HTC PRODIGY Service manual

Service Manual

PDA Phone Product

PRODIGY

HTC Proprietary

Confidential T reatment Requested

Rev . A

Nov 16, 2005

HTC Corp.

Engineering Mobility

HTC confidential

TITLE: Service Manual for PRODIGY

REV.

NO.

XA

A

DATE CONTENTS DEP. REVISED

GSD

Aug 13, 2005

Nov 16, 2005

First release

Formal release for MP

stage

Technical

Support

GSD

Technical

Support

Johnson Yang

APP´D

STGE.PER.

Henry_Lai

HTC confidential

Table of contents

1. INTRODUCTION ·······································································································5

2. PRODUCT SPECIFICATIONS ·····················································································5

2.1 PRODUCT CONFIGURATION···············································································5

2.2 SPECIFICATIONS OF PRODIGY···········································································6

3. LABELING·············································································································10

3.1 MAIN UNIT REGULATORY LABEL·······································································10

3.2 SERIAL NUMBER DESCRIPTION ········································································10

4. SERVICING TOOLS ································································································11

5. ASSEMBLING AND DISASSEMBLING ········································································12

5.1 DISASSEMBLING·····························································································12

5.2 ASSEMBLING··································································································26

5.3 NOTIFICATION ONCE PERFORMING GOLDEN CAP REPLACEMENT························37

5.4 NOTIFICATION ONCE PERFORMING M/B REPLACEMENT·····································38

5.5 NOTIFICATION ONCE PERFORMING LCM REPLACEMENT····································39

5.6 NOTIFICATION ONCE PERFORMING RIGID-FLEX BD REPLACEMENT·····················40

5.7 NOTIFICATION ONCE PERFORMING LCM HOUSING OR KEYPAD BEZEL REPLACEMENT········· 41

6. EQUIPMENT OF PROBLEM DIAGNOSTICS ································································43

6.1 LIST OF TEST JIGS··························································································43

6.2 H/W REQUIREMENT FOR PC···········································································43

6.3 SOFTWARE REQUIREMENT ·············································································43

7. DIAGNOSTIC PROGRAMS······················································································44

7.1 LIST OF TEST ITEMS ······················································································44

7.2 TEST ITEMS OPERATION·················································································45

7.3 HOW TO EXECUTE DIAG TEST PROGRAM·························································45

8. BATTERY TEST/JUDGEMENT PROCEDURE ······························································46

8.1 CERTIFICATION FLOW ·····················································································46

8.2 CURRENT CONSUMPTION MEASUREMENT·························································47

8.3 WHOLE UNIT CHARGE AND DISCHARGE TEST····················································50

8.4 BATTERY PERFORMANCE ON UNIT WITH RUN DOWN PROGRAM ························51

9. LCM INSPECTION CRITERIA ··················································································55

10.RF TEST·············································································································57

10.1 GSM FUNCTION TEST···················································································57

10.2 H/W REQUIREMENT ·····················································································57

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10.3 TEST CONNECTION························································································57

10.4 RF ANTENNA TEST SPEC. ············································································58

10.5 BLUETOOTH FUNCTION TEST ········································································62

10.6 WLAN FUNCTION TEST················································································66

11. FIRMWARE OF OS/ RADIO UPGRADE····································································68

11.1 RUU·········································································································68

11.2 UPLOAD FIRMWARE CODE FROM MASTER UNIT TO MINI-SD CARD ·················74

11.3 USE PRE-LOADED MINI-SD CARD TO RE-FLASH UNIT ··································79

12.TROUBLE SHOOTING AND REPAIR·········································································80 13 SPARE PART LIST·································································································85

