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Motorola i860 Field Service Manual Download Page 66

PREPARING FOR FIELD LEVEL TESTING:

  Disassembling and Reassembling the Unit

68P80400P73-

A

7-5

7.4

Disassembling and Reassembling the Unit

Motorola recommends the service technician follow a prescribed disassembly sequence to access 
specific items or components of the unit. This product is an efficiently designed package that 
incorporates the physical overlap and integration of some modular components. Refer to the 
Disassembly Sequence flowchart for a suggested path to reach specific components. 

NOTE:

In some cases, the technician may not need to remove certain components to reach others.

7.5

Disassembly Sequence Flowchart

7.6

Assembly/Disassembly Procedures

NOTE:

Installation procedures to be performed in reverse of disassembly except where noted.

Screws used to assemble the 

i

860 are: 1 antenna screw, T-4 drive; 4 housing assembly screws, 

T-6 drive.

Summary of Contents for i860

Page 1: ......

Page 2: ...68P80400P73 A i i860 Digital Multi Service Data Capable Portable Field Service Manual Basic and Field Level Test Procedures July 8 2004 ...

Page 3: ...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 Furthermore the purchase of Motorola products shall not be deemed to grant either directly or by implication estoppel or otherwise any license or rights under the copyrights patents or patent applications of Motorola excep...

Page 4: ...all hold your radio product as you would a wireline telephone Speak directly into the microphone Two way radio operation When using your radio product as a traditional two way radio hold the radio product in a vertical position with the microphone one to two inches 2 5 to 5 cm away from the lips Body worn operation To maintain compliance with FCC RF exposure guidelines if you wear a radio product ...

Page 5: ...overnment These limits are part of comprehensive guidelines and establish permitted levels of RF energy for the general population The guidelines are based on standards that were developed by independent scientific organizations through periodic and thorough evaluation of scientific studies The standards include a substantial safety margin designed to assure the safety of all persons regardless of...

Page 6: ...lug it from the power outlet immediately and discontinue its use For Vehicles Equipped with an Air Bag Do not place a portable radio product in the area over the air bag or in the air bag deployment area Air bags inflate with great force If a portable radio is placed in the air bag deployment area and the air bag inflates the radio product may be propelled with great force and cause serious injury...

Page 7: ... 100 feet and 16AWG for lengths up to 150 feet Do not operate any battery charger if it has received a sharp blow has been dropped or has been damaged in any way take it to a qualified service technician Do not disassemble a battery charger take it to a qualified service technician when service or repair is required Incorrect reassembly may result in a risk of electric shock or fire Maximum ambien...

Page 8: ...Products Position 4 Frequency Band Position 11 Version U 806 to 870 MHz Version Letter Alpha X 806 to 941 MHz Major Change Values given represent range only they are not absolute Position 5 Power Level Position 10 Feature level A 0 to 0 7 Watts 1 Basic 6 Standard Plus B 0 7 to 0 9 Watts 2 Limited Pkg 7 Expanded Pkg C 1 0 to 3 9 Watts 3 Limited Plus 8 Expanded Plus D 4 0 to 5 0 Watts 4 Intermediate...

Page 9: ... 16QAM Quad 64QAM Quad QPSK Recommended Battery SNN5704C SNN5705C Sensitivity 10 BER M 16 QAM 111 dBm Frequency Stability Referenced to base station 0 4 ppm Battery Voltage Nominal Range 3 6 Vdc 3 0 to 4 2 Vdc Spurious Response Immunity 51 dBm Spurious Emissions Conducted Radiated 13 dBm 13 dBm Dimensions HxWxD w 750mAh 87 3 x 46 8 battery door x 24 2 mm w 500mAh 87 3 x 46 8 battery door x 21 8 mm...

Page 10: ...lation Technology 1 1 iDEN Voice Compression Technology 1 3 RF Transmission Bursts 1 3 Calling Area Coverage 1 4 Global Positioning System GPS Section 1 5 SIM Cards 1 5 Removing and Inserting a SIM Card 1 5 CHAPTER 2 COMPONENTS ICONS AND INDICATORS 2 1 Component Views 2 1 Display Icons 2 2 Main Menu Icons 2 2 Status Icons 2 3 Call Icons 2 4 Contacts Type Icons 2 5 Outbox Icons 2 5 CHAPTER 3 DISPLA...

Page 11: ...cal and Electrical Checks 5 3 Shock and Pressure Test 5 3 SIM Card Swap Test 5 3 Accessory Swap Test 5 4 Lockup Test 5 4 Battery Connections Test 5 5 Testing the GPS Receiver 5 5 Voltage Recognition Test 5 6 Camera Test 5 6 Troubleshooting 5 7 Self Test Procedures 5 7 Passcode Test 5 7 Programming Menu Settings Check 5 8 Call Performance Test 5 13 CHAPTER 6 BASIC LEVEL TEST MODES AND PROCEDURES 6 ...

