nokia
CONNECTING PEOPLE
PAGE 1 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 14.02.2003
SQX 00591-en DJk
nokia
5100
NPM-6
SERVICE MANUAL
Service Level 1&2
Copyright © Nokia Corporation. This material, including documentation and any related computer programs, is
protected by copyright controlled by Nokia Mobile Phones. All rights are reserved. Copying, including
reproducing, storing, adapting or translating, any or all of this material requires the prior written consent of
Nokia Mobile Phones. This material also contains confidential information, which may not be disclosed to others
without the prior written consent of Nokia Mobile Phones.
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 2 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 14.02.2003
SQX 00591-en DJk
Introduction
The purpose of this document is to help Nokia service levels 1 and 2 workshop technicians to
carry out service to Nokia 5100. This Service Manual is to be used only by authorized Nokia
service partners, and the content of it is confidential. Please note that Nokia provides also
other guidance documents (e.g. Service Bulletins) for service partners, follow these regularly
and comply with the given instructions.
While every endeavor has been made to ensure the accuracy of this document, some errors
may exist. If you find any errors or if you have further suggestions, Nokia should be notified.
Please keep in mind also that this documentation is continuously being updated and
modified, so watch always out for the newest version.
Warnings and Cautions
Please refer to the phone’s user guide for instructions relating to operation, care and maintenance including
important safety information. Note also the following:
Warnings:
1.
CARE MUST BE TAKEN ON INSTALLATION IN VEHICLES FITTED WITH ELECTRONIC ENGINE
MANAGEMENT SYSTEMS AND ANTI–SKID BRAKING SYSTEMS. UNDER CERTAIN FAULT
CONDITIONS, EMITTED RF ENERGY CAN AFFECT THEIR OPERATION. IF NECESSARY, CONSULT THE
VEHICLE DEALER/MANUFACTURER TO DETERMINE THE IMMUNITY OF VEHICLE ELECTRONIC
SYSTEMS TO RF ENERGY.
2.
THE HANDPORTABLE TELEPHONE MUST NOT BE OPERATED IN AREAS LIKELY TO CONTAIN
POTENTIALLY EXPLOSIVE ATMOSPHERES EG PETROL STATIONS (SERVICE STATIONS), BLASTING
AREAS ETC.
3.
OPERATION OF ANY RADIO TRANSMITTING EQUIPMENT, INCLUDING CELLULAR TELEPHONES, MAY
INTERFERE WITH THE FUNCTIONALITY OF INADEQUATELY PROTECTED MEDICAL DEVICES. CONSULT
A PHYSICIAN OR THE MANUFACTURER OF THE MEDICAL DEVICE IF YOU HAVE ANY QUESTIONS.
OTHER ELECTRONIC EQUIPMENT MAY ALSO BE SUBJECT TO INTERFERENCE.
Cautions:
1. Servicing and alignment must be undertaken by qualified personnel only.
2. Ensure all work is carried out at an anti–static workstation and that an anti–static wrist strap is
worn.
3. Ensure solder, wire, or foreign matter does not enter the telephone as damage may result.
4. Use only approved components as specified in the parts list.
5. Ensure all components, modules screws and insulators are correctly re–fitted after servicing and
alignment. Ensure all cables and wires are repositioned correctly.
6. All PC’s used with NMP Service Software for this produce must be bios and operating system ”Year
2000 Compliant”.
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 3 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 14.02.2003
SQX 00591-en DJk
Table of content
1. EXPLODED VIEW........................................................................................................................................... 4
2. SPARE PARTS LIST........................................................................................................................................ 5
3. INFRARED GONOGO TEST.......................................................................................................................... 8
4. SW-UPDATE ..................................................................................................................................................... 9
5. GENERAL REPAIR INFORMATION ........................................................................................................ 10
6. DISASSEMBLY INSTRUCTIONS (ALSO SEE VIDEO CLIPS) ............................................................. 11
7. EXCHANGE OF SYSTEM CONNECTOR ................................................................................................. 13
8. EXCHANGE OF BATTERY CONNECTOR .............................................................................................. 14
9. QUICK TROUBLE SHOOTER PART1....................................................................................................... 15
10. QUICK TROUBLE SHOOTER PART2................................................................................................... 16
11. QUICK TROUBLE SHOOTER PART3................................................................................................... 17
12. ESD PROTECTION REQUIREMENTS.................................................................................................. 18
13. SERVICE NOTES....................................................................................................................................... 19
14. GONOGO TESTER .................................................................................................................................... 20
15. BATTERY TESTER ................................................................................................................................... 20
Change History
OriginatorStatus Version No. Date Comments
DJk Draft 0.1 24.11.2002 Initial draft
DJk Draft 0.2 28.012003 SPL included
DJk Approved
1.0 14.02.2003 Approval
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
1. EXPLODED VIEW
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts
PAGE 4 (20) SQX 00591-en DJk Approved 1.0
Confidential
10.02.2003
Description: See corresponding ITEM/CIRCUIT REF of the SPL (Spare Parts List)
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 5 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
2. SPARE PARTS LIST
ITEM/
CIRCUIT REF.
