Motorola SABER Handie-Talkie User manual

(AA) MOTOROLA INC.
wo
1. INTRODUCTION
SABER and SYSTEMS SABER submersible
radio models meet the stringent requirements of
U. S. MIL-STD-810C, Method 512.1, Procedure I,
and MIL-STD-810D, Method 512.2, Procedure I,
which require the radio to maintain watertight
integrity when immersed in three feet of water for
two hours. Radios shipped from the Motorola
factory have passed the water immersion test and
should not be disassembled. If disassembly is
necessary, refer to qualified service personnel and
service shops capable of restoring the watertight
integrity of the radio.
Submersible models can be identified by the
black escutcheon with white lettering on top of the
radio. lf the radio is accidentally dropped in water,
shake the radio to remove the excess water from
the speaker grille area before operating;
otherwise, the sound may be distorted until the
water has evaporated from this area. Also,
remove the battery and dry the battery contacts
on the bottom of the radio.
®, Motoroia, SABER, SYSTEMS SABER, EXPO, SECURENET,
and Handie-Talkie are trademarks of Motorola Inc.
©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.
SABER" and SYSTEMS SABER"
Handie-Talkie Portable Radios
Universal, Submersible Models
2. GENERAL INFORMATION
To ensure that the submersible radio is truly a
watertight unit, special testing, test procedures,
and specialized test equipment are required. The
special testing involves avacuum check of the
radio and pressure testing (troubleshooting) for
water leaks if the vacuum check fails. The
specialized test equipment is needed to perform
the vacuum check and pressure testing, if
required.
NOTE
When ordering replacement batteries for a
submersible radio, either NTN4596 (Ni-Cd, FM
approved, Ultra-High-Capacity) or NTN4538
(Ni-Cd, FM approved, Medium-Capacity)
should be ordered.
3. SPECIALIZED TEST EQUIPMENT
a. Vacuum Pump Kit, NLN9839
The vacuum pump kit includes avacuum
pump with gauge, and avacuum hose. An
adapter with gasket (NTN4264), which must be
ordered separately, connects the vacuum hose to
the radio's baseplate. The vacuum pump kit and
adapter are also used on Motorola EXPO™
radios.
CAUTION
It is strongly recommended that
maintenance of the submersible radio be
deferred to qualified service personnel and
service shops. This is. of paramount
importance as irreparable damage to the
radio can result from service by
unauthorized persons. If disassembly is
necessary, unauthorized attempts to repair
the radio may void any existing warranties
or extended performance agreements with
Motorola. it is also recommended that
submersibility be checked annually by
qualified service personnel.
b. Pressure Pump Kit, NTN4265
The pressure pump kit includes apressure
pump with gauge, and apressure hose; the
pressure pump kit is also used on Motorola EXPO
radios. As with the vacuum pump kit above, the
NTN4264 adapter connects the pressure hose to
the radio's baseplate.
c. Miscellaneous Hardware
Other items needed for testing the
submersible radio include:
*Large water container.
¢Fresh water
*Asupply of replacement seals, O-rings, and
gaskets (refer to the exploded view parts lists
in the applicable service manual for Motorola
part numbers).
Instruction Manual
68P81107C16-A
(AA) MOTOROLA INC.
wo
1. INTRODUCTION
SABER and SYSTEMS SABER submersible
radio models meet the stringent requirements of
U. S. MIL-STD-810C, Method 512.1, Procedure I,
and MIL-STD-810D, Method 512.2, Procedure I,
which require the radio to maintain watertight
integrity when immersed in three feet of water for
two hours. Radios shipped from the Motorola
factory have passed the water immersion test and
should not be disassembled. If disassembly is
necessary, refer to qualified service personnel and
service shops capable of restoring the watertight
integrity of the radio.
Submersible models can be identified by the
black escutcheon with white lettering on top of the
radio. lf the radio is accidentally dropped in water,
shake the radio to remove the excess water from
the speaker grille area before operating;
otherwise, the sound may be distorted until the
water has evaporated from this area. Also,
remove the battery and dry the battery contacts
on the bottom of the radio.
