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MECHANICAL PARTS REWORK AND REPAIR:

Mechanical Parts Rework Procedure

68P80401P05

9.5

Mechanical Parts Rework Procedure

9.5.1

Removal Procedure

1. Set proper temperatures.

2. With bottom heater ON, place the assembly on top of it to start preheating the PCB.

3. Place adequate nozzle in the hand-piece of the hot air machine.

4. Set desired air pressure.

5. Get the new component ready by fluxing it as per specifications.

6. Protect any heat-sensitive component by placing appropriate heat shield over (If necessary)

7. Lower the nozzle and evenly apply heat until reflow of all solder joints is observed.

8. Immediately remove component before solder joints re-solidifies.

9. Release faulty component onto a heat resistant surface.

10. Check for component disturbance before proceed and fix it if necessary.

9.5.2

Land Preparation Procedure

1. Swing out the top heater and maintain the board over the bottom heater.

2. Pre-fill and re-level the lands by fluxing the targeted area, re-flowing wire solder with a

soldering iron over each land uniformly. The quantity of solder applied is critical to achieving
acceptable joints.

3. Clean lands of flux residue.

9.5.3

Installation Procedure

1. Pick the new part and place it over the lands as per overlay or Pedro.

2. Swing in microscope to aid on component alignment.

3. Align part (tack if necessary) and swing microscope out.

4. Carefully cover component with appropriate heat shield to protect it from degradation.

5. Lower nozzle over the component/heat shield and start the heating cycle.

6. Observe until reflow is completed.

7. Rise nozzle and stop heat cycle.

8. Allow solder to resolidify.

9. Cool off the PC board using bench fan.

10. Inspect solder joints and adjacent components under microscope.

Summary of Contents for iDEN i580

Page 1: ...Field Service Manual Basic and Field Level Test Procedures iDEN Digital Multi Service Data Capable Portable ...

Page 2: ...68P80401P05 i i580 Digital Multi Service Data Capable Portable Field Service Manual Basic and Field Level Test Procedures 2006 ...

Page 3: ...xclusive 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 prod ucts 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: ...iving a phone call 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...

Page 5: ...vernment 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: ...ug 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 ambient...

Page 8: ... 83 i580 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 Int...

Page 9: ...ecommended Battery SNN5744B SNN5769A Sensitivity 10 BER M 16 QAM MotoTalk 3 BER FSK 111 dBm 119 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 MotoTalk Radiated 13 dBm 13 dBm 41 2 dBm Dimensions HxWxD w 750mAh 94 x 57 battery door x 34 mm w 500mAh 94 x 57 battery...

Page 10: ...ireless System 5 SIM Cards 6 Removing and Inserting a SIM Card 6 CHAPTER 2 FEATURES ICONS AND INDICATORS 8 i580 Features 8 Display Icons 9 Main Menu Icons 9 Status Icons 10 CHAPTER 3 DISPLAYS MESSAGES AND ALERTS 11 Power Up Sequence 11 Power Down Sequence 12 Messages 12 Self Test Errors 12 Self Test Reset Errors 12 Service Messages 13 Alert Tones 14 Using the Optional Vibrate Function 17 PREPARING...

Page 11: ...Check 37 Technician Test Procedures 40 Programming the i580 Unit 41 Connecting the Unit to the RSS Workstation 41 Codeplug Help 42 Codeplug Troubleshooting 42 CHAPTER 7 PREPARING FOR FIELD LEVEL TESTING 43 Preparing Equipment for Testing 43 Calibrating Equipment 43 Checking the RF Cable 43 Strong Signal Environments 43 Protecting Static Sensitive Devices 43 Using RSS 44 Connecting an iDEN Unit to ...

Page 12: ... Test 69 Reset Test 70 Reset Log Test 71 Model Assembly MA Test Mode Test 72 GPS Global Positioning System Receiver Test 73 MOTOtalk 74 Bluetooth Test 75 CHAPTER 9 MECHANICAL PARTS REWORK AND REPAIR 77 Recommended Equipment 77 Hot Air Machine 77 Preheater 77 High Performance Soldering Station 77 Microscope 77 Magnifier Lamp 77 Fume Absorber 77 Recommended Tools 78 Nozzles 78 Heat Shields 78 Tweeze...