Page 12: ... Unit 7 5 Disassembly Sequence Flowchart 7 5 Assembly Disassembly Procedures 7 5 Battery Cover 7 6 SIM Card 7 6 Antenna 7 7 Back Housing 7 8 Coin Cell 7 9 Main Board Microphone Seal and Keypad 7 10 Flip Assembly 7 11 Exploded View and Parts List 7 15 Component Parts List 7 16 Exploded View 7 17 CHAPTER 8 FIELD LEVEL TEST MODES AND PROCEDURES 8 1 Test Modes 8 1 Entering Test Mode 8 1 Required Test ...

Page 13: ...PPENDIX A ORDERING REPLACEMENT PARTS AND KITS A 1 Customer Service A 1 Replacement Parts A 1 Domestic Orders A 1 International Orders A 1 Replacement Kits A 2 Recommended Test Equipment and Tools A 3 Recommended Programming Equipment A 4 INDEX I 1 ...

Page 14: ... manual 1 1 Who Should Use This Manual This manual is intended for service technicians who should be familiar with the test equipment recommended in Appendix A To help pinpoint basic problems with the unit first perform the mechanical checks and self tests as described in Chapter 5 then proceed to field level troubleshooting and testing 1 2 How This Manual Is Organized This manual contains the fol...

Page 15: ...al italics Used for emphasis and new terms bold Defines menu items fields and buttons code Used for sample input and output 1 4 Related Publications The following publications are available separately iDEN i860 Digital Multi Service Data Capable Phone User s Guide NNTN5429A R 2660 Digital Communications System Analyzer Operator s Manual 68P80386B72 ...

Page 16: ... of the radio frequency RF signal Data is converted into complex symbols which alter the RF signal and transmit the information When the signal is received the amplitude and phase are converted back into symbols and then into the original data There are three different QAM modes that are used for different applications 64QAM 16QAM and 4QAM In voice applications 16QAM is used while in data applicat...

Page 17: ...iding time into 6 slots one for each unit Time allocation enables each unit to transmit its voice information without interference from another unit s transmission Transmission from a unit or base station is accommodated in time slot lengths of 15 milliseconds and frame lengths of 90 milliseconds see Figure 1 2 Note that Rx outbound indicates base to subscriber transmissions Tx inbound indicates s...

Page 18: ...network configuration established by the local service provider Adding error correction bits to the coded voice bits increases the required RF transmission bit rate to approximately 7 4 Kbps for the 4 2 Kbps voice coder and 14 8 Kbps for the 8 0 Kbps voice coder 1 2 1 RF Transmission Bursts All RF transmissions within an iDEN system occur in 15 millisecond blocks called bursts An iDEN base station...

Page 19: ...ipment typically it is a 6 1 channel The outbound PCCH carries system information and pages to specific subscriber units and asks them to respond if they are available for a call Inbound PCCH transmissions carry responses to the pages and requests by subscriber units to set up calls Inbound transmissions on the primary control channel only take 7 5 milliseconds and can be timed to occur in either ...

Page 20: ... reach the receiver The user s position Ux Uy Uz and the clock bias Cb is then calculated To use the GPS a receiver that can receive the spread spectrum signals must be built The detected signals are then converted from RF signals into appropriate digital input formats These digital inputs are processed and converted into position information Once the position coordinates are determined they are c...

Page 21: ...older see Figure 1 3 5 Grasp SIM card from one side and pull out Figure 1 3 Removing a SIM Card To insert a SIM card Figure 1 4 1 Open the SIM card holder 2 Carefully slide the SIM card into the holder see Figure 1 4 Position SIM card as shown 3 Close SIM door slide latch to shut 4 Reinstall the battery and reattach the battery cover F CAUTION Do not touch the gold colored area of the SIM card Ang...

Page 22: ... icons and status indicators associated with the unit 2 1 Component Views Figure 2 1 i860 Component Views Volume Controls Push To Talk PTT Button Audio Jack Accessory Connector Full sized Display Earpiece d Rear View Flip Closed c Front View Flip Closed a Flip Open b Top View Release Microphone Audio Jack Antenna External Display Speaker Button Mute Button Display Shift Button ...

Page 23: ...enu Icons a Net Browse the Web q Java Apps Use Java applications on your phone b Settings Display Info Phone Calls DC GC Options Volume Security Advanced Customize your phone m Ring Tones VibeAll list of ring tones Ring Tones menu Assign ring tones and turn ringer off c VoiceRecord Record and play audio messages j My Info View personal phone information including phone number and Direct Connect nu...

Page 24: ...g Three bars indicates that the battery has been fully charged two bars not flashing 2 3 charged one bar flashing 1 3 charged no bars the battery needs to be charged o p q r s Signal Strength Indicates the device is registered and the strength of the network signal The antenna portion of the icon is always displayed Up to 4 bars are displayed next to the antenna The more bars depicted the stronger...