®, Motoroia, SABER, SYSTEMS SABER, EXPO, SECURENET,
and Handie-Talkie are trademarks of Motorola Inc.
©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.
SABER" and SYSTEMS SABER"
Handie-Talkie Portable Radios
Universal, Submersible Models
2. GENERAL INFORMATION
To ensure that the submersible radio is truly a
watertight unit, special testing, test procedures,
and specialized test equipment are required. The
special testing involves avacuum check of the
radio and pressure testing (troubleshooting) for
water leaks if the vacuum check fails. The
specialized test equipment is needed to perform
the vacuum check and pressure testing, if
required.
NOTE
When ordering replacement batteries for a
submersible radio, either NTN4596 (Ni-Cd, FM
approved, Ultra-High-Capacity) or NTN4538
(Ni-Cd, FM approved, Medium-Capacity)
should be ordered.
3. SPECIALIZED TEST EQUIPMENT
a. Vacuum Pump Kit, NLN9839
The vacuum pump kit includes avacuum
pump with gauge, and avacuum hose. An
adapter with gasket (NTN4264), which must be
ordered separately, connects the vacuum hose to
the radio's baseplate. The vacuum pump kit and
adapter are also used on Motorola EXPO™
radios.
CAUTION
It is strongly recommended that
maintenance of the submersible radio be
deferred to qualified service personnel and
service shops. This is. of paramount
importance as irreparable damage to the
radio can result from service by
unauthorized persons. If disassembly is
necessary, unauthorized attempts to repair
the radio may void any existing warranties
or extended performance agreements with
Motorola. it is also recommended that
submersibility be checked annually by
qualified service personnel.
b. Pressure Pump Kit, NTN4265
The pressure pump kit includes apressure
pump with gauge, and apressure hose; the
pressure pump kit is also used on Motorola EXPO
radios. As with the vacuum pump kit above, the
NTN4264 adapter connects the pressure hose to
the radio's baseplate.
c. Miscellaneous Hardware
Other items needed for testing the
submersible radio include:
*Large water container.
¢Fresh water
*Asupply of replacement seals, O-rings, and
gaskets (refer to the exploded view parts lists
in the applicable service manual for Motorola
part numbers).
Instruction Manual
68P81107C16-A

Manual&Scan&
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I hope this service manual is of use to you. Motorola does
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copies are of poor quality.
Each page is captured at 600 DPI, and as 24-bit color, 8-
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If something is incorrect here, or unreadable please reach
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In the final PDF that’s color or grayscale will be JPEG
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and image quality, image quality will win. It’s 2021 and
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This was captured on a Canon DR-G2140 scanner which is ~
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If you have a hard to find/out of print manual and would
like to make it available please reach out, I may be able
to scan and return it to you.
Thank you,
Bryan Fields, W9CR
[email protected]

4. DISASSEMBLY AND REASSEMBLY
If disassembly and reassembly of the radio is
required, refer to the "DISASSEMBLY/
REASSEMBLY PROCEDURES" in the applicable
service manual.
a. Disassembly
Disassemble the radio according to the
"DISASSEMBLY" section of the applicable service
manual; refer also to the "SERVICING MAJOR
SUBASSEMBLIES" section.
b. Reassembly
Reassemble the radio according to the
"REASSEMBLY" section of the applicable
service manual; refer also to the "SERVICING
MAJOR SUBASSEMBLIES" section. Tighten all
hardware which was loosened or removed per the
Torque Specifications table. DO NOT RE-
ASSEMBLE THE RADIO WITHOUT FIRST
PERFORMINGTHE FOLLOWING PRELIMINARY
INSPECTION PROCEDURE:
(1) Remove the main seal O-ring from the control
top panel.
(2) Inspect the seal area around the control top
panel for foreign material that might prevent
the main seal O-ring from sealing properly.
(3) Instail Cca new main seal O-ring; discard the old
O-ring.
