Troubleshooting Leak Areas - Motorola EX500 Basic Service Manual

3-28
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. Operate the pump until the gauge reads approximately 1 psig.
CAUTION: Pressure any greater than 1 psig might push air around the main seal.
4. Maintain the pressure at 1 psig and immerse the radio into a water-filled container.
5. Watch for any continuous series of bubbles. A stream of bubbles indicates a sign of leakage.
NOTE Some air entrapment may cause the accumulation of bubbles, especially in the grille area,
but the bubbles should not be continuous.
6. 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
•
7. 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.
CAUTION: Keep the area around the chassis's vacuum port dry by ensuring that there is no water
around it.
8. Remove the pump connector from the chassis.
9. 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.

3.15.11Troubleshooting 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 3.15.10 "Pressure Test" on page 3-27, and when multiple
leaks exist, in the order listed.
Before reassembling the radio, always install a new Main seal O-ring, Battery Contact Seal
NOTE
in the defective area.
3.15.11.1 Front Housing
Do one or both of the following:
1. If a leak occurs at the Lens (only for EX560.XLS), Universal Connector, chassis/Housing
interface, PTT button area of the housing, replace the housing. Refer to Section 3.13
"EX560•XLS Radio Disassembly — Detailed" on page 3-19.
a. Remove the housing assembly from the radio.
b. Discard the housing assembly and main seal O-ring.
Ensuring Radio Immersibility