Page 13: ...ontact 82 M2 2 Pin Contact 83 J753 Microphone Socket 83 SW all Key Switch 83 D401 through D412 LED 84 APPENDIX A ORDERING REPLACEMENT PARTS AND KITS 85 Customer Service 85 Replacement Parts 85 Domestic Orders 85 International Orders 85 Replacement Kits 86 Recommended Test Equipment and Tools 90 Recommended Programming Equipment 90 ...

Page 14: ...hould 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 following chapters a...

Page 15: ...l 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 i580 Digital Multi Service Data Capable Phone User s Guide NNTN6775A R 2660 Digital Communications System Analyzer Operator s Manual 68P80386B72 ...

Page 16: ... amplitude and phase 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 wh...

Page 17: ...ing 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 sub...

Page 18: ...twork 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 t...

Page 19: ...one Network PSTN The PCCH is established by the base station equipment 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...

Page 20: ...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 communicated to the handset microprocessor and displayed on the screen or transmitted to the base station as required 1 4 MOTOtalk The purpose of the MOTOtalk feature is to allow simple direct simplex ...

Page 21: ... Removing and Inserting a SIM Card NOTE When a SIM card is defective and must be replaced with a new one the following information will be erased The recent calls list Call forwarding settings Net alerts Mobile originated text messages drafts and quick notes Information stored in Memo 3 most recent GPS enabled locations Voice records Voice names To remove a SIM card Figure 1 3 1 Power off the unit...

Page 22: ...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 Figure 1 4 Inserting a SIM Card ...

Page 23: ...status indicators associated with the unit 2 1 i580 Features Figure 2 1 i580 Feature Views Front View Open Top View Front View Closed Left Side Back View Right Side Volume Controls Walkie Talkie Button Controls Release Button Microphone Power Button Camera Key Display Retractable Antenna Mirror External Display End Calls Send Calls to Voicemail Speaker Key Send Calls to Voicemail Answer Calls Came...

Page 24: ...e your phone VoiceRecord Record and play audio messages Contacts Create view store edit contacts Messages Access messages Call Forward Set call forwarding options Datebook Schedule appointments Memo Store a number to access later Call Timers Phone usage information Recent Calls Access information about recent calls Shortcuts Create shortcuts to screens My Info View personal phone information inclu...

Page 25: ...ne is without service You cannot make or receive any type of call Phone In Use your phone is active on a phone call Private In Use your phone is active on a Private call Talkgroup In Use your phone is active on a Group Connect call SDG Call In Use unit active on an SDG call Active Phone Line 1 indicates phone line 1 is ready to make calls 2 indicates phone line 2 is ready to make calls Bluetooth i...

Page 26: ... reflects a stage in the sequence If the last display shows the idle screen the power up was successful if the last display shows No Service the unit is out of range or there is a hardware or software problem If the vibrate function is enabled for incoming phone calls voice mail or message mail the power up sequence includes a 500ms vibrate cycle Depending upon the service provider the power up se...

Page 27: ... test reset errors 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 0 100...

Page 28: ...le to perform dispatch or interconnect communication Charge or replace battery No Entry No numbers in phone list Add phone numbers to list No Service Phone unable to register Report problem to service provider Number Not 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...

Page 29: ...Tones Tone Low High Freq Cadence When Tone Occurs Automatic Callback Ear Spkr 1800H z 2x 24ms on 24ms off 48ms on Voice channel for prior request Call Alert Acknowledgment Received Ear Spkr 1800H z 2x 80ms off 80ms on Call Alert successfully sent Call Alert No Ack Received Ear Spkr 900Hz 1x500ms on Call Alert fails Call Alert Received Spkr Spkr 2300H z 4x 150ms off 150ms on every 10 seconds Call A...