(4) Check to ensure that both frame stud seals
are in place and are not damaged in any way.
Replace both frame stud seals if any damage
or foreign material is visible.
NOTE
When seating the main seal O-ring in the radio
housing, use hand pressure to press the radio
into the housing. Make sure that the baseplate
slotted-spanner nuts are properly aligned
before tightening them.
5. VACUUM TEST
Refer to the exploded view diagrams and
parts lists in the applicable service manual.
a. General
The vacuum test uses avacuum pump and
gauge. The pump creates avacuum condition
inside the radio, and the gauge monitors the radio
for astable vacuum reading; that is, checking for
aproperly sealed, watertight unit. Before starting
the vacuum test:
*Remove the battery and check the battery
contact mounting screws for correct torque.
*Check the two baseplate slotted-spanner nuts
for correct torque.
¢Check the antenna bushing spanner nut for
correct torque.
*Remove the universal connector cover to
expose the universal connector.
¢If the radio has abelt clip (NTN4741 only),
check the revision letter stamped on the
underside of the metal bracket. Revision "O"
belt clips may cause leakage and should be
replaced with alater version belt clip. Alf
radios with belt clips should be vacuum tested
with the belt clip attached since the belt clip
can affect the radios leak rate.
b. Conducting the Test
(1) Attach the vacuum hose to the vacuum pump.
Check the pump and hose for leaks by
blocking off the open end of the hose and
operating the pump afew times. The actual
reading of the gauge at this point is not
important; it is important that the gauge
pointer remains steady, indicating no vacuum
leaks in the pump.
(2) Ensure that arubber gasket is attached to the
hose-to-baseplate adapter. Screw the adapter
into the tapped hole in the baseplate.
(3) Attach the open end of the hose to the
adapter.
(4) Operate the pump afew times until the gauge
indicates 5in. Hg; do not pull more than 10 in.
Hg of vacuum on the radio. The gauge should
indicate aleaking-down and should stabilize at
some lower value. The leak-down is normal
and important; it indicates that the pressure is
equalizing across the port seal membrane.
CAUTION
Fhe main seal O-ring should not be visible
when. looking at the top side of the radio. if
theseal is visible, it is improperly installed.
NOTE
If this leak-down phenomenon does not occur,
the port seal is probably missing, damaged, or
wet. In this manual, refer to the "Baseplate
Elastomer Seal or Vacuum Port Seal"
paragraph of the "PRESSURE TEST" section.
Operate the pump again until the gauge
indicates 5in. Hg. Some additional leak-down
will occur. After repeating this action two or
three more times, the gauge should stabilize
at 5in. Hg.
4. DISASSEMBLY AND REASSEMBLY
If disassembly and reassembly of the radio is
required, refer to the "DISASSEMBLY/
REASSEMBLY PROCEDURES" in the applicable
service manual.
a. Disassembly
Disassemble the radio according to the
"DISASSEMBLY" section of the applicable service
manual; refer also to the "SERVICING MAJOR
SUBASSEMBLIES" section.
b. Reassembly
Reassemble the radio according to the
"REASSEMBLY" section of the applicable
service manual; refer also to the "SERVICING
MAJOR SUBASSEMBLIES" section. Tighten all
hardware which was loosened or removed per the
Torque Specifications table. DO NOT RE-
ASSEMBLE THE RADIO WITHOUT FIRST
PERFORMINGTHE FOLLOWING PRELIMINARY
INSPECTION PROCEDURE:
(1) Remove the main seal O-ring from the control
top panel.
(2) Inspect the seal area around the control top
panel for foreign material that might prevent
the main seal O-ring from sealing properly.
(3) Instail Cca new main seal O-ring; discard the old
O-ring.
(4) Check to ensure that both frame stud seals
are in place and are not damaged in any way.
Replace both frame stud seals if any damage
or foreign material is visible.
NOTE
When seating the main seal O-ring in the radio
housing, use hand pressure to press the radio
into the housing. Make sure that the baseplate
slotted-spanner nuts are properly aligned
before tightening them.
