Nokia Customer Care
4 - Service Tools and
Service Concept s
Issue 1 11/2005 COMPANY CONFIDENTIAL
Copyright © 2005 Nokia. All Rights Reserved.
RM-127
Nokia Customer Care 4 - Service Tools and Service Concepts
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2 COMPANY CONFIDENTIAL Issue 1 11/2005
Copyright © 2005 Nokia. All Rights Reserved.
RM-127
4 - Service Tools and Service Concepts Nokia Customer Care
Table of Contents
Page No
Service Tools....................................................................................................... 5
List of service tools ............................................................................................ 5
JVB-1 docking station with DA-61 docking station adapter ............................... 7
DA-61 docking station adapter........................................................................... 8
SA-25 antenna coupler ...................................................................................... 9
SF-17 CCS POS flash adapter........................................................................ 13
MJ-22 module repair jig ................................................................................... 14
RJ-107 soldering jig......................................................................................... 16
SS-42 camera removal tool ............................................................................. 17
ST-13 PA rework stencil .................................................................................. 18
Rework procedure............................................................................................ 19
RJ-46 antenna switch rework jig...................................................................... 21
ST-15 antenna switch solder paste stencil ...................................................... 21
FPS-8 flash prommer....................................................................................... 22
FPS-10 flash prommer..................................................................................... 22
FPS-11 multiprommer...................................................................................... 24
ACF-8 universal power supply......................................................................... 24
AC-33 power supply......................................................................................... 25
FLC-2 DC cable............................................................................................... 26
AXS-4 service cable......................................................................................... 26
XCS-1 service cable ........................................................................................ 27
SW security device PKD-1............................................................................... 27
FLS-4S POS (Point Of Sale) flash device (sales pack).................................. 28
PCS-1 Power Cable......................................................................................... 28
XRF-1 RF cable............................................................................................... 29
DAU-9S MBUS cable....................................................................................... 29
CA-31D USB cable.......................................................................................... 30
XCS-4 modular cable....................................................................................... 30
CA-35S power cable........................................................................................ 31
CA-41PS power cable...................................................................................... 31
CA-10DS bi-directional parallel cable.............................................................. 32
CA-44 DC adapter cable.................................................................................. 32
CA-52PS power cable...................................................................................... 33
SX-4 smart card............................................................................................... 33
Service Concepts..............................................................................................34
POS flash concept with FLS-4S....................................................................... 34
POS flash concept with FPS-8......................................................................... 35
POS flash concept with FPS-10....................................................................... 36
POS flash concept with FPS-11....................................................................... 37
JBV-1 flash concept with FPS-8 ...................................................................... 38
JBV-1 flash concept with FPS-10 .................................................................... 39
JBV-1 service concept..................................................................................... 40
Module jig flash concept with FPS-8................................................................ 41
Issue 1 11/2005 COMPANY CONFIDENTIAL 3
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Module jig flash concept with FPS-10.............................................................. 43
Module jig service concept............................................................................... 45
RF coupler service concept ............................................................................. 46
4 COMPANY CONFIDENTIAL Issue 1 11/2005
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4 - Service Tools and Service Concepts Nokia Customer Care
Service Tools
■ List of service tools
The table below gives a short overview of service tools that can be used for testing, erro r analysis and repair of product RM-127, refer to various set-ups.
Type
Designator
Programme Specific Tools
CA-44 DC adapter cable
CA-52PS Power cable
DA-61 Docking station adapter
MJ-22 Module jig
RJ-107 PWB soldering rework jig
RJ-46 Antenna switch rework jig
SA-25 RF coupler
SF-17 POS flash adapter
ST-13 uPA solder paste stencil
ST-15 Antenna switch solder paste stencil
Common Service Tools
Description
AC-33 Power supply
ACF-8 Universal power supply
AXS-4 D9-D9 serial cable
CA-10DS Bi-directional parallel cable
CA-31D USB cable
CA-35S Power cable
CA-41PS Power cable
CA-5S Service battery cable
DAU-9S Service cable
FLC-2 DC cable
FLS-4S POS flash dongle US
FLS-4S POS flash dongle E&A
Issue 1 11/2005 COMPANY CONFIDENTIAL 5
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Nokia Customer Care 4 - Service Tools and Service Concepts
Type
Designator
FLS-4S POS flash dongle APAC
FPS-10 Flash prommer
FPS-11 Multiprommer
FPS-8 Flash box
JBV-1 Docking station
PCS-1 Power supply cable
PKD-1 Software protection key
RJ-21 uPA rework jig
SCB-3 DC-cable
SPS-2 Solder paste spreader
SS-42 Camera removal tool (replaces SRT-10)
SX-4 Smart card
XCS-1 Service cable
Description
XCS-4 Service cable
XRF-1 RF-MEAS. CABLE/DCS1900
Programme Specific Service Tool Spare Parts
10pcs 2A fuse for MJ-22 module jig
10pcs Test pins for MJ-22 module jig
10pcs Test pins for MJ-22 module jig
1pc Wing screw M3x20 for MJ-22 module jig
10pcs Test pins for SF-17 POS flash adaptor
10pcs Flash interface pins for DA-61 docking station adaptor
10pcs SIM interface pins for DA-61 docking station adaptor
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■ JVB-1 docking station with DA-61 docking station adapter
The JVB-1 docking station has been designed for calibration and software update use. The DA61 docking station adapter makes signal connections to the phone. JVB-1 and DA-61 are used
as one unit.