13.1 UNIT SPARE PART LIST····················································································85

13.2 BOARD LEVEL SPARE PART LIST ······································································87

14. APPENDIX···········································································································88 A. CUSTOMER, RETAILER MISJUDGMENT·······························································88 B. HOW TO PERFORM WARM -RESET AND HARD-RESET ·········································90 C. REMOVE MAIN BATTERY BEFORE TURN OFF UNIT···············································90 D. RE-FLASH AGAIN ONCE FAILED DURING RE-FLASH PROCESS·······························90 E. IF UNIT HANG ON 100% WHILE USING RUU RE-FLASH········································91 F. IF THE SCREEN IS FROZEN AFTER RE-FLASH ·····················································91 G. IF UNIT CAN NOT TURN ON ················································································91 H. COMPONENT COMPATIBLE REQUEST·································································91 I. DIAGNOSTIC CARD VS. UNIT’S SPL VERSION ·····················································92

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NT.O

1. Introduction

This manual provides the technical information to support service activities of PDA phone (Prodigy). This document contains highly confidential information, any or all of this document should not be revealed to any third party.

2. Product Specifications

2.1 Product Configuration

Standard Package

ITEM CONTAINS

1 Main Unit 2 Stylus 3 AC Adapter w/ mini –USB plug 4 Stereo wired headset with microphone 5 Carrying Case 6 Car Kit 7 User’s Manual, Quick start guide, Sync., S/W (CD) 8 Battery 9 Travel charger 10 User’s Manual

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2.2 Specifications of Prodigy

Item Specification Soldering status z Meet Lead-free requirement Platform z Microsoft Windows Pocket PC phone edition

Outside Dimensions z 58mm(W) x 109mm(H) x 23.7mm (T) Weight z Less than 160 g (Main unit with battery pack) Battery z Removable rechargeable Lithium Polymer battery

z PDA form factor integrated quad-band GSM/EDGE,

Bluetooth, WiFi, 1.3/2 mega-pixel camera, and sliding QWERTY keyboard

z 1250 mAH z Battery Life:

* WMA: 12 hours

* WMV: 8 hours

z Talk time: 3.5 ~ 5 hrs z Standby Time: 150 ~ 200 hrs

AC Adapter z AC input 100 ~ 240 Vac, 50/60 HZ

z DC output : 5V / 1A (typical)

GPRS/GSM (Tri-band) module

z Quad-Band ( 850/900/1800/1900)MHz z Internal Antenna z Audio codec: AMR, EFR, FR, HR z Supplement services

* Call holding/waiting/ forwarding * CLI (Call line Identity) * Display own number * Network selection * Cell broadcast * Multi-party conference call * Spool Icon * Network lock

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EDGE functionality z EGPRS Class B,

z Multi-slot Class 10 z PBCCH z Incremental Redundancy

SIM z 1.8V/3V SIM Operation

z SIM Application Tool Kit release 98 class 3 z Over the Air (OTA) programming z FDN/AND/SDN z Security PIN 1&2 control

Memory

z ROM: 128MB (for program and users’ storage) z RAM: 64 MB DDR SDRAM

Processor/Chipset z TI OMAP 850 LCD Module z 64K-color TFT Transflective LCD with white LED back

light

z 2.8” 240 x 320 dots resolution z Sensitive Touch Screen

Interface

z One Infrared port IrDA SIR z 1.8V/3V SIM card z Mini-SD card slot (top) z 2.5ψ stereo audio jack z External antenna connector

Stylus z Lock type mechanism Keyboard/Button/Switch z Five way navigation button

z Power button z Volume control button (up & down) z 2 phone button, Send (Yes) & End (No) z 2 AP buttons ( message-left, IE-right) z 2 soft keys z Camera shutter button z Voice command/Voice recorder button z Reset Switch z RF button z Sliding QWERTY keyboard with 39 keys + 2 soft keys

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Notification z One Bi-color LED for GSM standby, GSM message,

GSM network status, notification, and charging status.

z Two respective (blue and green) LEDs for for

Bluetooth/ WiFi notification.

z Notification by sound, Message, Vibration on the

display.