5. VACUUM TEST
Refer to the exploded view diagrams and
parts lists in the applicable service manual.
a. General
The vacuum test uses avacuum pump and
gauge. The pump creates avacuum condition
inside the radio, and the gauge monitors the radio
for astable vacuum reading; that is, checking for
aproperly sealed, watertight unit. Before starting
the vacuum test:
*Remove the battery and check the battery
contact mounting screws for correct torque.
*Check the two baseplate slotted-spanner nuts
for correct torque.
¢Check the antenna bushing spanner nut for
correct torque.
*Remove the universal connector cover to
expose the universal connector.
¢If the radio has abelt clip (NTN4741 only),
check the revision letter stamped on the
underside of the metal bracket. Revision "O"
belt clips may cause leakage and should be
replaced with alater version belt clip. Alf
radios with belt clips should be vacuum tested
with the belt clip attached since the belt clip
can affect the radios leak rate.
b. Conducting the Test
(1) Attach the vacuum hose to the vacuum pump.
Check the pump and hose for leaks by
blocking off the open end of the hose and
operating the pump afew times. The actual
reading of the gauge at this point is not
important; it is important that the gauge
pointer remains steady, indicating no vacuum
leaks in the pump.
(2) Ensure that arubber gasket is attached to the
hose-to-baseplate adapter. Screw the adapter
into the tapped hole in the baseplate.
(3) Attach the open end of the hose to the
adapter.
(4) Operate the pump afew times until the gauge
indicates 5in. Hg; do not pull more than 10 in.
Hg of vacuum on the radio. The gauge should
indicate aleaking-down and should stabilize at
some lower value. The leak-down is normal
and important; it indicates that the pressure is
equalizing across the port seal membrane.
CAUTION
Fhe main seal O-ring should not be visible
when. looking at the top side of the radio. if
theseal is visible, it is improperly installed.
NOTE
If this leak-down phenomenon does not occur,
the port seal is probably missing, damaged, or
wet. In this manual, refer to the "Baseplate
Elastomer Seal or Vacuum Port Seal"
paragraph of the "PRESSURE TEST" section.
Operate the pump again until the gauge
indicates 5in. Hg. Some additional leak-down
will occur. After repeating this action two or
three more times, the gauge should stabilize
at 5in. Hg.

(5) Observe the gauge for approximately two
minutes.
©If the needie falls 2in. Hg or less (for
example, from 5in. Hg to 3in. Hg), then
the radio has passed the vacuum test and
is approved for submersibility. No
additional testing will be required.
©If the needle falls more than 2in. Hg (for
example, from 5in. Hg to less than 3in.
Hg), then the radio has failed the vacuum
test and the radio might leak if
submersed. Additional troubleshooting of
the radio will be required; complete this
procedure, then go to the "PRESSURE
TEST" section of this manual.
(6) Remove the vacuum hose and adapter from
the radio.
6. PRESSURE TEST
Refer to the exploded view diagrams and
parts lists in the applicable service manual.
a. General
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 apressure condition inside the radio,
submersing the radio in water, and observing the
radio for astream 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.
b. Conducting the Test
(1) Screw the adapter (with gasket) into the
tapped hole in the baseplate.
(2) Attach one end of the pressure hose to the
adapter and the other end to the pressure
pump.
(3) Operate the pump until the gauge reads
approximately 1psig. Some leak-down is
normal as the pressure equalizes across the
port seal membrane.
(4) Maintain the pressure at 1psig and submerse
the radio into awater-filled container.
(5) Watch for any continuous series of bubbles.
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
eakage. Pinpoint the problem(s) to one (or
more) of the following areas:
(a) housing
(b) baseplate elastomer seal or vacuum port
seal
(c) antenna bushing seal or
lightpipe seal
(d) frequency switch and on/off/volume
control
(e) rf connector
(f) dual-function switch and actuator
assembly
(g) frame stud seals
(h) main seal
(7) Remove the radio from the water container
and dry it thoroughly. Be especially careful to
dry the area around the main seal to prevent
contamination of the internal electronics while
the unit is open. Also, to keep the area around
the port seal dry, make sure that there is no
water around the baseplate vacuum port.
