Level 1 & 2 Service Manual 6809509A89-O W510 Digital Wireless Telephone W510 GSM 850/900/1800/1900 GPRS/EDGE
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © Motorola, Inc. 2007. All rights reserved.
Level Service Manual Contents Contents Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-i Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents ii March 01, 2007
Level 1 and 2 Service Manual W510 6809509A89-O 1 and 2 Introduction Motorola® Inc. maintains a worldwide organization that is dedicated to provide responsive, fullservice customer support. Motorola products are serviced by an international network of company-operated product care centers as well as authorized independent service firms. Available on a contract basis, Motorola Inc.
W510 Inc. certain exclusive rights to the copyrighted computer programs, including the exclusive right to copy, reproduce, modify, decompile, disassemble, and reverse-engineer the Motorola computer programs in any manner or form without Motorola's prior written consent.
Level 1 and 2 Service Manual Conventions Special characters and typefaces, listed and described below, are used in this publication to emphasize certain types of information. ➧ G E M Note: Emphasizes additional information pertinent to the subject matter. Caution: Emphasizes information about actions which may result in equipment damage. Warning: Emphasizes information about actions which may result in personal injury. Keys to be pressed are represented graphically.
W510 Parts Replacement When ordering replacement parts or equipment, include the Motorola part number and description used in this service manual. When the Motorola part number of a component is not known, use the product model number or other related major assembly along with a description of the related major assembly and of the component in question. In the U.S.A., to contact Motorola, Inc. on your TTY, call: 800-793-7834.
Level 1 and 2 Service Manual Specifications General Function Frequency Range GSM 850 Frequency Range GSM 900 Frequency Range DCS 1800 Frequency Range PCS 1900 Channel Spacing Channels Modulation Transmitter Phase Accuracy Duplex Spacing Frequency Stability Operating Voltage Transmit Current Drain Standby Current Drain Temperature Range Dimensions, with 880 mAh Li-Ion battery Size (Volume) Weight Battery Life, with standard 880 mAh LiIon Battery Battery Charge Time Alert Volume Transmitter Functions RF Pow
W510 Speech Coding Functions Speech Coding Type Bit Rate Frame Duration Block Length Classes Bit Rate with FEC Encoding 6 Specification Regular pulse excitation/linear predictive coding with long term prediction (RPE LPC with LTP) 13.0 kbps 20 ms 260 bits Class 1 bits = 182 bits; Class 2 bits = 78 bits 22.
Level 1 and 2 Service Manual Product Overview Motorola W510 telephones deliver GSM features in a small and lightweight package.
W510 Video • MPEG4 Video clip playback • H.263 • 3GP Display • Main display 176 x 220 pixel 262k TFT • CLI display 96 x 80 65k CSTN Memory • 15 MB internal memory • Accepts removable microSD memory up to 2GB modules Imaging • Primary camera resolution 1.3 MP Wireless Access Protocol (WAP) 2.0 Compliancy In the WAP environment, access to the Internet is initiated in wireless markup language (WML), which is derived from hypertext markup language (HTML).
Level 1 and 2 Service Manual Caller Line Identification Upon receipt of a call, the calling party’s phone number is compared to the phone book. If the number matches a phone book entry, that name will be displayed. If there is no phone book entry, the incoming phone number will be displayed. In the event that no caller identification information is available, an incoming call message is displayed. ➧ User must subscribe to a caller line identification service through their service provider.
W510 General Operation Controls, Indicators, and Input/Output (I/O) Connectors The W510 controls are located on the front and sides of the device, and on the keyboard, as shown in Figures 1 and 2. Internal Earpiece Main Display Left Soft Key Right Soft Key Go online Clear Key Voice Command Key Volume Keys Turn on & off, hang up, exit menus. Make & answer calls. Smart Key Mic Scroll up, down, left, or right. Press in to select. Charge up or connect. 061418o Figure 1.
Level 1 and 2 Service Manual Voice Command Key Volume Keys Smart Key EMU Connector 061419o Figure 2. Telephone Controls and Indicators Locations (Sides) Indicators, in the form of icons, are displayed on the LCD (see Figure 3). 2. GPRS 3. Bluetooth 4. Messaging Presence 1. Signal Strength/ Airplane Mode Service Provider 5. IM 10:15 am 10. Battery Level Options 6. Message Main Menu 7. Location 9. Active Line 8. Profile 061420o Figure 3. Main Screen Icon Display 1.
