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Motorola E815 Service Manual Download Page 15

6809492A18-B

          January 24, 2006 

15

Level 2 Service Manual

Tools and Test Equipment

Tools and Test Equipment

The following table lists tools and test equipment recommended for disassembly 
and reassembly of E815 and E816 telephones. Use either the listed items or 
equivalents. 

Table 1. General Test Equipment and Tools

Motorola Part Number

1

Description

Application

RSX4043-A

Torque Driver

Used to remove and replace screws

—

Torque Driver Bit T-6 Plus, Apex 440-6IP 
Torx Plus or equivalent

Used with torque driver

See Table 7

Rapid Charger

Used to charge battery and power 
phone

0180386A82

Antistatic Mat Kit (includes 66-80387A95 
antistatic mat, 66-80334B36 ground 
cord, and 42-80385A59 wrist band)

Provides protection from damage to 
device caused by electrostatic discharge 
(ESD)

6680388B67

Disassembly tool, plastic with flat and 
pointed ends (manual opening tool)

Used during assembly/disassembly of 
phone

6680388B01

Tweezers, plastic

Used during assembly/disassembly

—

Digital Multimeter, HP34401A

2

Used to measure battery voltage

6688054N01

Flip disassembly tool

Used to disassembly the flip assembly

SYN1241A

Black Stick

Used to pry the main display lens from 
the flip assembly

SYN1242A

Silver Metal Bezel

Used to open the phone

1. To order in North America, contact Motorola Aftermarket and Accessories Division (AAD) at (800) 422-4210 or 
FAX (800) 622-6210; Internationally, AAD can be reached by calling (847) 538-8023 or by fax (847) 576-3023.
2. Not available from Motorola. To order, contact Hewlett Packard at (800) 452-4844.

2

E815, E816 CDMA

6809492A18-B

Summary of Contents for E815

Page 1: ...Level 2 Service Manual 6809492A18 B E815 E816 Digital Wireless Telephone CDMA 800 1900 MHz ...

Page 2: ......

Page 3: ...g and Replacing the Speaker Cover and Keypad Bezel 20 Removing and Replacing the Keyboard Stiffener 22 Removing and Replacing the Flip Assembly and Transceiver Board 23 Removing and Replacing the Flip Display Lens 26 Removing and Replacing the Flip Assembly Sleeve 27 Removing and Replacing the Flip Knuckle 28 Removing the Display Bezel 29 Removing the Display Assembly 31 Removing and Replacing the...

Page 4: ...r on the housing Use the entire model number when inquiring about the product Numbers are also assigned to chassis and kits Use these numbers when requesting information or ordering replacement parts Product Names Product names are listed on the front cover Product names are subject to change without notice Some product names as well as some frequency bands are available only in certain markets Re...

Page 5: ... computer programs with the Motorola product About this Service Manual Using this service manual and the suggestions contained in it assures proper installation operation and maintenance Refer questions about this manual to the nearest Customer Service Manager Audience This service manual aids service personnel in testing and repairing E815 telephones Service personnel should be familiar with elec...

Page 6: ...s will be repaired but not refurbished as standard Appointed Motorola Service Hubs will perform warranty and non warranty field service for level 2 assemblies and level 3 limited PCB component The Motorola High Technology Centers will perform level 4 full component repairs Customer Support Customer support is available through dedicated Call Centers and in country help desks Product Service traini...

Page 7: ...ajor 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 Accessories and Aftermarket Division AAD Order replacement parts test equipment and manuals from AAD U S A Outside U S A Phone 800 422 4210 Phone 847 538 8023 FAX 800 622 6210 FAX 847 576 3023 Website http businessonline motorola c...

Page 8: ... antenna Weight 132g 4 65 oz with battery Temperature Range 30 C to 60 C 22 F to 140 F Humidity 80 Relative Humidity at 50 C 122 F Battery Life 750 mAh Li Ion Battery Up to 180 minutes digital talk time IS 95 A B Up to 250 hours IS 95 A B standby time Up to 350 hours IS 2000 standby time All talk and standby times are approximate and depend on network configuration signal strength and features sel...

Page 9: ... display on the outside of the flip assembly The main display is a 128 x160 pixel 262K color TFT LCD The external display is a 96x39 pixel 4 color OLED The camera is a 1 3 mega pixel VGA CMOS Sensor Camera The telephones are made of polycarbonate plastic with a metal enclosure The display and speaker as well as the 18 key keypad transceiver printed circuit board PCB microphone charger and headphon...