(8) Remove the adapter and pressure hose
added in steps (1) and (2).
c. Troubleshooting Leak Areas
Before repairing any leak, read all applicable
area repair paragraphs. This will help to eliminate
unnecessary disassembly and reassembly of a
radio with multiple leaks. Troubleshoot only the
faulty seal areas listed in the "PRESSURE TEST"
section, and, when multiple leaks exist, in the
order listed.
NOTE
Before reassembling the radio, always install a
new main seal O-ring, and new O-rings in the
defective area.
(1) Housing
lf aleak occurs in any portion of the housing
assembly (monitor, push-to-talk, or RAT switches,
speaker grille, or universal connector), replace the
housing.
(2) Baseplate Elastomer Seal or Vacuum
Port Seal
(a) These seals can, and should, be repaired
without removing the radio chassis from the
housing assembly. Remove the baseplate by
loosening the slotted-spanner nuts and
removing the center battery contact screw.
NOTE
Before removing the baseplate, note the
location and orientation of the battery latch and
battery latch spring.
(b) Inspect the elastomer seal for damage or
foreign material; replace or clean as
necessary. Remove the old vacuum port seal,
and inspect the sealing surfaces of the
housing and baseplate for damage; replace
any faulty items, and install anew vacuum
port seal.
(c) Ensure that the center O-ring portion of the
elastomer seal is fully seated around the
threaded bushing in the housing. Reassemble
the baseplate with the convex surface of the
latch spring toward the baseplate. Tighten the
battery contact screws and slotted-spanner
nuts to the correct torque.
(3) Antenna Bushing Seal or Lightpipe Seal
(a) Check the antenna bushing spanner nut for
correct torque. If the nut is loose, tighten it to
the correct value and run the pressure test
again. If the nut is not loose, the antenna
bushing must be replaced. This will require
the removal of the main circuit board from the
frame assembly according to the following
procedure:
1. Referring to the "DISASSEMBLY" section
in the applicable service manual,
disassemble the radio until the speaker
bracket assembly is disconnected and
removed from the frame assembly.
2. Read the precautions outlined in the
"SERVICING MAJOR SUBASSEMBLIES"
section of the service manual before
performing steps 3through 8, below.
3. Disconnect the PTT/controls flexible
circuit from the radio circuit board.
4. Remove the back shield.
5. Remove the two bottom connector screws
and three power amplifier module (U202)
screws (one through the PC board, and
two through the frame), securing the main
circuit board.
6. Gently remove the ground clip. If the clip
is bent during removal, replace it.
7. Remove the power amplifier module
(U202).
8. Grasping the main circuit board at the
bottom connector end, lift the board and
carefully slide it out from under the control
top panel.
CAUTION
When the main circuit board is
removed, fragile wireform and ground
contacts are exposed. Handle gently to
avoid damage.
(b) The control top panel must now be removed
from the frame assembly. Remove the two
screws that hold the panel to the side of the
radio frame.
(c) Remove the on/off/volume control and
frequency switch knobs by grasping the tip of
each knob with pliers and pulling the knob off
the shaft of the switch. Open the insert by
inserting ascrewdriver blade into the insert's
slot, then pull the nsert off the shaft. Remove
the torque washer from the volume control, if
necessary.
(d) Remove the detent washer from around the
frequency switch, noting the orientation of the
washer, relative to the switch, prior to removal.
Then, remove the spanner nut from each
switch.
(e) Noting the location of the lightpipe, which will
be loose, lift the control top panel off the
frame.
(f) Remove the antenna bushing spanner nut and
the antenna bushing from the control top
panel. inspect the sealing surfaces on the
control top panel and bushing; replace faulty
items as required. Remove and discard the
old antenna bushing O-ring, and install cea new
one.