Page 30: ...z 8x 64ms on 2400Hz 64ms on 2743Hz every 30 seconds Message mail received while unit is idle Msg Mail Received in Interconnect Ear Ear 2400 2743H z 8x 64ms on 2400Hz 64ms on 2743Hz every 30 seconds Message mail received while unit is in interconnect mode Message Volume Set Spkr Spkr 2400 2743H z 8x 64ms on 2400Hz 64ms on 2743Hz continuous Message volume changed on quiet channel or in Programming M...

Page 31: ...3200Hz 150ms on 2740Hz 2 5s off 1x 200ms on 2500Hz 200ms off 200ms on 2500Hz 200ms off 200ms on 2500Hz 2 5s off 1x 200ms on 2580Hz 200ms on 3200Hz 200ms on 2040Hz 2 5s off Phone call received Phone Ring Back Ear Ear 440 480Hz 2s on 4s off 440Hz 2s on 4s off 480Hz Called phone is ringing Private Call Received Spkr Spkr 2300H z 2x 88ms off 88ms on Private call received Reject Ear Spkr 900Hz 1x500ms ...

Page 32: ...em 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 1800H z 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 1800H z 1x80ms on Valid key pressed or unit powered u...

Page 33: ... 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 the OK button to change 4 Scroll to Vibrate 5 Press the OK button to select ...

Page 34: ...uipment used to troubleshoot this unit see Appendix A Ordering Replacement Parts and Kits 4 1 1 Reference Unit Use a reference unit i580 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 1 2 Reference Accessories Use reference ac...

Page 35: ... helpful to contact 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 dif...

Page 36: ...begins NOTE Do not use aerosol sprays tuner cleaners or other chemicals to clean the unit Damage to the plastic surfaces might occur To clean the unit takes 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 Table 5 1 ...

Page 37: ... of the unit Check if the unit turns off displays Reset or status LED if so equipped turns to red Then continue to the next step 3 Apply pressure to the front sides 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 conditi...

Page 38: ...Support Center 5 5 2 Accessory Swap Test Use this test to determine if the unit s accessories are defective NOTE When adding or removing accessories 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 ot...

Page 39: ...contact cleaning pen see Appendix A Ordering Replacement Parts Kits for part number to clean the contact area on the battery 5 Check the battery cover to ensure it fits 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 ...

Page 40: ...o accomplish this test the unit must first be registered on an iDEN system 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 Batter...

Page 41: ...for future use 5 6 2 Programming Menu Settings Check Use this test to verify that the unit s menu settings perform correctly The Programming Menu Settings check time is approximately 15 minutes Display Info The Display Info menu controls how the keypad and display appear Wallpaper Wallpapers can be set at different time settings and in a random order Settings Display Info Wallpaper OK Wallpaper Se...

Page 42: ...ton Call Waiting is turned back on when you end the call Auto Ans sets your phone to automatically answer an incoming call after a specified number of rings When this feature is on the phone answers by connecting you to the caller it does not send the call to voice mail unless you are out of coverage or on the line Flip Activation User can set the flip opening to answer and or end a call Settings ...

Page 43: ...group name from Contacts or recent calls list Tkgroup Area lets you name Talkgroups and choose your Talkgroup area One Touch PTT One Touch PTT sets your phone to call the most recent Private ID on the recent calls list or to a Private ID you choose every time you press the PTT button To set your phone to call the most recent Private ID on the recent calls list 1 From the main menu select Settings ...

Page 44: ... key to the user selected application Settings Personalize Left Softkey OK Right Softkey Customize the right soft key to the user selected application Settings Personalize Right Softkey OK Power Up User selects startup default application upon powering up the radio Settings Personalize Power Up OK App Volume Features The Volume menu sets the volume of sounds your phone makes Line1 sets ringer volu...

Page 45: ... phone s SIM PIN security feature When the SIM PIN requirement is on you are prompted to enter your PIN each time you turn on your phone Note If a SIM PIN is required your phone will not function until the SIM PIN is entered except for making emergency calls When the PIN requirement is off your phone can be used without entering a PIN Important When the SIM PIN requirement is off the personal data...