Page 10: ...PIM functionality PC Sync with optional Mobile Phone Tools Software Predic tive Text iTAP 1000 Multi fielded Phonebook Entries Voice Memo Currency Converter Calculator AFLT aGPS location services2 Simplified Text Entry iTAP predictive text entry Press a key to generate a character and a dynamic dictionary uses this to build and display a set of word or name options The iTAP feature may not be avai...

Page 11: ...lume Keys Adjust earpiece ringer volume Speakerphone Key Voice Recognition Key Press once to activate speaker independent voice recognition Press hold to record voice records contacts shortcut names 5 Way Navigation Key Scroll through menus lists set feature values Press K key in center to select highlighted item Accessory Port Send Key Make answer calls view recently dialed calls list Left Soft K...

Page 12: ...s constant graphical representations of battery capacity and signal strength as well as the real time clock Display animation makes the phone s icon menu move smoothly as the user scrolls up and down 050249o Figure 2 External Hardware Features Locations Whether a phone displays all indicators depends on the programming and services to which the user subscribes 032408o Camera Lens Take photos video...

Page 13: ...ls by a specific ringer tone Battery Function 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 66 33 and Low Battery Battery Removal Removing the battery causes the device to shut down immediately and loose any pending work partially entered phone book entries or outgoing messages...

Page 14: ... E All batteries can cause property damage and or bodily injury such as burns if a conductive materialsuch as jewelry keys orbeaded chains touch exposed terminals The conductive material may complete an electrical circuit short circuit and become quite hot Exercise care in handling any charged battery particularly when placing it inside a pocket purse or other container with metal objects G If the...

Page 15: ... 42 80385A59 wrist band Provides protection from damage to device caused by electrostatic discharge ESD 6680388B67 Disassembly tool plastic with flat and pointed ends manual opening tool Used during assembly disassembly of phone 6680388B01 Tweezers plastic Used during assembly disassembly Digital Multimeter HP34401A2 Used to measure battery voltage 6688054N01 Flip disassembly tool Used to disassem...

Page 16: ...nt used for the phone are listed in Table 1 preceding G Many of the integrated devices used in this phone 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 G Avoid stressing the plastic in any way to avoid damage to either the plastic or internal components ...

Page 17: ...Figure 4 3 Gently lift the top end of the battery cover away from the phone 4 Lift the battery cover away from the phone 5 To replace align the battery cover to the phone 6 Slide the bottom end of the battery cover into the phone 7 Lower the top end of the battery cover onto the phone until battery cover latch snaps into place 040335o Figure 4 Removing the Battery Cover ...

Page 18: ...phone 6 Insert the battery printed arrow first into the battery compartment and push down 7 Insert the ridge at the bottom of the housing into the base of the phone then push the battery down and snap it into place E All batteries can cause property damage and or bodily injury such as burns if a conductive materialsuch as jewelry keys orbeaded chains touch exposed terminals The conductive material...

Page 19: ...a threads are completely disengaged slide the antenna out of the housing See Figure 6 4 To replace insert the threaded end of the antenna carefully into the housing and after ensuring the threads are properly engaged rotate clockwise Tighten firmly by hand 5 Replace the battery and battery cover as described in the procedures 050256o Figure 6 Removing the Antenna G Ensure antenna threads are prope...

Page 20: ...silver bezel tool under the keypad bezel and gently bend the bezel outward from the rear housing to release the 2 snaps on the side of the housing See Figure 7 3 Repeat step 2 for the other side of phone 4 When all four snaps have been released insert the silver bezel tool under the outer edges of the speaker cover to release the latches on each side 040346o Figure 7 Releasing the Keypad Bezel Lat...

Page 21: ...he speaker cover onto the phone 8 Gently press down on the sides of the speaker cover to engage the latches 9 Align the keypad bezel with the phone housing 10 Carefully press the keypad bezel into the phone housing until the snaps engage 11 Replace the antenna battery and battery cover as described in the procedures 050338o Figure 8 Removing the Speaker Cover speaker cover metal disassembly tool ...

Page 22: ...Remove the two screws at the bottom of the phone near the polyphonic speaker See Figure 9 3 Lift the bottom end of the keyboard stiffener toward the flip knuckles 4 Use the disassembly tool to disconnect the keypad flex connector See Figure 10 032216o Figure 9 Removing the rear housing bottom screws 032216o Figure 10 Removing the Keyboard Flex Connector screw location Keyboard Flex Connector Keybo...