I004 6 6150099 SCREWS
1
I005 1 XXXXXXX LCD
I006 1 XXXXXXX UI BOARD ASSY
I007 1 9470283 EARPICECE GASKET
I008 1 5140251 EARPIECE
I010 1 6800055 VIBRA MOTOR
1
I017 1 XXXXXXX CONNECTOR
I018 1 XXXXXXX DC-JACK
I019 1 XXXXXXX MICROPHONE
I020 1 9458473 BATTERY-COVER
QTY PART NO PART NAME
9458503 UI MODULE ASSY (I005-I008)
5400257 CONNECTOR ASSY (I017-I019)
SOLDERING COMPONENTS ONLY FOR LEVEL 2
ITEM/
CIRCUIT REF.
S300 5200025 SM TACT SW SIDE TRAVEL 0.2 MM
S301 5200025 SM TACT SW SIDE TRAVEL 0.2 MM
S302 5200025 SM TACT SW SIDE TRAVEL 0.2 MM
V318 4860321 LED LWY87C-S2T2-1 >224 WHITE SMD2
V319 4860315 LED LWY87C-S2T2-1 >224 WHITE SMD2
X100 5409253 SM BATTERY CONN 3POL SPR 12V 2A
F100 5119019 SM FUSE F 1.5A 32V
G300 4700131 CELL CAPACITOR 0.01MAH 3V3
QTY PART NO PART NAME
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 6 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
VARIANT PARTS
ITEM/
CIRCUIT REF.
I001 1 9458884 A-SHELL ASSEMBLY DARK GREY
I001 1 9458885 A-SHELL ASSEMBLY GREEN
I002 1 9458890 B-SHELL ASSEMBLY DARK GREY
I002 1 9458891 B-SHELL ASSEMBLY GREEN
I003 1 9458517 PRINTED KEYMAT LATIN
I003 1 9790847 PRINTED KEYMAT ARABIC
I003 1 9790851 PRINTED KEYMAT CYRILLIC
I003 1 9790852 PRINTED KEYMAT GREEK
I003 1 9790853 PRINTED KEYMAT HEBREW
QTY PART NO PART NAME
SQX 00591-en DJk
SWAP UNITS
QTY PART NO PART NAME
0076462 NPM-6 N5100 SWAP EUROPE
0076463 NPM-6 N5100 SWAP POLAND
0076464 NPM-6 N5100 SWAP TURKEY
0076465 NPM-6 N5100 SWAP RUSSIA
0076466 NPM-6 N5100 SWAP CZECH
0076467 NPM-6 N5100 SWAP FRANCE
0076468 NPM-6 N5100 SWAP SOUTH AFRICA
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 7 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SERVICE TOOLS
TYPE QTY PART NO PART NAME
Accessory 0273560 BL-4C BATTERY BLOCK LI-ION 720MAH
Accessory 0272169 AC TRAVEL CHARGER ACP-8E (EURO)
Accessory 0272172 AC TRAVEL CHARGER ACP-8X (UK)
Accessory 0273505 HDS-3 STEREO HEADSET
0770459 FLA-42 POS FLASH LOADING ADAPTER
0730218 XCS-1 SERVICE CABLE
0680032 UNIV. POWERSUPPLY ACF-8
0770431 SRT-6 OPENING TOOL 5510
0770450 FLA-48 TESTPINS (10 PCS)
0080541 FLS-4S SALES PACK E&A (inclusive 0680032)
SQX 00591-en DJk
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 8 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
3. INFRARED GONOGO TEST
You need another infrared device (e.g. 6310i) to do a GoNoGo test. The infrared windows of
the devices must be directed to each other and should have a distance of approximate 15 cm.
