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6809490A75-O

November 16, 2004

37

Level 1 and 2 Service Manual

Disassembly

4.

Carefully slide the flex cable through the slot in the flip housing (see Figure 20).

5.

To replace, carefully slide the flex cable through the slot in the flip housing.

6.

Carefully lower the display assembly into place in the flip assembly.

7.

Place the camera boot over the camera assembly.

8.

Replace the flip CLI lens assembly, flip assembly, antenna, SIM, battery, and
battery cover as described in the procedures.

041194o

Figure 20. Removing the Flex Cable Assembly

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Summary of Contents for V635

Page 1: ...Level 1 and 2 Service Manual V635 Digital Wireless Telephone GSM 900 1800 850 1900 MHz GPRS ...

Page 2: ......

Page 3: ...acing the Rear Housing 24 Removing and Replacing the Transceiver Board Assembly 26 Removing and Replacing the Real Time Clock RTC Battery 28 Removing and Replacing the Keypad Volume Smart and Voice Buttons 29 Removing and Replacing the Headphone Speaker Jack 30 Removing and Replacing the Polyphonic Speaker Assembly 31 Removing and Replacing the Flip Assembly 32 Removing and Replacing the Flip CLI ...

Page 4: ...4 November 15 2004 6809490A75 O Contents V635 ...

Page 5: ...ent 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 Product Changes When electrical mechanical or production changes are incorporated into Motorola products a revision letter is assigned to the chassis or kit affected for example A B or C and s...

Page 6: ...ve license to use the Motorola product and the Motorola computer programs with the Motorola product About This Service Manual Use of this manual assures proper installation operation and maintenance of Motorola products and equipment It contains all service information required for the equipment described and is current as of the printing date Refer questions about this manual to the nearest Custo...

Page 7: ... 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 Motorola High Tech 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 training is avail...

Page 8: ...l number or other related major assembly along with a description of the related major assembly and of the component in question In the U S A to contact Motorola Inc on your TTY call 800 793 7834 Accessories and Aftermarket Division AAD Order replacement parts test equipment and manuals from AAD For EMEA spare parts call 49 461 803 1638 For Asia spare parts call 65 648 62995 U S A Outside U S A Ph...

Page 9: ...mAh Li Ion battery 47 8 mm x 88 2 mm x 24 9 mm 1 88 inches x 3 47 inches x 0 98 inches Size Volume 85 cc 5 18 in3 with battery Weight 118 grams 4 16 oz with battery Battery Life with standard 820 mAh Li Ion Battery Talk Time 230 425 minutes Standby time 179 235 hours All talk and standby times are approximate and depend on network configuration signal strength and features selected Standby times a...

Page 10: ...10 November 17 2004 6809490A75 O Specifications V635 Block Length 260 bits Classes Class 1 bits 182 bits Class 2 bits 78 bits Bit Rate with FEC Encoding 22 8 kbps Speech Coding Function Specification ...

Page 11: ...rophone flex connection external accessory connector smart button volume buttons and voice button The standard 700 mAh Lithium Ion Li Ion battery fits behind a removable back cover The phone accepts both 3V subscriber identity module SIM cards which fit into the SIM holder underneath the battery The antenna is a fixed stub type antenna Inexpensive direct connection to a computer or handheld device...

Page 12: ...directly in WML if available The information is then passed to the mobile subscriber via the mobile network SIM Application ToolkitTM Class 2 SIM Application Toolkit is a value added service delivery mechanism that allows GSM operators to customize the services they offer their customers from the occasional user who requests sports news and traffic alerts to a high call time business user who rece...

Page 13: ...reen The left and right soft keys perform the function shown in the corners of the display The right key will usually select an option whereas the left key will usually exit a function or return to a previous screen The menu key opens the initial menu structure or allows access to a submenu whenever M appears on the display See Figure 3 for details of the V635 menu structure 041208o Figure 1 Telep...

Page 14: ...s the strength of the phone s connection with the network Calls cannot be sent or received when the no signal indica tor is displayed Edge GPRS Indicator Shows that your phone is using a high speed Gen eral Packet Radio Service GPRS or Edge network connection Active Line Appears when a call is in progress Roam Indicator 5 Appears when the phone uses another network system out side the user s home ...

Page 15: ...dent feature Battery Level Indicator Shows the amount of charge left in the battery The more segments visible the greater the charge Recharge the battery as soon as possible when the Low Battery warning message appears Ring Style Indicator Shows the current selected ring style The default ring style is a ring tone Location Indicator Your phone may be able to send location information to the networ...

Page 16: ... is the standard main menu layout Menu organization and feature names may vary on your phone Not all features may be available on your phone Settings Menu l Personalize Home Screen Main Menu Skin Greeting Wallpaper Screen Saver Quick Dial t Ring Styles Style style Detail L Connection Bluetooth Link Sync USB Settings H Call Forward Voice Calls Fax Calls Data Calls Cancel All Forward Status U In Cal...

Page 17: ...auses the device to immediately shut down and any pending work for example partially entered phone book entries or outgoing messages is lost Operation For detailed operating instructions refer to the appropriate User s Guide listed in the Related Publications section toward the end of this manual To ensure proper memory retention turn OFF the phone before removing the battery Immediately replace t...

Page 18: ...18 November 17 2004 6809490A75 O General Operation V635 ...

