Motorola Xpr 7000 Seris Basic 68009498001 A Manual

							Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-31
immersed. Additional troubleshooting of the radio will be required; complete 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 the radio has failed the vacuum test. Do not perform 
the pressure test until the vacuum test has been completed. Pressure testing involves creating a 
positive pressure condition inside the radio, immersing the radio in water, and observing the radio 
for a stream of bubbles (leak). Since all areas of the 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 into a water-filled container. 
6.Watch for any continuous series of bubbles. A stream of bubbles indicates a sign of leakage.
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 
careful to dry the area around the main seal to prevent contamination of the internal Pressure any greater than 1 psig might push air around the main seal
NOTESome air entrapment may cause the accumulation of bubbles, especially in the grille area,
but the bubbles should not be continuous.
Please do not bend or over tighten pump connector to the chassis.
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							5-32Disassembly/Reassembly Procedures: Ensuring Radio Immersibility
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 contamination of the internal electronics after reassembling the 
radio.
5.8.9 Troubleshooting Leak Areas
Before repairing any leak, first read all of the steps 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 5-31, 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 Models only), Universal Connector, chassis/Housing 
interface, PTT button area of the housing, replace the housing. Refer to Section 5.6 Radio 
Disassembly – Detailed  on page 5-6.
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 Figure 5.
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.
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 5-6, remove the 
chassis assembly from the radio.Keep the area around the chassis’s vacuum port dry by ensuring that there is no 
water around it.
NOTEBefore reassembling the radio, always install a new Main seal O-ring, Battery Contact Seal
in the defective area.
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							Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-33
2.Refer to Section 5.6.2 Chassis Disassembly  on page 5-10, remove the Main Board from 
chassis.
3.Remove the main seal O-ring.
4.Inspect the seal area around the chassis for foreign 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 5.7.3 
Chassis Reassembly  on page 5-21.
7.Reassemble the chassis assembly followed by installing into Front Cover. (Refer to Section 
5.7 Radio Reassembly - Detailed  on page 5-17).
8.Inspect the main seal O-ring for proper seating. Observe carefully to ensure that the main 
seal O-ring is not pinched between 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 5-6 to remove the Battery 
Contact Seal.
2.Remove the Battery Contact 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 installing into Front Cover. (Refer to Section 
5.7 Radio Reassembly - Detailed  on page 5-17).
7.Inspect the main seal O-ring for proper seating. Observe carefully to ensure that the main 
seal O-ring is not pinched between the housing and the chassis.
IMPORTANT:Both Gore Label (5478220A01) and Gasket (3286058L01) need to be 
replaced after vacuum test, pressure test or water leakage troubleshoot-
ing.
NOTEWhen installing the assembled chassis to the Front Cover, ensure the O-ring at the top two
corners are not dislodged from the chassis groove. 
						

							5-34Disassembly/Reassembly Procedures: Ensuring Radio Immersibility
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 
chassis.
2.Remove the Breathing Vent Membrane.
3.Ensure that the chassis’s surface (at the Breathing Vent Label & Breathing Vent Membrane 
recessed) is clean, no/minimum scratches and free from any adhesive or other foreign 
materials.
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.
5.8.9.5  Battery Maintenance
1.As part of an Annual Battery Maintenece Program or as required (when the battery contacts 
are dirty or show signs of wear) it is recommended that the Battery‘s Radio-side and Charger-
side contacts are cleaned with DeoxIT®GOLD cleaner/lubricant.
2.DeoxIT®GOLD (Supplier CAIG Labs, P/N G100P) cleaner/lubricant pen has been found to be 
very effective at cleaning and extending the life of the battery‘s contacts. DeoxIT®GOLD 
cleaner/lubricant is available at numerous electronics suppliers (Radio Shack, McMaster Carr, 
Fry’s, etc.) and directly from manufacturer, CAIG Labs, at http://www.caig.com.
3.This pen based package is recommended as it provides better access to the recessed con-
tacts of the battery. The pen’s tip may need to be modified (trimmed on the sides) to improve 
penetration into the battery contact slots. Per the manufacturer’s instructions, shake the pen 
until the fluid begins to flow and wipe the batterys contact surface with the felt tip.  After 
cleaning, inspect the contact surfaces for signs of advanced wear.
4.Advanced contact wear is defined as wear through either the contact platings (gold and 
nickel) to the base metal (copper).  Copper exposure is characterized by a distinctive orange-
brown metal appearance surrounded by the silvery nickel underplate and gold top coat.
5.In some cases, a magnified (10x minimum) inspection may be required to verify wear through 
to the base material.  Polishing of the gold or nickel surface is common and is not considered 
a need for replacement.  In instances where advanced wear is evident, the battery should be 
replaced.
6.After cleaning the contact areas of any foreign material, let the lubricant/cleaner dry for 2 min-
utes.  Replace the battery on the radio and test for intermittency by moving the battery relative 
to the radio as might occur in regular use.
NOTERegular maintenance (at least annually) of this area is recommended to ensure
contamination free interface and to prolong the life of the battery contacts. 
						

							Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-35
5.8.10 Troubleshooting Charts
Troubleshooting Flow Chart for Vacuum Test (Sheet 1 of 2)
Sta rt
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 hole
5. Attach vacuum hose to pump 
connector
6. Place radio on flat surface
7. Operate pump (gauge = 6 in. Hg)
Gauge
does not fall 
below 
0.5 in. HgNO
YES
Run Pressure Test
1.Replace Breath-
ing Vent label and 
Breathing Vent 
Membrane
2. Radio approved 
for immersibility
Full 
equipment for
pressure test
procedure
availableYES
NO
B 
End
A 
						

							5-36Disassembly/Reassembly Procedures: Ensuring Radio Immersibility
Troubleshooting Flow Chart for Vacuum Test (Sheet 2 of 2)
Sta rtB
1Remove pump and
connectors from radio
2. Remove antenna
3. Separate front housing kit 
Examine and
reassemble
main O-ring Replace front
housing kit with
new unitReplace main
O-ring with
new unit Replace new
chassis kit
without PCBs  YES
NO NO NO NO
Changed
front housing
kitYESChanged
back chassis
kitYESChanged
main O-ringExamined
main O-ring
fitting 

YES
Send radio to
Motorola Depot
or
Motorola Service Center
End
A 
						

							Disassembly/Reassembly Procedures: Ensuring Radio Immersibility 5-37
Troubleshooting Flow Chart for Pressure Test & Leakage Areas
Sta rt
1. Remove vacuum hose from 
pump connector
2. Attach pressure hose to 
pump connector
1. Operate pressure pump 
(pressure = 1 psig)
2. Immerse radio into a water-
filled container
Continuous 
Series of 
bubblesYES
NO
Bubbles from 
Front 
HousingYES
NO
Bubbles from 
ChassisYES
NO
Bubbles from 
Battery Con-
tact SealYES
NO
Bubbles from 
Lens*/Univer-
sal Connector/ 
chassis/ 
Housing Inter-
face/ PTT 1. Dry the radio
2. Replace Housing, Main 
Seal O-Ring, and repeat 
steps in Troubleshooting 
Flow Chart for Vacuum Test.YES
1. Remove Knobs
NO
1. Dry the radio
2. Replace Battery Contact Seal, 
Main Seal O-Ring, and repeat 
steps in Troubleshooting Flow 
Chart for Vacuum Test. 1. Dry the radio
2. Replace Main Seal O-ring,
and repeat steps in 
Troubleshooting Flow Chart 
for Vacuum Test. 1. Dry the radio
2.Replace Breathing
Vent label and 
Breathing Vent 
Membrane
3. Radio approved 
for immersibility* Only for Display Model
EndEndEndEndEnd 
						

							5-38Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists
5.9 Radio Exploded Mechanical Views and Parts Lists
5.9.1 Full Keypad Model Exploded View and Parts List
Figure 5-27.  Full Keypad Model Exploded View
504443424140353432
33
26252421201716 1087
9 4321
5
6
11
12
13
14
15
18
19
22
23
27
28
29
30
31
38
3736
39
45
46
47
48 49
51 
						

							Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists 5-39
Table 5-3.  Full Keypad Model Exploded View Parts List
Item Description Part Number
1AntennaSee Chapter 7: 
Accessories
2 Volume Knob 36012005001
3Frequency Knob36012004001
4 Emergency Button 38012008001
5Nameplate, Front33012037001
6 Front Cover Kit* See Table 5-5
7UC EscutcheonPart of Front Cover 
kit
8 Dust Cover Assembly 15012157001
9Bluetooth / GPS Antenna85012045001
10 Screw, Shoulder, M1.2 X 3.2 MM 0371160D01
11Label, Agency IndicatorNot Field 
Replaceable
12 Full Keypad See Table 5-5
13Front Dampener, Color Display75012070001
14 Color Display Padding 75012137001
15Color Display Module72012010001
16 Back Dampener, Color Display 75012069001
17Conductive Pad (Small)75012148001
18 Conductive Pad (Big) 75012143001
19Keypad to Mainboard Flex84012214005
20 UC to Keypad Flex Part of Front Cover 
kit
21TX Shield Poron75012117001
22 Keypad Stiffener 75012094001
23Keypad-LCD Retainer42012029001
24 Mesh, Speaker 35012040001
25Speaker, Electromagnetic, 36mm Dia50012013001
26 Retainer Assembly, Speaker 0104045J57
27Keypad Retainer Screw0378212A02
28 Conductive Poron 3916290H01 
						

							5-40Disassembly/Reassembly Procedures: Radio Exploded Mechanical Views and Parts Lists
NOTE:* Comprises of 4,5,7,9,10,12,13,14,15,16,17,18,19,20,21,22,23,24,25,26,27,28,29,30,31 and 33
** Comprise of 32,34,35,36,37,39,40,41,42,44 and 47
29Microphone, EMI, Electret Condenser50012012001
30 Boot, Microphone 32012099001  
31Mic Membrane with Stiffener3578241A02
32 Screw, Main Board and GOB board 03012034001
33Screw, Thread Forming0386434Z02
34 Seal, Top Control 32012089001
35Back Cover Kit Assembly**See Table 5-5
36 Main O-Ring 32012097001
37Option Board KitPMLN5718AS
38 GOB to Mainboard Flex 84012217003
39ChassisPart of Back Cover kit
40 Rubber Plug 38012017001
41Housing, Shroud15012092001
42 Battery Contact Seal 32012096001
43NameplateSee Table 5-5
44 Warning Label 3371496L01
45Gasket 3286058L01
46 Gore Label 5478220A01
47RF Label54012133001
48 Chassis Label Not Field 
Replaceable
49BatterySee Chapter 7: 
Accessories
50 Belt Clip See Table 5-5
51Pad, Thermal7515526H01 Table 5-3.  Full Keypad Model Exploded View Parts List
Item Description Part Number