JVB-1 main electrical functions include the following:
• adjustable VBATT calibration voltage, current measurement limit voltage
“VCHAR”, current measurement calibration “ICHAR”
• adjustable ADC calibration voltage via BTEMP and BSI signal
• BTEMP and BSI calibration resistor
• signals from FBUS to the phone via parallel jig
• control via FBUS or USB
• Flash OK/FAIL indication
In calibration mode JVB-1 is powered by external power supply 11-16V DC. In flashing power
for the phone can be taken from FPS-8 or external power supply 11-16V DC.
Issue 1 11/2005 COMPANY CONFIDENTIAL 7
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■ DA-61 docking station adapter
Docking station adapter DA-61 with special white adapter is designed for assembled RM-127
phones. The docking station adapter supports testing, flashing, energy management calibration. If used in conjunction with the RF-coupler SA-25, also RF function testing is possible.
Features include:
• compatible for JBV-1
• easy phone attachment and detachment
• reliable phone locking
• switch for reliable detection of phone attachment
• replaceable test pins
• internal SIM holder with interface to phone SIM reader
Spare parts:
• Flash interface pins (10pcs)
• SIM interface pins (10pcs)
View of DA-61
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■ SA-25 antenna coupler
RF antenna coupler for use with the docking station adapter (DA-61).
Extends the docking station adapter to allow RF function tests in GSM bands 850, 900, 1800
and 1900 MHz.
Features include:
• easy attachment to DA-61 without use of tools
• reliable RF connection to phone module under test
• low attenuation and small “ripple” over the width of each GSM band
View of SA-25
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Installing instructions for RF coupler to docking station adapter
Open the housing by pressing the housing apart. Now you can remove the bottom plate of the
docking station adapter.
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Remove the four screws fixing the PWB by using Torx T6 screw driver. These screws are too
short, therefore four longer screws are delivered together with the coupler.
Install the coupler and use the new screws.
Issue 1 11/2005 COMPANY CONFIDENTIAL 11
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Close the docking station adapter by attaching the bottom plate.
Ready.
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■ SF-17 CCS POS flash adapter
Point of sales flash adapter for RM-127 phones.
SF-17 establishes a simple environment for SW update purposes and connects to the same
flash test pattern and the phone battery contacts.
Features include:
• flashing and testing of the attached phone
• overvoltage and reverse polarity protection of adapter and attached phone
• green LED: power supply valid and attached to the phone (3.5V<Vcc<7V)
• red LED: overvoltage condition, phone power supply disconnected (Vcc>7V)
• shielded 10-pin Western connector towards flash equipment or PC
• 3mm DC-jack for phone and adapter power supply
• phone battery contacts (VCC, GND, BSI)
• flash test pattern pins
View of SF-17
Spare parts
There are no serviceable parts inside SF-17, and SF-17 is not de signed for disassembly. Only
serviceable part are the spring loaded test pins that can be replaced without soldering and disassembly. Used test pin type is SX-1-J-2.0-G from manufacturer IDI.
Bent pins can be extracted from adapter’s receptacle using a tool. T o rn off pins can be replaced
using a slowly spinning 0.8 mm. For more detail, please refer to th e Service Tool Troubleshooting section.
Test pins (10pcs / plastic bag
Issue 1 11/2005 COMPANY CONFIDENTIAL 13
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Nokia Customer Care 4 - Service Tools and Service Concepts
■ MJ-22 module repair jig
Repair Jig for RM-127 phone module that allows full phone function.