Page 46: ...ectivity Network ID sets the phone s network IDs and their roaming options under the direction of your service provider Master Reset lets your service provider to reset your service in the event of a security or provisioning problem Reset Defaults Reset Settings returns all settings to their original defaults Reset All returns all settings to their original defaults and erases all stored lists Use...

Page 47: ...ess Menu Settings Volume Speaker Volume and use the Volume keys to set the speaker volume of the problem unit to 3 bars 5 Verify that the problem unit performs within audio quality standards If defects such as distortion hum or screeching exist replace the unit 6 Place a dispatch call to another unit in the group If defects such as distortion hum or screeching exist replace the unit 7 To automate ...

Page 48: ...with this unit Debug Trace Mode 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 Trace Mode 1 Power up the unit Wait until registration is complete before continuing NOTE Steps 2 through 5 must be performed quickly with no more than one second ...

Page 49: ... specific modification to the product code plug Programmed at shipment Displays the Customer Static Data version The first number indicates the customer The second number indicates the structure revision The third number indicates the data revision Displays the current software version programmed in the unit as well as the software type RSS model and build date Text 9 code version LDB version Vers...

Page 50: ...uld correspond with the number stamped on the SIM card The SN is applied during manufacturing Pressing OK allows the IMEI SIM ID to be traced Registration Log Displays the Dispatch Log Interconnect Log Packet Data Log Mobile IP Log and Phone Rst Log Registration Log information is updated when the user deselects and selects the Registration Log choice Err Channel Displays the physical channel that...

Page 51: ...hen re registers the unit 6 2 Test Mode Test Procedures Enter Debug or Test Mode to perform the following tests Audio Loopback Test ESN and IMEI Matching Test 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 ...

Page 52: ...ersists send the unit to the field level Support Facility 11 Press the Tx Off key and repeat the previous step 12 Press the Stop key to end the test 6 2 2 ESN and IMEI Matching Test Use this test to verify that the electronic serial number ESN matches the International Mobile Equipment Identifier IMEI on the Serial Number label located on the chassis of the unit The ESN IMEI Matching test time is ...

Page 53: ...to return to the Unit Info display and then scroll down to highlight the Software choice g Press Select to view the current software version programmed in the unit as well as the software type RSS model and build date 3 Press Back twice to return to the Trace Mode display 4 Scroll down to highlight Total Usage and then press View to view the Total Usage display This screen displays the number of m...

Page 54: ...number tag of the unit The SIM ID is the SIM electronic serial number and should correspond with the number stamped on the SIM card 15 Press Back to return to the Trace Mode display 16 Scroll down to highlight Registr Log and then press View to view the Registr Log display This screen displays the Dispatch Log Interconnect Log Packet Data Log Mobile IP Log and Phone Rst Log Registration Log inform...

Page 55: ... to return to the Trace Mode display 30 Scroll down to highlight Fatal Err and then press View to view the Fatal Err display This screen displays the Fatal Error log This log contains a count of any fatal errors logged during the unit s automatic self test 31 Press Back to return to the Trace Mode display 32 Scroll down to highlight Flags and then press View to view the Flags display This screen d...

Page 56: ...s the unit must be correctly connected to the test equipment Recommended equipment RS232 data cable NKN6560A or USB data cable NKN6559A and a PC computer workstation with RSS installed NOTE For a list of recommended programming equipment applicable part numbers and descriptions refer to Appendix A Ordering Replacement Parts and Kits To connect the unit to a PC using the iDEN RS 232 serial or USB d...

Page 57: ...et up your test equipment configuration See Figure 6 1 for an illustration of this configuration 2 Start the RSS program 3 Click on the 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 modificatio...

Page 58: ...t 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 Communications...

Page 59: ...oxes 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 i580 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 RSS to program an i580 unit for Half R...

Page 60: ...or 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 61: ...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 Use...

Page 62: ...ly 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 6 Disassembly Sequence Flowchart 7 7 Assembly Disassembly Procedures NOTE Installation procedures to be performed in reverse of disassembly except where noted Screws used to assemble the i580 are 1 antenna screw T 4 drive 6 housing as...