CAUTION
Ensure that all static electricity
safeguards are in place prior to
beginning radio disassembly.
(g) Before reassembling the radio, inspect the O-
rings on the lightpipe, on/off/volume control,
and frequency switch for damage and foreign
material. Also, ensure that the lightpipe and
the antenna bushing's hex head are properly
seated in the control top panel.
(h) Reassemble the radio in reverse order of
disassembly, using new frequency switch and
onoff/volume control knobs and inserts.
CAUTION
Pressure any greater than 1psig may push
air around the main seal and may damage
the grille area.
(5) Observe the gauge for approximately two
minutes.
©If the needie falls 2in. Hg or less (for
example, from 5in. Hg to 3in. Hg), then
the radio has passed the vacuum test and
is approved for submersibility. No
additional testing will be required.
©If the needle falls more than 2in. Hg (for
example, from 5in. Hg to less than 3in.
Hg), then the radio has failed the vacuum
test and the radio might leak if
submersed. Additional troubleshooting of
the radio will be required; complete this
procedure, then go to the "PRESSURE
TEST" section of this manual.
(6) Remove the vacuum hose and adapter from
the radio.
6. PRESSURE TEST
Refer to the exploded view diagrams and
parts lists in the applicable service manual.
a. General
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 apressure condition inside the radio,
submersing the radio in water, and observing the
radio for astream 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.
b. Conducting the Test
(1) Screw the adapter (with gasket) into the
tapped hole in the baseplate.
(2) Attach one end of the pressure hose to the
adapter and the other end to the pressure
pump.
(3) Operate the pump until the gauge reads
approximately 1psig. Some leak-down is
normal as the pressure equalizes across the
port seal membrane.
(4) Maintain the pressure at 1psig and submerse
the radio into awater-filled container.
(5) Watch for any continuous series of bubbles.
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
eakage. Pinpoint the problem(s) to one (or
more) of the following areas:
(a) housing
(b) baseplate elastomer seal or vacuum port
seal
(c) antenna bushing seal or
lightpipe seal
(d) frequency switch and on/off/volume
control
(e) rf connector
(f) dual-function switch and actuator
assembly
(g) frame stud seals
(h) main seal
(7) Remove the radio from the water container
and dry it thoroughly. Be especially careful to
dry the area around the main seal to prevent
contamination of the internal electronics while
the unit is open. Also, to keep the area around
the port seal dry, make sure that there is no
water around the baseplate vacuum port.
(8) Remove the adapter and pressure hose
added in steps (1) and (2).
c. Troubleshooting Leak Areas
Before repairing any leak, read all applicable
area repair paragraphs. This will help to eliminate
unnecessary disassembly and reassembly of a
radio with multiple leaks. Troubleshoot only the
faulty seal areas listed in the "PRESSURE TEST"
section, and, when multiple leaks exist, in the
order listed.
NOTE
Before reassembling the radio, always install a
new main seal O-ring, and new O-rings in the
defective area.
(1) Housing
lf aleak occurs in any portion of the housing
assembly (monitor, push-to-talk, or RAT switches,
speaker grille, or universal connector), replace the
housing.
(2) Baseplate Elastomer Seal or Vacuum
Port Seal
(a) These seals can, and should, be repaired
without removing the radio chassis from the
housing assembly. Remove the baseplate by
loosening the slotted-spanner nuts and
removing the center battery contact screw.
NOTE
Before removing the baseplate, note the
location and orientation of the battery latch and
battery latch spring.
(b) Inspect the elastomer seal for damage or
foreign material; replace or clean as
necessary. Remove the old vacuum port seal,
and inspect the sealing surfaces of the
housing and baseplate for damage; replace
any faulty items, and install anew vacuum
port seal.
(c) Ensure that the center O-ring portion of the
elastomer seal is fully seated around the
threaded bushing in the housing. Reassemble
the baseplate with the convex surface of the
latch spring toward the baseplate. Tighten the
battery contact screws and slotted-spanner
nuts to the correct torque.