Page 25: ...te w y x Messages you have one or more messages D EF Internet you are ready to browse the internet or are browsing the internet i j k l m n T9 Text Input you are using T9 Text Input to enter text U Airplane Mode your phone is set to airplane mode Y Z Packet Data you are ready to transfer packet data or are transferring packet data using a data cable N O TTY Indicates that unit is connected to a TT...

Page 26: ...tored must be assigned a Contacts type Contacts type icons that appear on the display are as follows 2 2 5 Outbox Icons Messages you have sent are stored in the outbox These icons appear next to messages in the outbox A Mobile phone number B Direct Connect Direct Connect number C Work1 phone number D Work2 phone number E Home phone number F email email address G Fax phone number H Pager phone numb...

Page 27: ...COMPONENTS ICONS AND INDICATORS Display Icons 2 6 68P80400P73 O This page intentionally left blank ...

Page 28: ...e or software problem If the vibrate function is enabled for incoming phone calls voice mail or message mail the power up sequence includes a 500 ms vibrate cycle Depending upon your service provider the power up sequence screens may differ from those shown Figure 3 1 Power Up Sequence Displays 1 Power Up Display 3 Connecting Display OR 5 Phone Ready Display Idle Screen 4 No Service Display Please...

Page 29: ...s These errors are displayed as SELF CHECK FAIL YXXXX YXXXX represents the identifier for that error Table 3 1 Self Test Errors Y XXXX Description of Error 0 0001 Non reset error log 0 0002 Codeplug error log Table 3 2 Self Test Reset Errors Y XXXX Description of Error 0 0100 RAM failure 0 0200 Data lines failure 0 0400 Address line failure 0 0800 Codeplug corruption invalid 0 1000 Flash checksum ...

Page 30: ...In Service Invalid target ID Re enter ID or try a different ID Please Try Again 1 Loss of service or system failure 2 Network problem 1 Ask provider how long problem will continue 2 Report problem to service provider Service Conflict Current service conflicts with previously activated service Deactivate previous service and try current service again Service Not Available Not currently available on...

Page 31: ...ed clear to transmit Data Ringer Ear Spkr 2091 2823Hz 14x 80ms on 2091Hz 100ms on 2823Hz 2 5 seconds off Unit receives an incoming circuit data call DTMF 0 9 Ear Ear DTMF Continuous DTMF is transmitted Earpiece Volume Set Ear Ear 1000Hz Continuous Earpiece volume changed on quiet channel or in Programming Menu PRGM Group Call Alert Spkr Spkr 2300Hz 2x 150ms off 150ms on Group call received In Serv...

Page 32: ...040Hz Available ringer tones 14x 24ms on 2091Hz 24ms on 2556Hz 2 5s off 14x 64ms on 2230Hz 64ms on 2040Hz 2 5s off 3x 400ms on 2310Hz 400ms on 2820Hz 2 5s off 14x 38ms on 3240Hz 38ms on 2140Hz 2 5s off 1x 200ms on 3160Hz 100ms on 1980Hz 200ms on 2580Hz 2 5s off 1x 200ms on 2540Hz 200ms on 2300Hz 200ms on 2030Hz 2 5s off 1x 150ms on 2740Hz 150ms on 3200Hz 150ms on 2740Hz 2 5s off 1x 200ms on 2500Hz...

Page 33: ...nnel or in Programming Menu System Busy Ear Spkr 480 620Hz 4x 0 25s on 0 25s off 480Hz 4x 0 25s on 0 25s off 620Hz All channels are busy Talk Permit Ear Spkr 1800Hz 2x 24ms on 24ms off 48ms on PTT transmission accepted Talk Prohibit Ear Spkr 900Hz Continuous PTT transmission not allowed TOT Warning Ear Spkr 900Hz 1x80ms on Transmission rights expiring Valid Key Press Ear Ear 1800Hz 1x80ms on Valid...

Page 34: ...rate for Direct Connect and Group Connect calls only 1 From the main menu select Settings 2 Way Radio Alert Type 2 If Alert Type does not appear from the main menu select Ring Tones Make sure Vibrate All or Silent All is set to Off Repeat step 1 3 Press O to change 4 Scroll to Vibe 5 Press O to select ...

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Page 36: ...shoot this unit see Appendix A Ordering Replacement Parts and Kits 4 6 1 Reference Unit Use a reference unit i860 unit known to be in good working order to verify the accuracy of some tests You may want to set the Auto Answer Settings Menu setting so that the reference unit automatically answers incoming calls for testing purposes 4 6 2 Reference Accessories Use reference accessories accessories k...

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Page 38: ...ntact your regional Customer Care representative to determine if the customer has service or billing issues or is known to be using the unit in a poorly covered area The representative also can inform you if there are system outages or known unit defects 5 2 Test Conditions During testing ensure the following antenna conditions are adhered to Reset conditions can be comparatively difficult to diag...