General features include:
• easy phone module insertion and removal, proven jig locking mechanism
• ESD-proof base material and jig design
• unlimited operation of a disassembled phone module
• unrestricted access to phone module components
• access to system connector for accessory testing
• jig SIM holder with interface to phone SIM reader
• the installed UI module on the module jig allows key and display function test
• microphone, ear speaker and integrated handsfree speaker supplied on jig for
testing
• LOCAL/NORMAL switch
• access to phone module POWER-ON push-button
• quick and easy repair of jig components
View of MJ-22
Power supply features
• jig and phone power supply via 3mm DC jack, fuse
• power stabilization and voltage regulator on jig (can be bypassed by jumper)
• reverse and over-voltage protection of jig and phone module
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Communication and status LED’s
• green: Power supply
• green: MBUS activity
• orange: FBUS activity
• jumper to disable LED’s for precise phone module current consumption measurements
Spare parts
• spring loaded test pins (used in upper part, can be replaced by soldering)
- Test pins (10pcs / plastic bag)
• both ends spring loaded test pin (used in lower part, can be replaced by hand after
disassembly of lower PCB)
- Test pins (10pcs / plastic bag)
• fuse inside holder
•wing screw M3x20
Usage hints
• Before first use, verify setting of power supply jumper on the rear (=bottom PCB)
of the jig; if power supply is >4.2 V, make sure jumper enables power regulation of
the jig in order to prevent overvoltage for the phone module under test and the jig.
• In case of flashing problems in the jig, verify the switch on the upper part of the
jig is in position “Flash”; position “Accessory” is intended for ACI tests with connected
ACI-communication enabled accessories, such as car kits or camera headsets.
• When shielding lids are removed from the shielding frame on the PWB, new
shielding lids must be used for proper closing of the shielding. It is not allowed to reuse the removed ones.
- Fuses (10 pcs)
- Replacement part (1pc)
Issue 1 11/2005 COMPANY CONFIDENTIAL 15
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Nokia Customer Care 4 - Service Tools and Service Concepts
■ RJ-107 soldering jig
Soldering jig is used for module level repair, either as fixation in µBGA rework places or when
there is need to hold a module on the work bench for any other repair.
Features include:
• convenient locking mechanism
• four (optional mount) rubber feet allow usage also on repair benches
• fixation of phone module in both ways possible (bottom or top side up)
• ESD proof material
• standard uBGA jig thickness and outer dimensions
View of RJ-107
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■ SS-42 camera removal tool
Used to unlock and lift out camera module.
Note: Replaces SRT-10 which can only be used for unlocking
View of SS-42
.
Issue 1 11/2005 COMPANY CONFIDENTIAL 17
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■ ST-13 PA rework stencil
The PA rework stencil is reused from RH-23.
SK-9 PA rework kit
containing
RJ-21 PA rework jig
(designed for RH-23 and RM-17)
ST-11 PA rework stencil
(designed for RH-23)
For RM-127 power amplifier repairs, the following sten cil is needed instead of the above mentioned stencil (to be ordered separately).
ST-13 PA rework stencil
(designed for RM-17)
If spreader is needed, please refer to
SPS-2 Spreader
Note: For RM-127, another stencil than the one included in the rework kit SK-9 is needed, because another PWB pad layout is used. Therefore, ensure that for RM-127 the stencil ST-13 is
used for PA repairs.
18 COMPANY CONFIDENTIAL Issue 1 11/2005
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■ Rework procedure
Due to the large mechanical tolerance of the power amplifiers, the following procedure is necessary:
1. Put the power amplifier into the RJ-21 rework jig. The PA should be placed in the
best fit location, this is determined by placing it in the largest location first, if this is to
large reposition the PA in the next size location. This should be carried out until the
best fit location is found.
2. Once the best fit location has been found, leave the PA there and put the stencil
on top of the jig and PA.
3. Put soldering paste on the PA properly.
Issue 1 11/2005 COMPANY CONFIDENTIAL 19
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Nokia Customer Care 4 - Service Tools and Service Concepts
4. Remove the stencil and the PA from the jig.
5. Start the soldering process.
20 COMPANY CONFIDENTIAL Issue 1 11/2005
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■ RJ-46 antenna switch rework jig
View of RJ-46
■ ST-15 antenna switch solder paste stencil
View of ST-15
Issue 1 11/2005 COMPANY CONFIDENTIAL 21
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Nokia Customer Care 4 - Service Tools and Service Concepts
■ FPS-8 flash prommer
The flash prommer FPS-8 is used with e.g. docking station (+adap ter) or the POS flash adapter.
Power is supplied to FPS-8 from the universal power supply.