CMOS Camera Main Camera (manufacture option)

z CMOS 1.3 mega Pixel with fixed lens z Or CMOS 2.1 mega Pixel with macro lens z Video/flash light z Preview Mirror

Audio z Build-in Microphone

z Receiver z Dual speaker on both sides z Loud speaker for Hands-free supported z Full duplex z WAV/WMA/AMR/AAC/MP3 codec. z 16 bits with 8KHz,11 KHz, 22KHz,44.1 KHz,

sampling rate

Bluetooth z Compliant with V1.2

z Class 2 transmit power z Supported profiles:

¾ Generic Access profile ¾ Serial Port profile ¾ Headset profile ¾ Object Push profile ¾ DUN profile ¾ Heads-free profile ¾ Generic Object Exchange profile ¾ HID profile

z Co-exist with WiFi

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WiFi z IEEE 802.11b/g compliant

z Internal WLAN Antenna z 11, 5.5, 2 and 1 Mbps per channel, auto fallback for

extended range

z ELP mode z Support 802.11i&AES z Security

* WPA authentication

z QoS

* 802.11 WME QoS * 802.11e is preferred *Fast AP to AP handover

Regulatory z PTCRB

z R&TTE: EMC/EMI, CEM, Safety z FCC z WiFi Certification z Bluetooth Certifiaction z Microsoft Windows Mobile version 5.0 logo

Accessories z Carrying Case

z AC adapter with mini-USB plug z Sync. Cable (mini-USB) z Battery (rechargeable and replaceable) z Car adapter z Stylus z Car Kit w/car stereo mute function z Stereo-wired headset with microphone z Mono bluetooth headset with microphone z Keyboard z Cradle (optional) z User manual, quick start guide, Sync. S/W (CD) z Travel charger

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3. Labeling

3.1 Main unit Regulatory label (Stick on the keypad housing of main unit)

Here is an example only. Actually printing format is depended on customer’s request. Repair center need to re-print new regulatory label once replacing M/B for new IMEI, As to printing format, please refer to returned unit from end user.

Label Characteristic: Material: polyester Color: pantone 422c Ink: pantone 425c

3.2 Serial number description

For S/N: SSYWWPPZZZZZ SS: SITE CODE --> HT or TW Y: Year Last Digital of the Year. WW: Week Code : 01 ~ 54 PP: Product Code : By HTC define ZZZZZ: Serial Number (00001 ~ 99999) Use Base 10

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4. Servicing Tools

This chapter provides information for the servicing tools for Prodigy.

Repair Level Definition

Unit L0 Accessory test and unit swap L1 Unit Test and ROM Re-flash L2 Refurbishment and Module Swap +L1 L2.5 M/B Repair(connecter, button, MIC…) +L2

List of Servicing Tools

level No. Item Use for Remark

L 1

1 Mini USB DATA interface

Cable

Check for mini USB

communication; RUU re-flash 2 Earphone Headset For Audio test. 3 AC Adapter Transfer AC to DC for Unit 4 WLAN AP For WiFi test 5 Mini Memory Card with Diag.

For unit Diag. test HTC design

test program (need be encoded by HTC)

6 128MB mini SD memory card

( must be encoded by HTC)

7 Unit current consumption test

fixture 8 Power supply 9 Current Meter

For unit Re-flash ROM code transfer to mini SD card

Measure Unit current consumption

HTC design

10 Mobile tester For RF test 11 Special Made Plastic Stick Assembly & Disassembling HTC special

L 2

12 Hand tools Assembly & Disassembling 13 Label printer Print agency label if replacing

tools

M/B 14 Lead-free Soldering station Board level repair L 2.5 15 Air heater Board level repair

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5. Disassembling and Assembling

5.1 Disassembling

Tools needed of Assembling and Disassembling Prodigy From left to right in the picture

1. Lens Cleaning Tissue.

2. Philip Screw Driver #0.

3. Torex Screw Driver T5X40

4. Special Made Plastic Stick.

5. Tweezers.

Remove the Stylus, mini-SD Card slot Filler, and protection rubber of antenna connector.