Page 23: ...tiffener away from the hinge flex any more than necessary to engage the hooks 10 Lower the keyboard stiffener onto the transceiver board When complete the conductive pad should be compressed between the keyboard stiffener and the hinge flex NOT bunched up between the hinge flex and the PCB 11 Insert and tighten two screws near the polyphonic speaker assembly 12 Replace the speaker cover keypad bez...

Page 24: ...gure 12 4 Carefully separate the flip assembly from the transceiver board and rear housing assembly 032216o Figure 12 Removing the Flip Assembly Flex Connector G This product contains static sensitive devices Use anti static handling procedures to prevent electrostatic discharge ESD and component damage Flip Flex Connector disassembly tool ...

Page 25: ...ign the flip assembly flex connector to the transceiver board 8 Connect the flip assembly flex connector to its socket on the transceiver board 9 Align the flip assembly screw bosses to the screw holes on the transceiver board 10 Hold the assembly together and insert the flip assembly screws into the rear housing assembly and tighten to 14 Ncm 1 25 inch pounds 11 Replace the keyboard stiffener spe...

Page 26: ... Use the flat end of the disassembly tool into the gap and carefully separate the display lens from the flip assembly 4 To replace align the display lens to the flip assembly Expose the display lens adhesive Carefully press the display lens into position on the flip assembly 5 Replace the transceiver board and flip assembly keypad stiffener speaker cover keypad bezel antenna battery and battery co...

Page 27: ...ry off the flip sleeve with the plastic disassembly tool this will result in damage to the display printed flex cable 3 To replace insert the flip assembly into the flip assembly sleeve and push firmly until the flip assembly is fully inserted into the flip assembly sleeve 4 Replace the flip display lens transceiver board flip assembly keyboard stiffener speaker cover keypad bezel antenna battery ...

Page 28: ...board flip display lens and flip assembly sleeve as described in the procedures 2 Remove the knuckle by removing the hinge assembly side followed by the side where the flex is routed 3 Carefully slide the display flex through the knuckle Avoid damage to the display flex see Figure 16 G The flexible printed cable FPC flex is easily damaged Exercise extreme care when handling 040371o Figure 16 Remov...

Page 29: ...nsceiver board flip display lens flip assembly flip assembly sleeve and flip knuckle as described in the procedures 2 Use the metal tweezers to release the five latches in the sequence shown see Figure 17 G The flexible printed cable FPC flex is easily damaged Exercise extreme care when handling 032218o Figure 17 Removing the Display Bezel bezel latch bezel latch display bezel bezel latch 1 2 3 4 ...

Page 30: ...terial A new speaker gasket will be used for reassembly Ensure that the felt cover on the speaker assembly is not damaged while removing the gasket material 7 To replace align the connector with it s socket on the transceiver board 8 Gently press the flex connector into position onto the flex connector socket 9 Lower the new display bezel over the display module Gently and firmly press the latches...

Page 31: ...et 4 Carefully lift the display module and the camera module up and away from the remainder of the flip assembly 5 To replace align the camera module to the camera bracket 6 Angle the display module upward while inserting the camera module into the camera bracket 7 Seat the camera module into the camera bracket while pivoting the display module downward into place on the flip assembly 8 Carefully ...

Page 32: ... on the display assembly see Figure 20 3 Carefully lift the camera module away from the display assembly 4 To replace align the camera module connector to its socket on the display assembly 5 Carefully but firmly press the connector into the socket until properly seated 6 Replace the display assembly display bezel flip knuckle flip assembly sleeve flip assembly flip display lens transceiver board ...

Page 33: ...bly as described in the procedures 2 Use the plastic tweezers to lift the keypad from the front housing as shown in Figure 21 3 To replace insert the keypad into the front housing ensuring the keys align properly with the openings in the front housing 4 Replace the transceiver board rear housing assembly antenna battery and battery housing as described in the procedures 032220o Figure 21 Removing ...

Page 34: ...ator assembly to its place in the flip housing assembly 4 Carefully press the motor vibrator assembly into position in the flip housing Ensure that the motor vibrator assembly is fully seated and the surface of the motor vibrator assembly is flush with the outer plane of the flip housing Ensure the motor vibrator shaft turns freely 5 Replace the display assembly display bezel flip knuckle flip ass...

Page 35: ...3 Lift the CLI lens away from the flip housing and discard it 4 Use the disassembly tool to pry the camera bezel away from the flip housing 5 Lift the camera bezel away from the flip housing 6 Remove any residual adhesive left from the foam gasket that held the bezel down 050994o Figure 23 Removing the CLI Lens 050993o Figure 24 Removing the Camera Bezel Disassembly tool CLI lens Flip housing Came...