Page 63: ...e 7 2 2 Push or pull down latch 3 Hold latch in the down position and use fingernail to lift cover off housing bottom edge 4 Pull cover down slightly to release from top clips and pull up to remove 7 8 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 Figure 7 2 2 3 3 ...

Page 64: ...move Battery 68P80401P05 49 7 9 Remove Battery 7 9 1 Remove 1 Place fingernail against the battery base exposed section 2 Push the battery up towards unit s top to release from bottom clip and lift up the battery to remove Figure 7 3 2 1 ...

Page 65: ...move 1 Slide tray lock away from SIM tray 2 Open SIM Card Tray by lifting at tray access tab 3 Grasp exposed corner of SIM Card and pull to slide SIM Card out 7 11 Remove Antenna Tools Required Tools T4 Torx Bit Tweezers 7 11 1 Remove 1 Loosen T4 counter clockwise Remove completely Figure 7 4 1 3 ...

Page 66: ... grab the edge of antenna tube and pull it out 7 11 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 Pull antenna whip in and out to check for correct operation Reinsert T 4 screw and tighten clockwise to 0 5 in lb 4 Align and insert new valence plug Must be flush with surface...

Page 67: ...ots Gently pull apart the housing halves 3 Once the housings are free avoid stressing flex strip near the PTT key 4 Wedge black stick under flex pad to unseat flex connector NOTE Do not touch flex contacts with fingers or dirty tools Do not damage the flex strip 7 12 2 Install 1 Reattach flex connector carefully without contamination see Figure 7 6 2 Bring housing halves together checking alignmen...

Page 68: ...ers 7 13 1 Remove 1 Wedge black stick under flip flex connector Gently pry upwards along length until release 2 Lift main board straight up from housing bosses 3 Remove the housing keypad backer 4 Lift Keypad straight up from housing frame 5 Clean around keypad holes Replace keypad if worn or dirty Figure 7 7 1 4 Housing Bosses ...

Page 69: ...dled properly Handle the Flex Ribbon with care especially when working it through the front housing slot 1 Remove the keypad and main board from the front housing Make sure the flip is in the open position 2 Remove the three T 4 screws securing the frame flip center hinge Flip the unit over and lift the flip center hinge straight up to remove 3 Locate the slight gap between the right knuckle and f...

Page 70: ...e from the front housing 6 Once the Flip Assembly is free of the front housing carefully feed the Flex Connector through the slot in the front housing Take extra precaution to prevent stressing and or tearing the Flex Ribbon 7 Angle the flex connector end slightly while prodding the flex ribbon out through front housing slot The flex connector will pass through the slot albeit tightly 8 Remove the...

Page 71: ...ert the Hinge Assembly Mechanism into flip right knuckle Gently press inward until seated and ensure that the two surfaces are flush 2 Carefully guide the flex connector through access slot in front housing 3 Align flip assembly to front housing to resemble a semi closed position 4 Slip the left knuckle side of the flip into position on the front housing 5 Slip the right knuckle into the front hou...

Page 72: ... inward into the right knuckle of the front housing 7 Once set check the hinge position by opening and closing the flip looking for binding or other unusual action Flip should open smoothly stay open and close completely 8 Align frame flip center hinge within the slot between the left and right knuckle of the flip 9 Insert the three T4 screw Tighten clockwise to 0 5 in lb Figure 7 11 6 8 ...

Page 73: ...VEL TESTING Exploded View and Parts List 58 68P80401P05 7 16 Exploded View and Parts List This section contains the component parts list and exploded view for the i580 unit i580 Component Parts List Black Yellow Grey Tanapa ...

Page 74: ...PREPARING FOR FIELD LEVEL TESTING Exploded View and Parts List 68P80401P05 59 i580 Exploded View ...

Page 75: ...ng most tests 8 1 Test Modes Some 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 i580 unit Debug Mode 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 ...

Page 76: ...e 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 77: ...l Test Checklist 62 68P80401P05 Table 8 4 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 MA Test Mode ...