W510 2. GPRS Indicator – Shows when your phone is using a high-speed General Packet Radio Service (GPRS) network connection. Indicators can include: > = GPRS connection < = GPRS data transfer 3. 4. 8 = GPRS secure data transfer 9 = GPRS unsecure data transfer Bluetooth Indicator – Shows when your phone is connected to another device in a Bluetooth connection. Messaging Presence Indicator – Shows your instant messaging (IM) status.
Level 1 and 2 Service Manual Figures 4 shows the Idle Screen display. Recent Calls Service Provider 10:15 am Contacts Left Soft Key Label Messages Web Access Options Main Menu Right Soft Key Label 061421o Figure 4. Main Screen Display Battery Information Battery Charge Indicator The telephone displays a battery charge indicator icon in the idle screen to indicate the battery charge level. The gauge shows four levels: 100%, 50%, 30%, 15% and Low Battery.
W510 6809509A89-O 1 and 2 Tools and Test Equipment W510 Tools and Test Equipment The following table lists tools and test equipment recommended for disassembly and reassembly of W510 telephones. Use either the listed items or equivalents. Table 1. General Test Equipment and Tools Motorola Part Number1 0-00-00-40810 Description Application (U)SIM test card Used to enable manual test procedures.
Level 1 and 2 Service Manual Disassembly Disassembly The procedures in this section provide instructions for the disassembly of a W510 telephone. Tools and equipment used for the phone are listed in Table 1, preceding. G G Many of the integrated devices used in this equipment are vulnerable to damage from electrostatic discharge (ESD). Ensure adequate static protection is in place when handling, shipping, and servicing the internal components of this equipment.
Disassembly 4. Lift the end of the battery and remove it completely. See Figure 2. Battery 061423o Figure 2. Removing the Battery E There is a danger of explosion if the Lithium Ion battery is replaced incorrectly. Replace only with the same type of battery or equivalent as recommended by the battery manufacturer. Dispose of used batteries according to the manufacturer’s instructions. 5. 6. 7.
Level 1 and 2 Service Manual Disassembly Removing and Replacing the Subscriber Identity Module (SIM) and Memory Card 1. Remove the battery door and battery as described in the procedures. SIM memory card slot 061424o Figure 3. Removing the SIM and Memory Card 2. 3. 4. 5. 6. 7. 8. 9. 6809509A89-O Slide the SIM away from the SIM holder, as shown in Figure 3. Carefully lift the SIM from the phone.
Disassembly Removing and Replacing the Rear Housing G This product contains static-sensitive devices. Use anti-static handling procedures to prevent electrostatic discharge (ESD) and component damage. 1. G Remove the battery cover, battery, SIM and memory card as described in the procedures. In addition to 2 screws, the rear housing assembly is fastened with plastic latches. These are fragile and should be released with care. 2.
Level 1 and 2 Service Manual Disassembly 3. Flip the handset over and using a hand tool to insert from the left or right side, unlatch the catches on the front housing cap, as shown in figure 5. Using a Torx driver with a T-5 bit, remove the screws at each side of the phone. Retain the screws for reassembly. Housing Screw Housing Screw Disassembly Tool 061426o Figure 5. Removing the Rear Housing Latches 4. Carefully rotate the rear housing away from the front housing and flip assembly.
Disassembly 6. 7. 8. To replace, carefully align the rear housing to the front & flip assembly. Gently press the housings together until they fit snuggly. Replace the 4 housing screws and tighten to a final torque setting of 1.4 +/- 0.1 lbs. Do not over tighten. 9. Flip over the phone & replace the 2 front housing cap screws & tighten to a final torque setting of 1.4 +/- 0.1 lbs. Do not over tighten. 10. Replace the SIM, memory card, battery, and battery cover as described in the procedures.
Level 1 and 2 Service Manual Disassembly Removing and Replacing the Antenna 1. 2. Remove the battery cover, battery, SIM, memory card, rear housing and transceiver board assembly as described in the procedures. Use the plastic tweezers to grasp the plastic antenna latches and carefully release them from the transceiver board slots. See Figure 8. CAUTION: Carfully release these plastic clips BEFORE removing the antenna holder assembly. 061467o Figure 8.
Disassembly 3. Use the disassembly tool to release the antenna assembly as shown in Figure 8. Antenna Disassembly Tool Antenna holder assembly 061428o Figure 9. Removing the Antenna Assembly 4. 5. 6. 7. 22 Carefully lift the antenna assembly away from the phone. To replace, assembly starts from right to left. Align the antenna assembly to the phone. Carefully press the antenna assembly into position until the antenna assembly latches snap into position.