The sales pack includes the following hardware items:
• FPS-8 flash prommer
• ACF-8 universal power supply
• AXS-4 service cable (D9-D9)
• CA-10DS bi-directional parallel cable
View of FPS-8
■ FPS-10 flash prommer
FPS-10 interfaces with:
•PC
• Control unit
• Flash adapter
• Smart card
FPS-10 flash prommer features:
• Flash functionality for BB5 terminals
• Smart card reader for SX-2 or SX-4
• USB traffic forwarding
• USB to FBUS/Flashbus conversion
• LAN to FBUS/Flashbus and USB conversion
• Vusb output switchable by PC command
FPS-10 sales package includes:
• FPS-10 flash prommer
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• Power supply with 5 country-specific cords
• USB cable
View of FPS-10
Issue 1 11/2005 COMPANY CONFIDENTIAL 23
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■ FPS-11 multiprommer
View of FPS-11
■ ACF-8 universal power supply
ACF-8 universal power supply is used to power FPS-8. ACF-8 has 6 V DC and 2.1 A output.
View of ACF-8
24 COMPANY CONFIDENTIAL Issue 1 11/2005
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■ AC-33 power supply
Universal power supply for FPS-10; included in the FPS-10 sales package
View of AC-33
Issue 1 11/2005 COMPANY CONFIDENTIAL 25
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■ FLC-2 DC cable
The FLC-2 is used to supply a controlled operating voltage.
View of FLC-2
■ AXS-4 service cable
The AXS-4 D9-D9 service cable is used to connect two 9 pin D connectors e.g. between PC
and FPS-8. Cable length is 2 meters.
View of AXS-4
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■ XCS-1 service cable
The XCS-1 service cable is used to connect FLS-4 to SF-17.
View of XCS-1
■ SW security device PKD-1
SW security device is a piece of hardware enabling the use of the service software when connected to the parallel (LPT) port of the PC. Without the dongle present it is not possible to use
the service software. Printer or any such device can be conne cted to the PC through the dongle
if needed.
Caution: Make sure that you have switched off the PC and the printer before making connections!
Caution: Do not connected the PKD-1 to the serial port. You may damage your PKD-1!
View of SW security device
Issue 1 11/2005 COMPANY CONFIDENTIAL 27
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■ FLS-4S POS (Point Of Sale) flash device (sales pack)
FLS-4S is a dongle and flash device incorporated into one package, developed specifically for
POS use.
View of FLS-4S
■ PCS-1 Power Cable
The PCS-1 power cable (DC) is used to connect e.g. JVB-1 to FPS-8.
View of PCS-1
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■ XRF-1 RF cable
RF cable XRF-1 is used to connect e.g. module jig to RF measurement equipment.
View of XRF-1
■ DAU-9S MBUS cable
The MBUS cable DAU-9S has a modular connector, and is used with between PC's serial port
and e.g. module jig.
View of DAU-9S
Issue 1 11/2005 COMPANY CONFIDENTIAL 29
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■ CA-31D USB cable
The CA-31D USB cable is used to connect FPS-10 or FPS-1 1 to a PC. It is included in the FPS10 and FPS-11 sales packages.
View of CA-31D
■ XCS-4 modular cable
XCS-4 is a shielded cable (one specially shielded conductor) modular cable for flashing and
service purposes.
View of XCS-4
30 COMPANY CONFIDENTIAL Issue 1 11/2005
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■ CA-35S power cable
View of CA-35S
■ CA-41PS power cable
View of CA-41PS
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■ CA-10DS bi-directional parallel cable
Bi-Directional parallel cable included in FPS-8 sales pack.
View of CA-10DS
■ CA-44 DC adapter cable
View of CA-44
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■ CA-52PS power cable
Charger plug to charger plug service cable.
View of CA-52PS
■ SX-4 smart card
SX-4 is a BB5 security device used to protect critical features in tuning and testing.
SX-4 also needed together with FPS-10 when DCT-4 phones are flashed.
