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(4) Frequency Switch and
On/Off/Volume Control
(a)
Remove
the
suspect
knob by grasping
it
with
pliers and pulling
it
off
the shaft of the switch.
Then, grasp
the insert
with the
pliers and
pull
it
off
the shaft.
If
you are
working
on
the
frequency switch, remove
the detent
washer
from
around the switch as well, noting the
orientation
of
the
washer, relative
to
the
switch,
prior to
removal.
If
you are working
on
the volume control, remove the torque washer
as
well,
if
necessary.
(b)
Check
the switch's spanner
nut for
correct
torque.
If
the nut is
loose,
tighten
it
to
the
correct value and
rerun the
pressure test.
If
the
nut
is
not
loose, determine
if
the
leak
is
internal (from within the switch)
or
external
(from around the
switch) by pressurizing the
radio to
1
psig, submersing
the
unit in
water,
and observing the flow of bubbles.
(c)
Following the procedures detailed
in
"(3)
Antenna Bushing
Seal
or
Lightpipe
Seal,"
above, disassemble
the radio
until
the control
top
panel is removed
from the
frame
assembly.
(d)
If
the
leak
is from the internal switch
seal,
replace the switch;
follow the unsoldering and
replacement instructions contained
in
the new
switch's
instruction
sheet.
If
the leak is
from
the external switch
seal, replace
the switch's
O-ring.
(e) Before reassembling the radio, inspect the
light pipe
seal
and both
switch
seals
for
damage
and foreign material.
Repair
or
clean
as necessary.
(f)
Reassembie
the radio
in
reverse
order
of
disassembly, using new frequency switch
and
on/off/volume control knobs and inserts.
(5)
RF
Connector
(a) To replace the
rf
connector seal, disassemble
the radio until the main circuit board is
removed
from the
frame assembly, following
the
procedures detailed
in
"(3) Antenna
Bushing
Seal
or
Lightpipe
Seal,"
above.
(b)
While applying light pressure
on
the
rf
connector,
pull
and disconnect the
rf
ground
clip.
If
the bubbles
in
the pressure test come
through the
rf
connector (as opposed
to
around the
connector),
then
replace
the
connector.
Lift out the
rf
connector and replace
the O-ring. Inspect the
rf
connector hole
in
the
control top panel for foreign material, and
clean
as
required.
(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.
(d)
Reassemble
the radio
in
reverse
order
of
disassembly.
(6) Dual-Function Switch and Actuator Assembly
(a)
Remove
the knob
assembly
by
gently
separating
the two arms of the switch bracket
{located between the switch and the main O-
ting
seal)
and pulling the knob up and
away
from
the control top.
(bo)
Remove
the O-ring
from
the knob's shaft and
replace
it
with
a
new, prelubricated O-ring.
NOTE
The
switch bracket should
hold the
switch
firmly
against
the
inside
of the control top
panel.
If
this
is not the
case,
replace the
switch bracket.
(c) Before reinserting the knob into the
switch
bracket, ensure
that the slot
in
the switch is
properly aligned
with the
blade
on the
knob's
shaft.
(d)
Reinsert
the knob
into
the switch bracket; the
arms
of
the switch
bracket
will snap into
position (approximately
0.2 inches
apart).
NOTE
The
knob should not be loose
in
the switch
bracket;
if
the knob is loose, replace the switch
bracket.
(7) Frame
Stud Seals
(a)
Remove
the
seals
by pulling them
off
the
frame studs.
(b) Inspect
sealing areas
on the radio housing for
foreign material,
scratches, and nicks. Clean
off
foreign material
as
required; replace the
housing assembly
if it
is
damaged
in
any way.
(c) Install the new
seals,
ensuring that they are
fully
seated against
the radio frame before
reassembling the
radio.
(8) Main
Seal
(a) Remove and discard the
old main
seal O-ring
around the control top panel. Inspect the
sealing surfaces
on
the housing and control
top panel, replacing faulty items and
cleaning
off
any foreign
material.
(b)
Inspect the speaker bracket assembly
to
ensure that the two tabs
protruding from the
top of the
speaker bracket
are properly seated
between
the frame and the control top panel.
An improperly located
speaker bracket
will
distort the housing
in
the
seal area, causing
leakage.
(c) Remove
the antenna before installing a new
main
seal O-ring.
Install the main
seal O-ring
by first placing
it
in
the groove
on the
antenna
side
of the radio,
then by slowly stretching the
O-ring around and over the frequency switch
and on/off/volume control, and
finally
by
dropping
it
into
the
groove
on
the push-to-talk
switch side
of the radio.
(d) Inspect
again
for proper
seating
of the main
seal
all
around the control top panel, and for
foreign material. Observe carefully
to
ensure
that the main
seal O-ring
is not
pinched
between the radio housing and the control
top
panel during insertion
of
the radio
chassis
into
the housing
assembly. Pinched
main
seal O-
rings are one
of the
most common
causes
of
vacuum test failures.