Make sure that infrared is activated in receiver device.
Warning: Do not point the IR (infrared) beam at anyone’s eye or allow it to interfere with
other IR devices. This device is a Class 1 Laser product.
Test unit Reference unit
Settings on the test unit:
o From Home Menu, select
key. This displays Phonebook entries. Create one new
entry, if phone and SIM memory are empty.
o Choose one phonebook entry and select
o
Select
o
Select
o Select
o Sending in progress, please wait
o If sending of business card fails
, make sure again, that infrared windows
are directed to each other and If infrared is activated in reference device
try again sending.
Then
,
o Test was successful, if you get this message on receiver device
.
You will not get a confirmation on sender device.
o Press
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
for Home Menu
nokia
CONNECTING PEOPLE
PAGE 9 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
4. SW-UPDATE
To use FLS-4S Flash Dongle you have to follow the user guide inside the sales package. Please check
always the latest version of flash software, which is available on Partner Web Site.
Flash Concept – (Point of Sales)
It is very important to follow this insertion and removal procedure, otherwise the contact
pins of Flash Adapter will be damaged.
Standard installation for software updates.
Insert the Flash Adapter FLA-42 like a battery, start at the
battery connector site.
Open the Battery Cover.
Now, push down the bottom side of the phone, do not use
too much force.
When removing the Flash Adapter, always start from the
bottom side of the unit
Description: See corresponding ITEM/CIRCUIT REF of the SPL (Spare Parts List)
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
.
Take away the unit now.
nokia
CONNECTING PEOPLE
PAGE 10 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
5. GENERAL REPAIR INFORMATION
In this section the technician will get some general hints how to carry out repairs:
o Before starting the repair you must take care of ESD precautions like being in your ESD Protected Area and
connecting your wristband.
o Use gloves to avoid corrosion and fingerprints.
o Protect windows and displays with a foil to avoid dust and scratches.
o When cleaning the pads you have to use a soft cloth/ESD brush and isopropanol. It is not allowed to use a
glass fiber pencil because it scratches the surface and will lead later on to corrosion.
o Mechanical parts (ex. shielding lids), which didn’t repair the failure, can be reused, if they are not soldered.
o Use always original Nokia parts or accessories.
o Meet the torque requirements when assembling the unit (see also the document “torques for transceiver
assembly” on Nokia Partner Web Site).
o Always use your own equipment for testing where you are sure that it works. E.g. if the customer complains
about charger function, please test the phone with your own charger to be sure if phone or charger causes the
malfunction.
o When doing the Faultlogger entries, always note the Item code, which caused the malfunction. Also, fill in the
appropriate part code from the assembly, if needed.
o Please be aware that some malfunctions could be software related and solved by an update.
Following General Service Bulletins have to be followed:
SB-055 Common notice for good ventilation
SB-089: Do not try to repair prototypes (indicated on Type Label).
SB-107: Be sure that you have minimum hardware requirements in place.
SB-115: Handling of liquid damages.
SB-121: Return the defective part, if one of your service tools causes malfunction.
SB-122: Soldering with manual hot air gun is totally forbidden because of the very sensitive µBGA
components and µVia technology.
SB-124 Service Policy for packaging serviced products
SB-131: Check these guidelines when refurbishing products.
SB-132: You can use a Golden Phone for inspecting your measuring equipment.
Please check Nokia Partner Web Site (PWS) for latest news and files on a regular basis.
This legend is valid for all parts of the Quick Trouble Shooter
Follow the steps until the problem is solved. If this does not help, you are not authorized to go forward.
Only underlined components ( e.g. I007
Follow the arrows step by step
Pads or contacts: Check optical and
mechanical condition as well as
corrosion. Clean if necessary.
) can be changed.
Check optical and mechanical
condition of contacts as well as
corrosion. Clean with ESD brush only, if
necessary.
Measure component for electrical
functionality and change, if needed.
No more actions possible, send product
to the appropriate service partner with
higher service level.