Page 39: ...faces might occur To clean the unit approximately 3 minutes 1 Prepare a 0 5 solution of a mild dishwashing detergent and water 2 Apply the solution sparingly to the external surfaces of the unit with a soft absorbent cloth Prevent moisture from getting inside the unit 3 Remove any dirt from the unit using a stiff non metallic short bristled brush 4 Wipe and dry the unit with a soft absorbent lint ...

Page 40: ...es and back of the unit with your thumbs Never apply direct pressure to any display or lens area If unit turns off displays Reset or status LED if so equipped turns to red retry this test with a battery known to be in good working condition Verify that the contacts in the unit and on the battery are clean 4 Start test again If the reset intermittent contact condition persists power down the unit a...

Page 41: ...ries the main screen displays Device Attached or Device Detached and the external screen displays a similar message The accessory swap test time is approximately 5 minutes 1 Remove the accessory and check the contact areas for foreign material damage or other defects 2 Replace the problem accessory with the reference accessory 3 Verify the reference accessory works with the unit If the reference a...

Page 42: ... and attaches properly to the back of the unit Replace if necessary 6 Use a pencil or similar object to depress the battery contacts They should spring back to their original position If the battery contacts do not spring back they are damaged Replace the unit 5 5 5 Testing the GPS Receiver The GPS receiver does not require alignment The functionality of the receiver can be checked using the auton...

Page 43: ...tem Compare the readings on the unit under test with the readings on a reference unit The voltage recognition test time is approximately 4 minutes 1 Perform the Battery Connections test 2 Power up the unit with a fully charged battery that is known to be in good working order Three voltage bars 4 Vdc should appear on the Battery Strength icon Note that 0 bars 0 10 of full charge 1 bar 11 34 of ful...

Page 44: ...ng properly Self test procedures include gathering information from the unit s displays and testing the functionality of basic components These procedures usually do not require test equipment other than a reference SIM card The following self tests can be performed on an i860 unit Passcode Programming Menu Settings Call Performance 5 7 1 Passcode Test Use this test to determine the passcode for t...

Page 45: ...ears on the idle screen sets the format of the time and date and sets the year Menu View User can select the menu display in either LIST or ICON view Settings Display Info Menu View OK Large Dialing Displays transient large number text while dialing Settings Display Info Large Dialing OK Contrast sets the contrast on the display To set the contrast of the display 1 From the main menu select Settin...

Page 46: ...alls 1 From the main menu select Settings Phone Calls Notifications 2 Choose the option you want Receive All Tones sound during calls for all types of messages Msg Mail Only Tones sound during calls for mail messages tones for all other types of messages are held until you end calls Delay All Tones for all types of messages are held until you end calls 3 Press O Tip To set notifications options du...

Page 47: ...u Settings Personalize Menu Options OK Add Remove Apps Up Key At idle user can press UP key as shortcut to selected application Settings Personalize Up Key OK Down Key At idle user can press DOWN key as shortcut to selected application Settings Personalize Down Key OK Left Key At idle user can press LEFT key as shortcut to selected application Settings Personalize Left Key OK Right Key At idle use...

Page 48: ...ode KeypadLock locks the phone s keypad either immediately or automatically after a set period of inactivity To lock the keypad 1 From the idle screen press m 2 Press If you press a key while the keypad is locked instructions for unlocking the keypad display briefly To unlock the keypad 3 From the idle screen press m 4 Press While the keypad is locked you can respond to incoming calls messages and...

Page 49: ...ings features Alert Timeout controls the amount of time a tone continues to sound when you receive a message notification or call alert Headset Spker If you use a headset or similar device with your phone you can set your phone to send incoming sound to the headset only or to the headset and the speaker at the same time 1 From the main menu select Settings Advanced Headset Spker 2 Press O 3 Scroll...

Page 50: ...he test units by an appropriate distance Required equipment reference unit The call performance test time is approximately 7 minutes 1 Power up the unit Wait until registration is complete before continuing 2 Place an interconnect call from the problem unit to the reference unit 3 Ensure that both units have a signal strength of 3 bars or more 4 Press Menu Settings Volume Speaker Volume and use th...

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Page 52: ...de Test mode NOTE Do not enter these modes until the unit has been powered up and the power up sequence has been completed 6 1 1 Entering Debug Mode Use this procedure to access the debug mode To enter debug mode 1 Power up the unit Wait until registration is complete before continuing NOTE Steps 2 through 5 must be performed quickly no more than one second between each key press 2 Press 3 Press 4...

Page 53: ...atch and interconnect or a Packet Data channel since manufacture Tx Status First line displays the SQE Carrier data Outbound signal quality Frequency band current carrier code and color Second line displays Tx power cutback in RSSI Third line displays current temperature and the difference between the current temperature and temperature 2 seconds ago Rx Status First line displays the SQE Carrier d...