Page 78: ...e 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 on...

Page 79: ...ss Start The Call SEQ 1 thru 6 lights 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...

Page 80: ...ates 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 5125M...

Page 81: ...Remove the antenna 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 ...

Page 82: ... Main board one at a time in that sequence until the dis play 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 83: ... 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 Assem bly 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 keys...

Page 84: ... 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 trou bleshooting procedure Replace the Main board Fail Pass Replace the Hous...

Page 85: ...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 Replac...

Page 86: ...11 3 Enter Trace Mode see 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 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 interconnect call 9 Look for an...

Page 87: ...y See the Required Tools section or contact Motorola s Aftermarket Accessories Division AAD 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 Pres...

Page 88: ... Global Positioning System Receiver Test Use this test on a unit to check its GPS functionality Yes No Phone returns location coordinates Find an open sky area Extend antenna and power up unit Obtain reference GPS receiver Yes No GPS not working Location coordinates match reference Activate GPS GPS working ...

Page 89: ... golden radio as transmitter determine pass or fail Then use the golden radio as receiver and determine pass or fail No Voice received on the receiving radio Place each radio on Channel 1 and Code 1 1 Edit 2 Edit 3 Scroll to 1 4 OK 5 Down to Code 6 Edit 7 Scroll to 1 8 OK 9 Back 1 Place Radios 5 10 feet apart 2 Press PTT on one radio Yes Fail if 5 attempts failed Pass Place radio under test and a ...

Page 90: ...e headset put the headset into discoverable mode On the handset under Bluetooth Hands Free Find Devices scan for the headset Headset found under scan results Bond with Headset Make phone call with Bluetooth headset Successful Bluetooth audio in phone call Bluetooth Status Message given on handset Bluetooth not working Verify Status message in Table 3 4 Bluetooth is working Message Description stat...

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Page 92: ... Kar 1000 S or similar 9 1 3 High Performance Soldering Station Pace HeatWise 200 with thermal recovery system or similar 1 6mm 0 06 CHISEL P N1124 0019 P1 to fill lands Big during Land Preparation procedure 2 0 40mm 0 016 1 64 60 BEVEL P N1124 0011 P1 to fill level lands Big during Land Preparation procedure 3 10 80mm 425 BLADE P N1124 0501 P1 to wick off or level solder BGAs during Land Preparat...

Page 93: ... or similar 9 2 5 Vacuum Pick X Kar XVP 200 or similar 9 3 Recommended Supplies Indium Indalloy NC771 flux pen Motorola P N 1185768C01 for rework of bottom connector RF connector and switches 9 4 Rework Repair Requirements 9 4 1 Temperatures Bottom heat is necessary to rework Falcon boards Use Lead free Temperature Profile Ιndium Indalloy NC771 flux pen Motorola P N 1185768C01 must be used for rew...

Page 94: ...hite dots must be removed before rework or baking and must be placed back on before assembling or re assembling the radio Audio jack cover dog house must be removed If present prior to rework or baking 9 4 3 Components Identification SIM Ribbon Connector Audio Jack Battery Contacts Accessory Connector Flip Ribbon Connector ...

Page 95: ...fore proceed and fix it if necessary 9 5 2 Land Preparation Procedure 1 Swing out the top heater and maintain the board over the bottom heater 2 Pre fill and re level the lands by fluxing the targeted area re flowing wire solder with a soldering iron over each land uniformly The quantity of solder applied is critical to achieving acceptable joints 3 Clean lands of flux residue 9 5 3 Installation P...

Page 96: ...it and or function and may cause future failures 9 5 4 J600 RF Connector NOTE Use Flux Pen Indium Indalloy NC771 ONLY Motorola P N 1185768C01 Use flux sparingly 9 5 5 J752 Audio Jack 9 5 6 J401 30 Pin Board to Flex Connector NOTE Tack down a couple of leads if necessary Top 330ºC Bottom 100ºC N P07 OK Industries 151 min Pace 6 7 F over M105 and F over J600 during Installation Procedure Top 330ºC B...