Next, Remove the battery cover by releasing lock switch

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Remove battery cover

Warning: To reduce risk of fire or

burns, do not disassemble, crush, puncture, short external contacts, or dispose of in fire or water. Replace only with specified batteries. Recycle or dispose of used batteries properly

Remove main battery from unit

Use the plastic stick to Insert and gently twist into the gap between keypad housing and antenna cover.

Unlock the inside hook

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There are 2 hook on the top side of Antenna cover, Use 2 thumbs to push the bottom of antenna cover

Take care of disassembling Antenna cover during the process, it is easy to damage the hook of Antenna cover

Antenna cover is removed

Release 4 screws from keypad housing

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To insert plastic stick into the gap of top of keypad housing

Unlock hook

There are 3 hooks at right side

Another 3 hooks at left side

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Disassembly keypad housing

The keypad housing is removed

There are 2 parts on the keypad housing,

1. Flash light

2. Vibrator

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Use Plastic stick to unlock hooks of flash light module

Use tweezes to remove Vibrator

Flash-light module and Vibrator are removed

3 4

Following need to be removed

1. Camera

2. Speaker

1

3. Speaker

4. Keyboard FPC cable

2

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Remove Camera

Remove speakers

Both side speakers are removed

Disconnect keyboard FPC cable

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Shift the Keypad bezel as left picture

Take care the record button while disassembly main board

Use plastic stick to raise main board

The main board is connected with Rigid-Flex Board

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Disconnect the FPC cable

The main board is released

Shift the keypad bezel back

Disassembly 4 screws on both sides.

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Disassembly keypad bezel of keyboard

Remove 8 screws

Disassembly keyboard

Keyboard and keypad are moved

Caution: Don’t need to separate FPC keyboard and metal plate

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Remove 4 screws

Use plastic stick to unlock the hook

There are 6 hooks at both side, and 2 hooks at top and bottom side

Unlock another side

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Let FPC cable through the space of Housing case, Separate LCM housing and LCM Bezel

Remove protect tape of LCM connector from the Rigid-Flex Board

Remove 2 screws of top side from Rigid-flex board

Remove 2 screws of bottom side from Rigid-flex board

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Disconnect LCM FPC cable

Disassembly Rigid-Flex Board

Disassembly LCM from LCM Bezel

Disassembly Receiver

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Disassembly AP keypad and Navigation keypad

Disassembly process is done

The Unit Disassembly is done

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5.2 Assembling Make sure sponges and Mylar, Gasket,… are stuck in the main board

1. 76H01061-00M * 1

2. 72H01048-00M * 1

3. 72H01049-00M * 1

4. 72H01065-00M * 2

Assembly AP keypad to LCM bezel

Assembly Receiver to LCM Bezel

Assembly Navigation keypad to LCM bezel

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Assembly LCM to LCM Bezel

Top site – Rigid-Flex BD Check and make sure following Gasket have been stick on the Rigid-Flex BD

Gasket * 2; p/n :72H01135-00M

Back site – Rigid-Flex BD

Stick 3 gaskets for Rigid-Flex BD Gasket * 3; p/n :72H01135-00M

Stick anti-short tape * 1 ; p/n: 76H01036-00M

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Install 2 screws to fix top side of Rigid-Flex Board

Torque : 0.6 +- 0.05 kgf-cm

Install 2 screws to fix bottom side of Rigid-Flex Board

Torque : 0.6 +- 0.05 kgf-cm

Connect LCM FPC cable to Rigid-Flex board

Once the Rigid-Flex BD is assembled,

1

Please stick 2 anti-short tapes

1. Anti-short tape for LCM connector * 1

p/n: 76H01036-00M

2. anti-short tape for Navi key * 1

2

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