Level 1 and 2 Service Manual Disassembly Removing and Replacing the Top Flip Assembly Cover 1. 2. 3. Remove the battery cover, battery, SIM, memory card, rear housing, and transceiver board assembly as described in the procedures. Remove the 4 flip assembly screw caps. Use the T-5 driver to remove the 4 screws from the flip assembly (see Figure 10). Retain the screws for re-assembly. Screws Screws 061431o Figure 10. Removing the Flip Assembly Screws 4.
Disassembly 5. Lift the flip cover away from the flip assembly. Be careful not to damage the display flex cable (see Figure 12). 040723o Figure 12. Removing the Flip Assembly Cover 6. 7. 8. 9. ➧ 24 To replace, align the flip cover to the flip assembly, gently press the flip cover onto the flip assembly until the flip cover latches engage.* Insert the 4 screws, tighten to a final torque setting of 1.4 +/- 0.1 lbs to secure the flip cover to the flip assembly. Avoid damage to the flex cable.
Level 1 and 2 Service Manual Disassembly Removing and Replacing the CLI Lens 1. 2. 3. Remove the battery cover, battery, SIM, memory card, rear housing, transceiver board assembly and top flip cover as described in the procedures. Use the disassembly tool to gently pry apart the CLI lens and the flip bracket. Divide CLI lens and flip bracket along the edge of CLI lens. 040722o Figure 13. Separating the CLI Lens 4. Add protective film on CLI. 040723o Figure 14. Replacing Protective Film on CLI 5. 6.
Disassembly Removing and Replacing the Camera Assembly 1. G Remove the battery cover, battery, SIM, rear housing, and transceiver board assembly, flip assembly cover, and CLI lens cover as described in the procedures. The flexible printed cable (FPC) (flex) is easily damaged. Exercise extreme care when handling. 2. 3. Unlock the ZIF connector and remove the camera assembly flex connector. Carefully lift the camera assembly and flex out of the flip assembly (see Figure 15).
Level 1 and 2 Service Manual Disassembly Removing and Replacing the Display Module Assembly 1. G Remove the battery cover, battery, SIM, rear housing, transceiver board assembly, flip assembly cover, CLI lens and camera assembly, as described in the procedures. The flexible printed cable (FPC) (flex) is easily damaged. Exercise extreme care when handling. 2. 3. 4.
Disassembly 8. Carefully lift the display lens away from the flip assembly. Display Module Figure 17. Removing the Display Module Assembly 9. To remove the main display module lens, carefully disconnect the flex connector for the main display and then pry it off from the metal shield. 10. To remove the CLI display, pill off the kapton tape covering the CLI Flex circuit & ZIF connector. 11. Using the disassembly tool, carefully unseat the CLI flex circuit from the adhesive underneath.
Level 1 and 2 Service Manual Disassembly 12. Remove the CLI dispaly from the Flip pcb. Figure 18. Removing the Display Module Lens ➧ A new adhesive strip might be required for proper securing of the CLI Flex in place on the Flip pcb. 13. To replace the CLI display, insert the CLI flex into the ZIF connector & close the latch. 14. Properly align the CLI display onto the bracket & press down on the CLI flex to ensure proper contact. 15. Paste a new kapton tape across the CLI flex & ZIF connector. 16.
Disassembly 18. Align the display module to the flip assembly & then insert the receiver into the slot provided. 19. Insert the display bracket. 20. Insert the Flex cable to the slot of the connector on flip PCB. 21. Replace the display bracket, camera assembly, flip assembly cover, transceiver board, rear housing, antenna, SIM, battery, and battery connector as described in the procedures. Removing and Replacing the Flip Hinge 1. 2. 3. 4. 5.
Level 1 and 2 Service Manual Disassembly 6. 7. 8. Use the disassembly tool to push the left knuckle out towards the left side. Press the hinge inwards using the disassembly tool. Seperate and remove the flip and front housing. 040722o Figure 20. Removing the Flip Hinge 9. 10. 11. 12. 13. 6809509A89-O To replace the flip hinge, replace the flip and front housing. Snap the right hinge back into place. Using the disassembly tool to guide the left knuckle back into its socket. Assemble the cap lock.
Subscriber Identity Module (SIM) and Identification Subscriber Identity Module (SIM) and Identification SIM A SIM is required to access the existing local GSM network, or remote networks when traveling (if a roaming agreement has been made with the provider). The SIM contains: • All the data necessary to access GSM services. • The ability to store user information such as phone numbers. • All information required by the network provider to provide access to the network.
Level 1 and 2 Service Manual Subscriber Identity Module (SIM) and Identification International Mobile Station Equipment Identity (IMEI) The International Mobile station Equipment Identity (IMEI) number is an individual number unique to the PCB and is stored within the unit's memory. The IMEI uniquely identifies an individual mobile station and thereby provides a means for controlling access to GSM networks based on mobile station types or individual units. The full IMEI structure is listed in Table 2.