Page 54: ...cy and band Pressing OK allows the current frequency and band to be traced Dispatch IDs Displays the Dispatch Group ID affiliated with the unit in the current dispatch location area Also displays the Dispatch Individual ID affiliated with the unit in the current dispatch location Pressing OK allows the dispatch IDs to be displayed periodically Band Info Displays primary and secondary bands Bandmap...

Page 55: ... Test Engineering Debug Check 6 2 1 Audio Loopback Test Use this test to check the functionality of the microphone and the audio quality of the earpiece The loopback test checks the unit s audio by passing a test signal from the Codec microphone input to the Codec Rx output To perform the audio loopback test test time approx 3 min 1 Enter test mode 2 With the Test Mode screen displayed press m The...

Page 56: ...e continuing 2 Enter debug mode The Unit Info display appears 3 Scroll down until the IMEI SIM ID choice is highlighted then press View to view the IMEI SIM ID display 4 Write down the digits shown in the IMEI line 5 Verify that this number matches the IMEI on the Serial Number label The last zero on the label will be missing If the numbers do not match send the unit to the field level of service ...

Page 57: ...us display The first line displays the SQE Carrier data outbound signal quality frequency band current carrier code and color code The second line displays the Tx Rx power current adjusted transmit output power and receiver input power of the unit The third line displays the current temperature and the difference between the current temperature and the temperature two seconds ago 7 Press Back to r...

Page 58: ...iew the Err Chan Codes display This screen displays the physical channel that the unit is connected to or the radio link procedure that is currently active Also displays error codes of errors encountered during normal operation if Err Chan codes is On At power up Err Chan Codes is Off 19 Press Back to return to the Trace Mode display 20 Scroll down to highlight Current Freq and then press OK to vi...

Page 59: ...he Flags display This screen displays the error log which contains any errors logged by the unit software 33 Press Back to return to the Trace Mode display 34 Scroll down to highlight Coin Cell and then press OK to show the Preset Charging Voltage on line 1 and Current Battery Voltage on line 2 35 Press Back to return to the Trace Mode display 36 Scroll down to highlight CE Status and then press O...

Page 60: ...ent Parts and Kits To prepare the unit for both codeplug and subscriber code programming using the data cable Figure 6 1 1 Attach the 17 pin connector on the data cable to the corresponding connector located at the base of the unit 2 Attach the other end of the data cable to the serial port or USB port on the RSS computer workstation that is used for testing purposes Figure 6 1 Data Cable Programm...

Page 61: ...e Help choice on the menu bar and then select Contents The RSS online Help is displayed 4 Click on the Troubleshooting link and follow the detailed directions To prevent the loss of call lists create a backup of the codeplug before attempting any form of modification Refer to the Radio Service Software User s Guide for instructions on reading and saving codeplug information 6 5 2 Codeplug Troubles...

Page 62: ...e that the test results are true Cable length is critical to consistent Rx sensitivity and Tx power measurements Use a high quality shielded 50 ohm coaxial cable that is approximately 1 5 feet in length Place the unit to be tested at least 6 inches from the R 2660 Communications System Analyzer The cable loss should be less than 2 dB 7 1 3 Strong Signal Environments When using the R 2660 Communica...

Page 63: ...ecific information about RSS dialog boxes and fields To access online Help press F1 while you are viewing an RSS screen If you are using the R 2660A Communications System Analyzer in the iDEN mode which is 6 1 capable use RSS to program an i860 unit for Full Rate operation Use the 6 1 Interconnect softkey for all interconnect testing If you are using the R 2660B or later which is 3 1 capable use R...

Page 64: ...tor on the battery eliminator 6 Connect the N type connector of the RF cable to the R 2660 RF In Out connector 7 Attach the power leads on the battery eliminator to the DC power supply 8 Turn on the power supply and adjust output between 5 0 and 12 0 Vdc With the correct setting the regulated battery eliminator will provide 4 0 Vdc to the subject unit 9 If power supply is capable set current limit...

Page 65: ... field 6 Use the arrow keys to move the cursor to the Meter field in the display zone 7 Press More until INITIAL REG appears in the Meter field 8 Press the INITIAL REG softkey The display zone displays DISPATCH in the Registration Type field 9 Press RF to move to the RF zone 10 Enter the appropriate values in the following RF zone fields These values might be different depending on your bandmap Us...

Page 66: ...t incorporates the physical overlap and integration of some modular components Refer to the Disassembly Sequence flowchart for a suggested path to reach specific components NOTE In some cases the technician may not need to remove certain components to reach others 7 5 Disassembly Sequence Flowchart 7 6 Assembly Disassembly Procedures NOTE Installation procedures to be performed in reverse of disas...