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(4) Frequency Switch and
On/Off/Volume Control
(a)
Remove
the
suspect
knob by grasping
it
with
pliers and pulling
it
off
the shaft of the switch.
Then, grasp
the insert
with the
pliers and
pull
it
off
the shaft.
If
you are
working
on
the
frequency switch, remove
the detent
washer
from
around the switch as well, noting the
orientation
of
the
washer, relative
to
the
switch,
prior to
removal.
If
you are working
on
the volume control, remove the torque washer
as
well,
if
necessary.
(b)
Check
the switch's spanner
nut for
correct
torque.
If
the nut is
loose,
tighten
it
to
the
correct value and
rerun the
pressure test.
If
the
nut
is
not
loose, determine
if
the
leak
is
internal (from within the switch)
or
external
(from around the
switch) by pressurizing the
radio to
1
psig, submersing
the
unit in
water,
and observing the flow of bubbles.
(c)
Following the procedures detailed
in
"(3)
Antenna Bushing
Seal
or
Lightpipe
Seal,"
above, disassemble
the radio
until
the control
top
panel is removed
from the
frame
assembly.
(d)
If
the
leak
is from the internal switch
seal,
replace the switch;
follow the unsoldering and
replacement instructions contained
in
the new
switch's
instruction
sheet.
If
the leak is
from
the external switch
seal, replace
the switch's
O-ring.
(e) Before reassembling the radio, inspect the
light pipe
seal
and both
switch
seals
for
damage
and foreign material.
Repair
or
clean
as necessary.
(f)
Reassembie
the radio
in
reverse
order
of
disassembly, using new frequency switch
and
on/off/volume control knobs and inserts.
(5)
RF
Connector
(a) To replace the
rf
connector seal, disassemble
the radio until the main circuit board is
removed
from the
frame assembly, following
the
procedures detailed
in
"(3) Antenna
Bushing
Seal
or
Lightpipe
Seal,"
above.
(b)
While applying light pressure
on
the
rf
connector,
pull
and disconnect the
rf
ground
clip.
If
the bubbles
in
the pressure test come
through the
rf
connector (as opposed
to
around the
connector),
then
replace
the
connector.
Lift out the
rf
connector and replace
the O-ring. Inspect the
rf
connector hole
in
the
control top panel for foreign material, and
clean
as
required.
(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.
(d)
Reassemble
the radio
in
reverse
order
of
disassembly.
(6) Dual-Function Switch and Actuator Assembly
(a)
Remove
the knob
assembly
by
gently
separating
the two arms of the switch bracket
{located between the switch and the main O-
ting
seal)
and pulling the knob up and
away
from
the control top.
(bo)
Remove
the O-ring
from
the knob's shaft and
replace
it
with
a
new, prelubricated O-ring.
NOTE
The
switch bracket should
hold the
switch
firmly
against
the
inside
of the control top
panel.
If
this
is not the
case,
replace the
switch bracket.
(c) Before reinserting the knob into the
switch
bracket, ensure
that the slot
in
the switch is
properly aligned
with the
blade
on the
knob's
shaft.
(d)
Reinsert
the knob
into
the switch bracket; the
arms
of
the switch
bracket
will snap into
position (approximately
0.2 inches
apart).
NOTE
The
knob should not be loose
in
the switch
bracket;
if
the knob is loose, replace the switch
bracket.
(7) Frame
Stud Seals
(a)
Remove
the
seals
by pulling them
off
the
frame studs.
(b) Inspect
sealing areas
on the radio housing for
foreign material,
scratches, and nicks. Clean
off
foreign material
as
required; replace the
housing assembly
if it
is
damaged
in
any way.
(c) Install the new
seals,
ensuring that they are
fully
seated against
the radio frame before
reassembling the
radio.
(8) Main
Seal
(a) Remove and discard the
old main
seal O-ring
around the control top panel. Inspect the
sealing surfaces
on
the housing and control
top panel, replacing faulty items and
cleaning
off
any foreign
material.
(b)
Inspect the speaker bracket assembly
to
ensure that the two tabs
protruding from the
top of the
speaker bracket
are properly seated
between
the frame and the control top panel.
An improperly located
speaker bracket
will
distort the housing
in
the
seal area, causing
leakage.
(c) Remove
the antenna before installing a new
main
seal O-ring.
Install the main
seal O-ring
by first placing
it
in
the groove
on the
antenna
side
of the radio,
then by slowly stretching the
O-ring around and over the frequency switch
and on/off/volume control, and
finally
by
dropping
it
into
the
groove
on
the push-to-talk
switch side
of the radio.
(d) Inspect
again
for proper
seating
of the main
seal
all
around the control top panel, and for
foreign material. Observe carefully
to
ensure
that the main
seal O-ring
is not
pinched
between the radio housing and the control
top
panel during insertion
of
the radio
chassis
into
the housing
assembly. Pinched
main
seal O-
rings are one
of the
most common
causes
of
vacuum test failures.
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AVAILABLE SEPARATELY
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