HTCMD (Handset Test Command) HTCMD (Handset Test Command) Enter test command Insert Test SIM Card & Battery into handset. To enter Test Command Screen, Press button followed by 048263* Enter Suspend Mode Enter “54”, then select When “Success” message appears, press to activate. (MUST DO) Display Light OFF Test Enter 62*1*0 followed by , , the Display Backlight should light OFF, select after test.
Level 1 and 2 Service Manual Display Segment/ Pixel Test HTCMD (Handset Test Command) Turn On All Pixels to inspect the display grid on LCD Enter 55*2*001 & select , select after test. Turn On Checkboard pattern A Enter 55*2*002 & select , select after test. Turn On Checkboard pattern B Enter 55*2*003 & select , select after test. Turn On Border pixels ON Enter 55*2*004 & select , select after test.
Troubleshooting Troubleshooting Troubleshooting Chart Table 3. : Level 1 and 2 Troubleshooting Chart SYMPTOM 1. Telephone will not turn on or stay on. PROBABLE CAUSE VERIFICATION AND REMEDY a) Battery either discharged or defective. Measure battery voltage across a 50 ohm (>1 Watt) load. If the battery voltage is <3.4 Vdc, recharge the battery using the appropriate battery charger. If the battery will not recharge, replace the battery. If battery is not at fault, proceed to b.
Level 1 and 2 Service Manual Troubleshooting Table 3. : Level 1 and 2 Troubleshooting Chart (Continued) SYMPTOM PROBABLE CAUSE VERIFICATION AND REMEDY 6. Receive audio from earpiece speaker is a) Connections to or from transceiver Gain access to the transceiver board assembly weak or distorted. board assembly defective. as described in the procedures. Check flex and the flex connector from the flip assembly to the transceiver board assembly. If flex is at fault, replace flip assembly.
Troubleshooting Programming: Software Upgrade and Flexing Contact your local technical support engineer for information about equipment and procedures for flashing and flexing. Exploded View Diagram (Main assembly) Right knuckle Assy 0171494A01 Xcvr M1.5 self-tap screws 0387347Y03 Cap Lock Grounding 4270356D03 EL-Dome Panel BOTTOM FlipBumpers Magnet 3871444A01 5987825N02 Left knuckle caps M1.6 Flip Screws 1571452A01 0387726M10 Hinge 1.
Level 1 and 2 Service Manual Troubleshooting Exploded View Parts List (Main assembly) The following part number table is provided only for reference. Please contact your local Motorola parts organization for current part number information. Table 4. Exploded View Parts List E There is a danger of explosion if the Lithium Ion battery pack is replaced incorrectly. Replace only with the same type of battery or equivalent as recommended by the battery manufacturer.
Troubleshooting Table 5. Accessories(Continued) Part Description Part Number 128MB microSD card & Mot SD adapter SYN1403 1GB microSD card & Mot SD adapter SYN1406 256MB microSD card & Mot SD adapter SYN1404 2GB microSD card & Mot SD adapter SYN1407 512MB microSD card & Mot SD adapter SYN1405 Grey EMU data cable SKN6234 USB 2.
Level 1 and 2 Service Manual Troubleshooting Table 5.
Troubleshooting Table 5. Accessories(Continued) Part Description Part Number Stereo Headset - EMU SYN1301 Adapter EMU to 2.5mm stereo SYN1505 Adapter EMU to 3.
Level 1 and 2 Service Manual Troubleshooting Table 5.
Troubleshooting 44 March 01, 2007 6809509A89-O
Level 1 and 2 Service Manual 1 and 2 6809509A89-O W510 IndexINDEX INDEX A flip assembly, removing and replacing 23 flip display module assembly, removing and replacing 27 active line indicator 12 airplane mode indicator 11 antenna, removing and replacing 21 G GPRS indicator 12 B battery charge indicator 13 function 13 removing 15 battery housing removing 15 battery indicator 12 Bluetooth indicator 12 I C L identification 32 international mobile station equipment identity 33 mechanical serial numb
INDEX profile indicator 12 R rear housing removing 18 regulatory agency compliance 1 removing antenna 21 battery 13, 15 battery housing 15 camera assembly 26 flip assembly 23 flip display module assembly cover 27 rear housing 18 SIM 17 transceiver board assembly 20 replacement parts contact information 4 replacing antenna 21 battery 15 camera assembly 26 flip assembly 23 flip display module assembly 27 rear housing 18 SIM 17 transceiver board assembly 20 Product Family W510 SIM Toolkit 8 SIM, removing a