Page 67: ...2 2 Push button down until cover releases and pull cover away 3 Push cover up to release from top clips 7 7 2 Install 1 Bring top clips of cover into their respective slots 2 While keeping clips engaged close cover until release latch fully snaps into place 7 8 SIM Card See SIM card removal and installation in Overview section or in the User s Guide Figure 7 2 ...

Page 68: ...d see Figure 7 3 3 Loosen T 4 counterclockwise Remove completely 4 Hold unit stationary while pulling at antenna collar until antenna assembly releases 7 9 2 Install 1 Carefully push antenna collar into position 2 Insert antenna assembly with whip fully extended contact toward interior of unit Push firmly until fully seated 3 Reinsert T 4 screw and tighten clockwise to 0 5 in lb 4 Reinsert valence...

Page 69: ...tube channel 2 Gently separate the housing halves Do not stress flex strip near PTT key Remove audio jack seal see Figure 7 4 3 Wedge black stick under flex pad to unseat speaker vibe coin PTT SB 20 pin flex connector see Figure 7 5 NOTE Do not touch flex contacts with fingers or dirty tools Do not bend or crease the flex strip 7 10 2 Install 1 Reattach flex connector carefully without contaminati...

Page 70: ...up coin cell flex strip carefully with stick Do not crease or fold flex see Figure 7 7 3 Note polarity of cell Wedge point of black stick under coin cell to work out of holder see Figure 7 8A 7 11 2 Install 1 Observe correct polarity 2 Insert cell into holder at angle see Figure 7 8B 3 Carefully press down on cell until fully seated see Figure 7 8B Figure 7 6 Figure 7 7 A B Figure 7 8 ...

Page 71: ...prying up on seal perimeter Do not push or touch microphone see Figure 7 10 3 Remove keypad by peeling away from bosses see Figure 7 11 7 12 2 Install NOTE Do not contaminate microphone or seal Use clean tools 1 Slip microphone seal over microphone Carefully tamp down around microphone perimeter until seated 2 Place main keypad into front housing Gently align and press onto bosses ensuring upper r...

Page 72: ...ton by wedging out with a sharp scribe exposing the hinge mechanism see Figure 7 14 and Figure 7 15 Discard damaged pushbutton 3 Attach tool to the hinge mechanism Mate the tool s recessed part with the matched protruding part on the mechanism Match alignment line on tool with the MOTOROLA name on front housing see Figure 7 16 4 Insert and turn tool clockwise to engage the hinge mechanism see Figu...

Page 73: ...PREPARING FOR FIELD LEVEL TESTING Flip Assembly 7 12 68P80400P73 A Figure 7 14 Figure 7 15 Figure 7 16 Figure 7 17 Figure 7 18 ...

Page 74: ... while aligning flip and housing Torque T 4 screw head to 0 5 in lbs 3 Attach hinge tool to hinge mechanism see Figure 7 19 Mate tool recess with matching protrusion on hinge mechanism 4 Insert the mechanism tool into the flip knuckle hole see Figure 7 20 Maintain alignment of the tool s line with the MOTOROLA name 5 Push in the tool mechanism until it stops then rotate the tool clockwise approxim...

Page 75: ...PREPARING FOR FIELD LEVEL TESTING Flip Assembly 7 14 68P80400P73 A Figure 7 20 Figure 7 21 ...

Page 76: ...PREPARING FOR FIELD LEVEL TESTING Exploded View and Parts List 68P80400P73 A 7 15 7 14 Exploded View and Parts List This section contains the component parts list and exploded view for the i860 unit ...

Page 77: ...3E01 6 Cap Hinge Button Right 3885896F01 7 Cover Hinge Button Right 3885614F01 8 Housing Back Assembly 1585325F01 9 Antenna Retract 8585744F01 10 Screw Center 0385693E01 11 Plug Cover Antenna Screen 3864307H01 12 Battery High Capacity Assembly Battery Slim Assembly SNN5705B SNN5717A 13 Label Escutcheon See Appendix A 14 Cover Battery High Capacity Assembly Cover Battery Slim Assembly 1585658F01 15...

Page 78: ...PREPARING FOR FIELD LEVEL TESTING Exploded View and Parts List 68P80400P73 A 7 17 7 15 2 Exploded View 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ...

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Page 80: ...me tests require that a certain mode be entered to conduct the test and or retrieve data from the unit The following test modes are used with the i860 unit Engineering debug mode includes trace mode Test mode NOTE Do not enter these modes until unit registration has been completed 8 1 1 Entering Test Mode Use this procedure to access test mode To enter test mode 1 Power up the unit Wait until regi...

Page 81: ...he following list to identify the test equipment required to perform the technician tests Refer to the appendix for test equipment part numbers and descriptions Battery eliminator Data cable RS232 or USB data cable R 2660 Digital Communications System Analyzer RF Adapter Variable 5 0 to 12 0 Vdc power supply 3 0 A capability 8 3 Field Level Test Checklist Use the following test checklist to ensure...

