring Radio Immersibility Troubleshooting Flow Chart for Pressure Test & Leakage Areas Start 1 . Remove vacuum hose from pump connector 2 . Attach pressure hose to pump connector 1 . Operate pressure pump (pressure = 1 psig) 2 . I mmerse radio into a water- fill ed container Continuous Series of bubbl es Y ES NO Bubbl es from Front Housing Y ES NO Bubbl es from Chassis Y ES NO Bubbl es from Battery Con- tact Sea l Y ES NO Bubbl es from Lens* /U niver- sal Connector/ chassis/ Housing Inter- face/ PTT 1 . Dry the radio 2 . Rep lace Housing , Main Sea l O-Ring, and repeat steps in Troubl eshooting F low Chart for Va c u u m Te s t .YES 1. Remove Knobs NO 1. Dry the radio 2 . Repl ace Battery Contact Seal, Main Seal O-Ring, and repeat steps in Troub leshooting F low Chart for Vacuum Te s t. 1 . Dry the radio 2 . Repl ace Main Seal O-ring, and repeat steps in Troub leshooting F low Chart for Vacuum Te s t. 1 . Dry the radio 2 .Re p lace Bre athing Vent labe l and Breathing Vent Membrane 3 . Radio approved for immersibil ity * Onl y for Disp lay Mode l EndEndEndEndEnd
Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists 5-27 5.9 Radio Exploded Mechanical Views and Parts Lists 5.9.1 Display Model Exploded View and Parts List Figure 5-21. Display Model Exploded View 1 2 3 4 5 6 7 8910 11 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 15
5-28Disassembly/Reassembly Procedures : Radio Exploded Mechanical Views and Parts Lists Table 5-3. Display Model Exploded View Parts List Item Description Part Number 1Screw with Washer0371981L01 2 Screw, Speaker Retainer 0386434Z02 3Retainer, Speaker4271352L02 4 Speaker 5085798F09 5Assembly, Front HousingPMLN4646_ 6 Nameplate for DP 3601 Nameplate for DP 3600 3371390L03 3371390L04 7Cover, Dust1571477L01 8 Antenna Refer to separate Accessory List Leaf- let 6866574D04 9Knob, Frequency3615204H01 10 Knob, Volume 3615205H01 11Module, Display7215182H01 12 Screw 0386104Z04 13Board, Interface0104022J35 14 Retainer, Display 4215189H01 15Clip, Shield4271320L01 16 Shield, Can 2615156H01 17Back Cover KitSee Section 1.4: Model Charts 18 Pad, Thermal 7515526H01 19O-ring, Chassis3215181H01 20 Retainer, O-ring 4216293H01 21Retainer, O-ring4216292H01 22 Assembly, Chassis Molded w/ MIP Shield 0104023J31 23Seal, Battery Contact3215177H02 24 Screw 0316281H01 25Seal, Pot3271570L01