(3) Antenna Bushing Seal or Lightpipe Seal
(a) Check the antenna bushing spanner nut for
correct torque. If the nut is loose, tighten it to
the correct value and run the pressure test
again. If the nut is not loose, the antenna
bushing must be replaced. This will require
the removal of the main circuit board from the
frame assembly according to the following
procedure:
1. Referring to the "DISASSEMBLY" section
in the applicable service manual,
disassemble the radio until the speaker
bracket assembly is disconnected and
removed from the frame assembly.
2. Read the precautions outlined in the
"SERVICING MAJOR SUBASSEMBLIES"
section of the service manual before
performing steps 3through 8, below.
3. Disconnect the PTT/controls flexible
circuit from the radio circuit board.
4. Remove the back shield.
5. Remove the two bottom connector screws
and three power amplifier module (U202)
screws (one through the PC board, and
two through the frame), securing the main
circuit board.
6. Gently remove the ground clip. If the clip
is bent during removal, replace it.
7. Remove the power amplifier module
(U202).
8. Grasping the main circuit board at the
bottom connector end, lift the board and
carefully slide it out from under the control
top panel.
CAUTION
When the main circuit board is
removed, fragile wireform and ground
contacts are exposed. Handle gently to
avoid damage.
(b) The control top panel must now be removed
from the frame assembly. Remove the two
screws that hold the panel to the side of the
radio frame.
(c) Remove the on/off/volume control and
frequency switch knobs by grasping the tip of
each knob with pliers and pulling the knob off
the shaft of the switch. Open the insert by
inserting ascrewdriver blade into the insert's
slot, then pull the nsert off the shaft. Remove
the torque washer from the volume control, if
necessary.
(d) Remove the detent washer from around the
frequency switch, noting the orientation of the
washer, relative to the switch, prior to removal.
Then, remove the spanner nut from each
switch.
(e) Noting the location of the lightpipe, which will
be loose, lift the control top panel off the
frame.
(f) Remove the antenna bushing spanner nut and
the antenna bushing from the control top
panel. inspect the sealing surfaces on the
control top panel and bushing; replace faulty
items as required. Remove and discard the
old antenna bushing O-ring, and install cea new
one.
CAUTION
Ensure that all static electricity
safeguards are in place prior to
beginning radio disassembly.
(g) Before reassembling the radio, inspect the O-
rings on the lightpipe, on/off/volume control,
and frequency switch for damage and foreign
material. Also, ensure that the lightpipe and
the antenna bushing's hex head are properly
seated in the control top panel.
(h) Reassemble the radio in reverse order of
disassembly, using new frequency switch and
onoff/volume control knobs and inserts.
CAUTION
Pressure any greater than 1psig may push
air around the main seal and may damage
the grille area.

(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 1psig, 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 anew, 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 anew
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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SYSTEMS SABER SECURENET VHF SERVICE MANUAL 68P81067C10
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SABER THEORY/MAINTENANCE MANUAL 68P81044C05
(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 1psig, 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 anew, 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 anew
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.
RELATED PUBLICATIONS AVAILABLE SEPARATELY
SABER |OPERATING INSTRUCTIONS 68P81065C60
SABER II/IIl OPERATING INSTRUCTIONS 68P81065C65
SYSTEMS SABER OPERATING INSTRUCTIONS 68P81060C10
SABER VHF SERVICE MANUAL 68P81043C90
SABER UHF SERVICE MANUAL 68P81043C95
SABER SECURENET VHF SERVICE MANUAL 68P81045C70
SABER SECURENET MID-BAND SERVICE MANUAL 68P81063C30
SABER SECURENET UHF SERVICE MANUAL 68P81045C75
SYSTEMS SABER SECURENET VHF SERVICE MANUAL 68P81067C10
SYSTEMS SABER SECURENET UHF SERVICE MANUAL 68P81066C95
SABER THEORY/MAINTENANCE MANUAL 68P81044C05