Page 82: ... Test Checklist 68P80400P73 A 8 3 Table 8 1 Field Level Test Checklist Done Technical Tests Pass Fail Registration Call SQE TX Power 800BER1 800BER2 800BER3 800BER4 900BER1 900BER2 900BER3 Power Up Keypad Audio Reset Reset Log GPS Receiver Camera Test ...

Page 83: ...he radio bandmap Unit passed test Look for system coverage accessory or software problems Pass Power up the unit Enter initial Registration mode see Operating the R 2660 Press Start The Call SEQ 1 thru 6 lights up when the unit has registered Verify the unit can complete an interconnect call Press End Home until unit displays Ready Press Interconnect 3 1 or 6 1 and Start on the R 2660 Press Send o...

Page 84: ...ts up when unit has registered Replace the Main board Notes 1 Watch unit for resetting during this procedure 2 Master reset can be completed on the unit by pressing Menu Settings Security 3 Registration and calls might take over 1 minute to complete 4 See the Strong Signal Environment section in Chapter 7 Pass Pass Change Gen to 80 dBm and check the SQE Reference chart to verify the unit s SQE per...

Page 85: ...ted States the Main board can only be replaced and programmed at the factory or iDEN Radio Support Center Power up unit Enter test mode see Entering Test Mode Pass Fail Press STOP Press Exit on the unit to exit this mode or press Menu Edit right Scroll key to continue on to BER test Continue with the BER test Watch for a signal on the R 2660 Make sure the R 2660 is set for the proper frequency 813...

Page 86: ...enna Set power supply between 5 0 and 12 0 Vdc Power up the unit Enter test mode Do the following 1 Press the Menu key and then the Edit option key 2 Press the Change option key and scroll down to 800BER1 3 Press Select to select the test 4 Press the Back key and then press Menu Fail Pass Lower Gen to 109 dBm and check the RX BER in the display The BER should be less than 10 when at Gen 109 dBm Fr...

Page 87: ...e Main board one at a time in that sequence until the display lights up Pass Fail Pass Verify that the display pixels light up Fail Check the battery level meter for 3 bars on the unit s display Pass Replace the Main board Fail Check the battery level meter for 3 bars on the unit s display Replace the battery Note In the United States the Main board can only be replaced and programmed at the facto...

Page 88: ...ss Fail Swap the Display module and the Main board one at a time in sequence until the display lights up Verify that all the display tests complete correctly Enter the Model Assembly MA Test Mode Pass Fail Rerun the MA Test Mode Keypad Test for the main keypad Replace the Main board Replace the Main board and repeat the test Proceed to the MA Test Mode Keypad Test and press all the main keypad key...

Page 89: ...End the interconnect call Initiate the dispatch call see the Registration Call test Press the PTT on the R 2660 and speak into the microphone Listen for a reply from the speaker Unit passed test Complete a call Talk into the microphone and listen for your reply from the R 2660 speaker Pass Pass Pass Perform Registration Call troubleshooting procedure Replace the Main board Fail Pass Replace the Ho...

Page 90: ...g 5 Make sure the R 2660 is set to a frequency in the unit bandmap Tap the front face of the unit with your fingers Unit passed test Pass No reset SQE Reference Chart Note Gen levels in the SQE chart include RF Adapter losses Gen SQE Level 70 dBm 26 80 dBm 25 90 dBm 23 100 dBm 20 Increase attenuation 10 dB at a time to confirm operation in a weak signal environment See the SQE Reference chart Repl...

Page 91: ...e page 6 1 The Unit Info display appears 4 Scroll down and highlight Resets and then press View to view the Resets display 5 Look for and record any reset errors Refer to the iSB Bulletin for reset classifications If the log contains reset errors perform the Reset test 6 Place a dispatch call 7 Look for and record any reset errors If the unit attempts to reset perform the Reset test 8 Place an int...

Page 92: ...Mode be performed after any servicing of the unit MA Test mode is achieved by starting from a power down condition 1 Press and hold three number keys simultaneously with the Power key such as 1 2 3 4 5 6 7 8 9 2 Release once the opening screen appears in the main display 3 Follow instructions as they appear pressing the indicated keys 4 No instruction Press any key OK key or Scroll right 5 No reac...

Page 93: ...FIELD LEVEL TEST MODES AND PROCEDURES Model Assembly MA Test Mode Test 8 14 68P80400P73 A 8 13 Model Assembly MA Test Mode Test Continued ...

Page 94: ...5 8 14 GPS Receiver Use this test on a unit to check functionality of the GPS Yes No Phone returns location coordinates Find an open sky area Turn unit on Obtain reference GPS receiver Yes No GPS not working Location coordinates match reference Activate GPS GPS working ...

Page 95: ... color synchronization error Fail Pass Verify that the viewfinder shows the captured image correctly Power up the unit Enter the Model Assembly MA Test Mode Fail Pass Unit passed test Look for system coverage accessory or software problems Replace the camera module and repeat the test Replace the main FPC and repeat the test Fail Pass Replace the main board ...