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 11 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
6. DISASSEMBLY INSTRUCTIONS (ALSO SEE VIDEO CLIPS)
Do not open the unit, if you don’t have a torque driver, which is capable of
40 Ncm, but send the product to the appropriate
service partner with higher service level.
Attention!
It is not allowed to open the unit more than once,
otherwise the unit is not splash proofed any more
and has to be sent to Level 3/4 service partner.
Always use new screws for assembly.
(SB-006 for NPM-6)
Press the grip markings on both sides of the B-Shell and
remove B-Shell.
To remove the A-Shell press Locking Springs as shown
and pull A-Shell from the unit.
Unscrew the six screws, using the order shown and a
screwdriver TORX PLUS® size 6. For assembly, the reverse
order has to be used. For screws around Display a
torque of 40Ncm and for Connector screws a torque of
25Ncm have to be used.
Separate the UI-Module from Radio Module carefully,
because of the board-to board-connector.
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
Use tweezers to remove Vibra Motor.
nokia
CONNECTING PEOPLE
PAGE 12 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
Remove Earpiece. Note the guiding pin when assembling. Remove Keymat.
SQX 00591-en DJk
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 13 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
7. EXCHANGE OF SYSTEM CONNECTOR
The System Connector is attached with double-sided
adhesive gasket to C-Cover. Also note the gasket on
C-Cover.
Press SRT-6 between C-Cover and System Connector and
remove Battery Cover.
Press again SRT-6 between C-Cover and System
Connector and remove System Connector.
To remove the remaining adhesive gasket use SRT-6 only.
Do not use sharp-edged tools for this procedure.
Remove System Connector.
Remove protection foil from System Connector.
Place System Connector to its guidance exactly.
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
Now press connector to C-Cover firmly, while taking care
not to slip C-Cover on your table.
nokia
CONNECTING PEOPLE
PAGE 14 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
8. EXCHANGE OF BATTERY CONNECTOR
These are the two soldered support angles.
Use a side cutter to cut the support angles.
Push tweezers in outer openings of battery connector and
lift up the plastic cover.
Note that you need a soldering iron with higher
temperature, when cleaning or soldering the grounding
pad.
Desolder all pins and clean the pads.
Tin one of pads to fix the connector before soldering the
following pins.
Note location of connector pins and support angles to fit
them precisely.
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
Solder first support angle. When position is exactly, solder
the other pins.
nokia
CONNECTING PEOPLE
PAGE 15 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
9. QUICK TROUBLE SHOOTER PART1
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 16 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
10. QUICK TROUBLE SHOOTER PART2
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 17 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
11. QUICK TROUBLE SHOOTER PART3
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
f
t
,
CONNECTING PEOPLE
PAGE 18 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
12. ESD PROTECTION REQUIREMENTS
Electrostatic discharge can easily damage the sensitive components o
electronic products. Therefore every Service Partner has to take care of a
least some precautions like ESD restricted area, floor, table, covering
chair(s), shoes or arm wrist.
Please refer to the Partner Website document
ESD protection requirements for NMP Service Level 1/2 Service Suppliers
example configuration of an epa-area
source: www.armeka.com
example workbench and testers
source: http://www.armekaengineering.com
example configuration of a workbench
source: www.warmbier.com
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 19 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
13. SERVICE NOTES
We recommend using Service Notes when shipping phones to other Service Partners. It prevents the
product from scratches, it is ESD-neutral and has the possibility to give valuable feedback of the fault
symptom through a structured form.
Please refer to the document Service Notes for faulty NMP transceiver on Partner Website to get
further information.
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
nokia
CONNECTING PEOPLE
PAGE 20 (20) Approved 1.0
Nokia Mobile Phones Customer Care EMEA
Technical Services, Repair Concepts Confidential 10.02.2003
SQX 00591-en DJk
14. GONOGO TESTER
The will’tek GoNoGo Tester has to be used to
carry out the final test after your service
action to guarantee the functionality of the
phone.
Please refer to the actual information in
the Nokia Care Point Extranet within the
Partner Web Site.
15. BATTERY TESTER
The Astratec battery tester lets
you test the capacity of Nokia
batteries.
Please refer to the actual
information in the Nokia Care
Point Extranet within the
Partner Web Site.
Service Manual 5100 Level 1&2 Copyright 2002-2003 © Nokia Corporation
Loading...