View of SX-4
Issue 1 11/2005 COMPANY CONFIDENTIAL 33
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Service Concepts
■ POS flash concept with FLS-4S
Item Type Description
1 SF-17 POS flash adapter
2 XCS-1 Service cable
3 FLS-4S Flash device
4 ACF-8 AC charger
5 Computer with Phoenix SW
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■ POS flash concept with FPS-8
Item Type Description
1 SF-17 POS flash adapter
2 FLC-2 Power cable
3 XCS-4 Modular cable
4 FPS-8 Flash prommer box
5 ACF-8 AC charger
6 AXC-4 D9-D9 cable
7 CA-10DS Printer cable
8 PKD-1 SW protection key
9 Computer with Phoenix SW
SRAM module
Issue 1 11/2005 COMPANY CONFIDENTIAL 35
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■ POS flash concept with FPS-10
Item Type Description
1 SF-17 POS flash adapter
2 CA-35S Power cable
3 XCS-4 Modular cable
4 FPS-10 Flash prommer box
5 SX-4 Smart card
6 AC-33 Power supply
7 CA-31D USB cable
8 PKD-1 SW protection key
9 Computer with Phoenix SW
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■ POS flash concept with FPS-11
Item Type Description
1 SF-17 POS flash adapter
2 XCS-1 Service cable
3 SX-4 Smart card
4 FPS-11 Flash prommer box
5 AS-33 Power supply
6 CA-31D USB cable
7 PKD-1 SW protection key
8 Computer with Phoenix SW
Issue 1 11/2005 COMPANY CONFIDENTIAL 37
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■ JBV-1 flash concept with FPS-8
Item Type Description
1 JBV-1 Docking station
2 DA-61 Docking station adapter
3 PCS-1 Power cable
4 XCS-4 Modular cable
5 FPS-8 Flash prommer box
6 ACF-8 AC charger
7 AXC-4 D9-D9 cable
8 DC-10DS Printer cable
9 PKD-1 SW protection key
10 Computer with Phoenix SW
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■ JBV-1 flash concept with FPS-10
Item Type Description
1 JBV-1 Docking station
2 DA-61 Docking station adapter
3 CA-41PS Modular cable
4 XCS-4 Power cable
5 FPS-10 Flash prommer box
6 SX-4 Smart card
7 AC-33 Power supply
8 CA-31D USB cable
9 PKD-1 SW protection key
10 Computer with Phoenix SW
Issue 1 11/2005 COMPANY CONFIDENTIAL 39
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■ JBV-1 service concept
This concept is for baseband calibration.
EM calibration including Zocus should be carried out in JBV-1 and DA-61.
Note: Power to JBV-1 should be supplied from an external power supply, not a flash prommer.
JBV-1 input voltage: normal +12V, maximum +16V.
Item Type Description
1 JBV-1 Docking station
2 DA-61 Docking station adapter
3 CA-52PS Service battery cable
4 PCS-1 Power cable
5 DAU-9S MBUS cable
6 PKD-1 SW protection key
7 Computer with Phoenix SW
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■ Module jig flash concept with FPS-8
Flashing with MJ-22 is recommended in local mode.
The following equipment is required for the AMS software update when the system mo dule is
placed in the MJ-22 and connected through an FPS-8 setup.
Item Type Description
1 MJ-22 Module jig
2 PCS-1 Power cable
3 XCS-4 Modular cable
4 FPS-8 Flash prommer box
5 ACF-8 AC charger
6 AXS-4 D9-D9 cable
7 CA-10DS Printer cable
8 PKD-1 SW protection key
Issue 1 11/2005 COMPANY CONFIDENTIAL 41
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Item Type Description
9 Computer with Phoenix SW
SF-12 SRAM module
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■ Module jig flash concept with FPS-10
Flashing with MJ-22 is recommended in local mode.
The following equipment is required for the AMS software update when the system mo dule is
placed in the MJ-22 and connected trough an FPS-10 set up.
Item Type Description
1 MJ-22 Module jig
2 CA-41PS Power cable
3 XCS-4 Modular cable
4 FPS-10 Flash prommer box
5 SX-4 Smart card
6 AC-33 AC charger
Issue 1 11/2005 COMPANY CONFIDENTIAL 43
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Item Type Description
7 CA-31D USB cable
8 PKD-1 SW protection key
9 Computer with Phoenix SW
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■ Module jig service concept
This concept is for troubleshooting and RF calibration.
MJ-22 is intended to use with external power supply.
MJ-22 input voltage: normal +4V , maximum +6.5V .Ensure that the jumper is set for volt age reg-
ulation before the external power supply is connected. When a prommer is used for power supply (+4V), the jumper should be set to bypass regulator . EM calibration including Zocus are only
done with JBV-1. Module jig MJ-22 does not support Zocus calibration.
Item Type Description
1 MJ-22 Module jig
2 XRF-1 RF cable
3 DAU-9S MBUS cable
4 PCS-1 Power cable
5 PKD-1 SW protection key
6 Computer with Phoenix SW
Issue 1 11/2005 COMPANY CONFIDENTIAL 45
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■ RF coupler service concept
Item Type Description
1 JBV-1 Docking station
2 DA-61 Docking station adapter
3 SA-75 RF coupler
4 PCS-1 Power cable
5 XRF-1 RF cable
6 DAU-9S MBUS cable
7 PKD-1 SW protection key
8 Computer with Phoenix SW
46 COMPANY CONFIDENTIAL Issue 1 11/2005
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