Page 97: ...y 9 5 8 M002 SIMM Connector 9 5 9 M105 Battery Contact Top 330ºC Bottom 100ºC N P32 OK Industries 151 min Pace 6 7 L over J400 during Installation Procedure Top 330ºC Bottom 100ºC N P32 OK Industries 201 min Pace 8 9 L over M002 J401 during Installation Procedure Top 330ºC Bottom 100ºC N P20 OK Industries 151 min Pace 6 7 F over J600 during Removal Procedure F over J600 F over M105 during Installa...

Page 98: ...t away from switch area after rework to avoid reliability issues Tack down a couple of leads if necessary Top 330ºC Bottom 100ºC N Q07 OK Industries 151 min Pace 6 7 J over J753 during Removal Procedure J over J753 F over M2 during Installation Procedure Top 330ºC Bottom 100ºC N P20 OK Industries 151 min Pace 6 7 F over M2 during Removal Procedure F over M2 C over J753 during Installation Procedur...

Page 99: ...tion NOTE Use Liquid Flux Indium Indalloy NC771 ONLY Use flux sparingly NOTE Always protect switches from heat and Flux intrusion to avoid component malfunction Top 330ºC No Bottom Heat N Q07 OK Industries 151 min Pace 6 7 I over nearby SW during Removal Procedure I over nearby SW A over LED during Installation Procedure ...

Page 100: ...ernational outside U S Canada 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 Processi...

Page 101: ...O High Performance Li Ion Battery SNN5782B BT9O Maximum Capacity Li Ion Battery SNN5759A Battery Doors i580 High Performance Battery Door w escutcheon Yellow see Table A 2a i580 Maximum Capacity Battery Door wI Nextel escutcheon Yellow NNTN2332N i580 Maximum Capacity Battery Door w Motorola escutcheon Yellow NNTN2332MOT i580 High Performance Battery Door wI escutcheon Grey Grey see Table A 2b i580...

Page 102: ...y Install Car Kit NNTN4744 Universal Dash Mount System NNTN5113 Data Products USB data cable charging NNTN54O5 RS232 data cable charging NNTN54O6 Mini Keyboard NTN2074 SD Card Reader SYN1O45 32MB microSD Card w SD Card Adapter SYN14O1 Wired Audio PTT Stereo Headset NNTN5774 PTT Headset Earbud NNTN533O PTT headset Over the Ear NNTN5004 PTT headset Over the Head NNTN5005 PTT headset Flexible Earwrap...

Page 103: ...H700 Bluetooth Premium Headset w Boom 98686H HF820 Bluetooth Easy Install Car Kit 98666H HF850 Bluetooth Pro Install Car Kit 98675H IHF1 000 Bluetooth Premium Pro lnstall Car Kit 98676H PC850 Bluetooth Class I USB Adapter 98716H Table A 2a Battery Door Assembly Kit Number Escutcheon Text NNTN2331 NA Nextel NNTN2331 MOTA Motorola NNTN2331 ISRA MIRS NNTN2331 JORA Xpress NNTN2331 KORA KTP NNTN2331 NI...

Page 104: ...otorola NNTN2344 ISRA MIRS NNTN2344 JORA Xpress NNTN2344 KORA KTP NNTN2344 NIIA Nextel International NNTN2344 SOLA Linc NNTN2344 TELA Telus For tables A 3 and A 4 only use the charging data cables below USB data cable charging NNTN54O5 RS232 data cable charging NNTN54O6 Table A 1 Description Kit Number ...

Page 105: ...ols Description Part 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 Power Supply 0 15VDC 0 3A S1348D SIM Card Reference NTN9208 Torx Bit T 4 Commercially av...

Page 106: ...icrosoft Windows 2000 Windows 98 or Windows NT 3 5 1 or later Table A 4 Recommended Software Name Part Number Description Radio Service Software RSS Carrier Version Super Agent Version RVN4121 RVN4122 Monitors the unit s code plug parameters iDEN Wireless Data Services Software Programs a laptop handheld device or desktop computer to use the i580 unit as a modem to transfer circuit or packet data ...

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