Page 36: ...he flip housing Observe the notches on the bottom of the camera bezel Press down on the camera bezel firmly to secure it to the flip housing 8 Expose the adhesive on the back side of the new CLI lens 9 Place the new CLI lens onto the flip housing and press down firmly to secure the adhesive to the housing 10 Reassemble flip sleeve as described in the procedures ...

Page 37: ...entification Each Motorola CDMA phone is labeled with a variety of identifying numbers Figure 25 describes the current identifying labels 020463o Figure 25 CDMA Telephone Identification Label MOTOROLA INC FCC ID IHDT5UV1 EE 3 CANADA 109 182 230A TYPE UVKA 832 2412 CHANNEL OPERATION SWF3001A H7 25821A2 VY SN D414AF0EYAA A56 G6 Mfg by Type approval information NAMPS info analog Transceiver model cod...

Page 38: ... a Antenna assembly defective Check to make sure that the antenna pin is properly connected to the transceiver board assembly If connected properly substitute a known good antenna If the fault is still present proceed to b b Transceiver board defective Replace the transceiver board refer to 1c Verify that the fault has been cleared and reassemble the unit with the new transceiver board 3 Display i...

Page 39: ...een cleared and reassemble with the new transceiver board assembly 7 Phone does not sense when flip is opened or closed usually indicated by inability to answer incoming calls by opening the flip or inability to make outgoing calls a Flip assembly defective Temporarily replace the flip assembly with a known good assembly If fault has been cleared reassemble with the new flip assembly If fault not ...

Page 40: ... 24 2006 6809492A18 B Troubleshooting E815 E816 CDMA Programming Software Upgrade and Flexing Contact your local technical support engineer for information about equipment and procedures for flashing and flexing ...

Page 41: ...6809492A18 B January 24 2006 41 Level 2 Service Manual Troubleshooting Exploded View Diagram Figure 26 Exploded View 3 2 12 4 5 6 7 8 9 10 11 13 14 16 17 15 19 20 21 22 18 24 26 28 27 25 23 1 ...

Page 42: ... assy Same 16 3289413N04 Main display gasket Same 17 0789349Y02 Display bezel assembly Same 18 1389566N14 Generic Label 1389566N30 19 1589331N05 Keypad bezel assy 1589331N07 20 0187521Y06 keyboard assembly 0187521Y07 21 transceiver PC Board Assy Same 22 0789414N03 Rear endo assy 0789415N05 23 8587488Y03 Antenna 8587488Y06 24 0389469N02 Screw stiffener Same 25 0387791L01 Screw knuckle 0387791L04 26...

Page 43: ...ladin Bluetooth Headset SYN9826A Caller ID Bluetooth Headset TBD Quadrant Bluetooth Speaker TBD Qwerty Bluetooth Keyboard TBD Platform Stereo Headset TBD FM Stereo Headset SYN8609 Retractable Headset new customizable SYN9050 One Touch Headset new customizable SYN9351 Mono Headset Black SYN8390B Mono Headset Silver AAYN4264A Mono Headset new customizable SYN9350 Over the Ear Headset SYN8908 Neck Lo...

Page 44: ...44 January 24 2006 6809492A18 B Troubleshooting E815 E816 CDMA ...

Page 45: ...acing 27 flip display lens removing and replacing 26 flip knuckle removing and replacing 28 I identification 37 product 4 Introduction 4 K keyboard stiffener removing and replacing 22 keypad removing 33 keypad bezel removing 20 keypad removing and replacing 33 M menu structure 13 motor vibrator Assembly removing and replacing 34 N names product 4 O operation 11 alert settings 13 battery 13 control...

Page 46: ...r Board 23 flip assembly sleeve 27 flip display lens 26 flip knuckle 28 keyboard stiffener 22 keypad 33 keypad bezel 20 motor vibrator assembly 34 speaker cover 20 S service manual about 5 audience 5 conventions 6 scope 5 service policy 6 customer support 6 out of box failure 6 product support 6 shut down upon battery removal 13 SIM card personality transfer 37 speaker cover removing and replacing...

Page 47: ......

Page 48: ...rks indicated as such herein are trademarks of Motorola Inc Reg U S Pat Tm Off 2005 Motorola Inc All rights reserved Personal Communications Sector Sawgrass International Concourse 789 International Parkway Sunrise FL 33325 6220 6809485A75 6809492A18 B ...

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