Page 96: ...nada A 2 Replacement Parts When ordering replacement and accessory parts the complete part number should be included If the correct part number cannot be located call Motorola Parts Identification at 1 800 422 4210 A 3 Domestic Orders Send written orders for replacement parts test equipment or manuals to Motorola Inc Accessories and Aftermarket Division Attn Order Processing 1313 E Algonquin Road ...

Page 97: ...andard 8mm Battery Door NNTN5530A Desktop Chargers Q Series Dual Pocket Desktop Charger Base NNTN4742A Q Series Dual Pocket Desktop Charger Kit NTN2073A Q Series Desktop Charger Insert NNTN4996A Battery Only Chargers Battery Only Charger NNTN5225A Rapid Travel Chargers Wall Mount Charger USA Black NNTN4963A Wall Mount Charger USA Two Tone Aftermarket NNTN4680A Wall Mount Charger Brazil Black NNTN4...

Page 98: ... Ear Piece TBD PTT headset over the ear NNTN5004A PTT headset over the head NNTN5005A PTT headset ear bud Black NNTN5006A PTT headset ear bud Chrome NNTN5330A Klaus Power Plug Adapters Euro Plug SYN7456A UK Plug SYN7455A Aus NZ Plug SYN8127A Korean Plug SYN7460A Escutcheon Labels Label i860 Escutcheon Korea NNTN5487A Label i860 Escutcheon Motorola NNTN5482A Label i860 Escutcheon EZENFREE NNTN5803A...

Page 99: ...art Number Battery Eliminator Regulated NNTN5589A Black Stick SLN7223A Cable Audio Jack Test NNTN5175A Cable SMA to N Type RF Contact Motorola Communications System Analyzer Motorola R 2660 Data Cable RS 232 Serial Port NKN6560A Data Cable USB NKN6559A Digital Volt Ohm Meter Keithly 2001 or eq Hinge Assembly Tool 6664616H01 Hinge Removal Tool 6664617H01 Pliers Needlenose 6680384A33 Power Supply 0 ...

Page 100: ...r IBM PC Compatible RSS Workstation N A Pentium microprocessor with 32MB RAM min 4MB hard disk space min Two serial ports and one parallel port network capability Microsoft Windows 2000 Windows 98 or Windows NT 3 5 1 or later Table A 5 Recommended Software Name Part Number Description Radio Service Software RSS Carrier Version Super Agent Version RVN4121 RVN4122 Programs the unit iDEN CompanionPro...

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Page 102: ...2 checks mechanical 5 3 cleaning a unit 5 2 Codeplug Repair procedure 6 9 codeplug troubleshooting 6 10 coding technique 1 3 Communications System Analyzer See R 2660 compression voice 1 3 conditions test 5 1 connecting to RSS workstation 6 8 conventions manual xiv Customer Care contacting 5 1 customer service contacting A 1 D debug mode 6 1 digital bit stream 1 3 modulation 1 1 dispatch mode 1 4 ...

Page 103: ... parts ordering A 1 Passcode test 5 7 PCCH See primary control channel power down sequence 3 2 power up sequence 3 1 Power Up test 8 8 preventive maintenance 5 2 primary control channel PCCH 1 4 procedures See tests programming unit 6 8 programming equipment recommended A 5 RSS A 5 RSS workstation A 5 Programming Menu Settings Check 5 8 Public Switch Telephone Network PSTN 1 4 publications related...

Page 104: ...DMA See Time Division Multiple Access technician tests Audio 8 10 BER 8 7 Codeplug Repair Procedure 6 9 Codeplug Troubleshooting 6 10 Engineering Debug Check 6 5 Keypad 8 9 Model Assembly MA Test Mode 8 13 8 14 Power Up 8 8 procedures 6 8 Registration Call 8 4 Reset 8 11 Reset Log 8 12 SQE 8 5 TX Power 8 6 technology digital modulation 1 1 voice compression 1 3 test conditions 5 1 environments 7 1...

Page 105: ...eaning 5 2 connecting to RSS workstation 6 8 displays in testing mode 6 2 dual band 1 4 equipment preparation 7 1 errors 3 2 icons 2 2 LED indicators 2 2 mechanical checks 5 3 messages 3 3 power down sequence 3 2 power up sequence 3 1 preparing for testing 7 1 programming 6 8 reference 4 1 self tests 5 7 troubleshooting 5 7 6 10 using RSS 7 2 V Vector Sum Excited Linear Prediction VSELP 1 3 vibrat...

Page 106: ...Motorola Confidential Proprietary 2004 by Motorola Inc 8000 W Sunrise Blvd Ft Lauderdale FL 33322 Printed in U S A 6 04 All Rights Reserved 6880400P73 68P80400P73 A ...

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