Page 19: ...and to power device 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 device 6680388B01 Tweezers plastic Used during assembly disassem...

Page 20: ... 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 E All batteries can cause property damage and or bodily injury such as burns if a conductive materialsuch as jewelry keys orbeaded chains touch ...

Page 21: ... printed arrow first into the battery compartment and push down 7 Insert the ridge at the bottom of the battery housing into the base of the phone then push the cover down and snap it into place 041170o Figure 2 Removing the battery E There is a danger of explosion if the Lithium Ion battery is replaced incorrectly Replace only with the same type of battery or equivalent as recommended by the batt...

Page 22: ...SIM holder away from the SIM to unlock as shown in Figure 3 3 Carefully lift the SIM from its contacts 4 To replace insert the SIM into the holder ensuring the keyed corner of the SIM aligns with the notch molded into the holder 5 Slide the SIM holder over the SIM to lock 6 Replace the battery and battery door as described in the procedures 041173o Figure 3 Removing the SIM SIM SIM Latch ...

Page 23: ... are completely disengaged pull the antenna straight out of the phone to remove 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 housing as described in the procedures 041174o Figure 4 Removing the antenna G Ensure antenna threads are properly ...

Page 24: ...G This product contains static sensitive devices Use anti static handling procedures to prevent electrostatic discharge ESD and component damage G In addition to 4 screws the rear housing assembly is fastened with plastic latches These are fragile and should be released with care G Housing screws in the knuckle are longer than the housing screws at the base of the V635 041175o Figure 5 Removing th...

Page 25: ...mbly then press the rear chassis assembly down until the 2 housing catches engage with the corresponding openings on the rear chassis assembly Press the housings together until the catches snap into place 6 Replace the 4 transceiver screws and tighten to a torque setting of 1 5 inch pounds Do not over tighten 7 Replace the antenna SIM battery and battery cover as described in the procedures 041176...

Page 26: ...y tool under the flex connector and remove the connector from the transceiver board See Figure 7 G This product contains static sensitive devices Use anti static handling procedures to prevent electrostatic discharge ESD and component damage G The flexible printed cable FPC flex is easily damaged Exercise extreme care when handling 041177o Figure 7 Disconnecting the flex from the transceiver board...

Page 27: ... mating connector on the transceiver board and press firmly until it snaps into place 6 Replace the rear housing antenna SIM battery and battery cover as described in the procedures 041181o Figure 8 Removing the transceiver board assembly Be sure the volume smart buttons and voice button are correctly positioned in relation to the corresponding switches on the transceiver board Verify operation of...

Page 28: ...ssembly tool to pry the RTC battery out of its socket on the transceiver board see Figure 9 3 Remove the RTC battery while making not of the polarity 4 To replace align the RTC battery with it s socket on the transceiver board 5 Press the RTC battery into its socket 6 Replace the transceiver board assembly rear housing antenna SIM battery and battery cover as described in the procedures 041182o Fi...

Page 29: ...embly out of the front housing with caution see Figure 10 3 To replace carefully set the keypad volume smart buttons and voice button assembly into the front housing ensuring the keys align properly with the openings in the front housing and fits over the keypad guides molded into the front housing 4 Replace the transceiver board assembly Display flex connector rear housing assembly antenna SIM ba...

Page 30: ... To replace align the headphone speaker jack to the rear housing assembly 4 Insert the top end of the headphone speaker jack into the rear housing assembly 5 Press the bottom end of the headphone speaker jack into the rear housing Be careful not to damage the headphone jack speaker leads 6 Ensure headphone jack speaker leads will contact the transceiver board when reassembled 7 Replace the rear ho...

Page 31: ...place remove any remaining adhesive residue from speaker cavity 6 Remove any adhesive protection material from the speaker assembly 7 Align the speaker assembly to the opening in the rear housing 8 Carefully press the polyphonic speaker assembly into it s cavity on the rear housing 9 Replace the headphone speaker jack rear housing antenna SIM battery and battery cover as described in the procedure...

Page 32: ...14 Avoid damage to the flex cable 4 Lift the keypad housing assembly away from the flip assembly Be careful not to damage the display flex cable To replace carefully thread the display flex 031649o Figure 13 Removing the flip assembly knuckle 041184o Figure 14 Removing the front housing Flip Assembly Flip Assembly Knuckle Display Flex Connector Keypad Housing Front Housing Display Flex Connector F...

Page 33: ...r through the slot on the keypad housing assembly Avoid damage to the flex cable 5 Place the flip knuckle over the flex cable and align knuckle to keypad housing 6 Replace the transceiver board assembly rear housing antenna SIM battery and battery cover as described in the procedures ...

Page 34: ...scribed in the procedures 2 Slide the flip assembly cover away from the flip assembly see Figure 15 3 Remove the 4 flip assembly screws see Figure 16 Set the screws aside for re assembly 4 Lift the CLI lens assembly away from the flip assembly 041187o Figure 15 Removing the Flip Cover 041188o Figure 16 Removing the Flip Assembly Screws Flip Assembly Flip Cover Flip Cover Screws Flip Cover Screws C...

Page 35: ... the CLI display lens to the flip assembly to lock the latches on the CLI display lens assembly Be careful not the damage the CLI display flex or flex connector while re assembling the CLI display lens assembly 10 Insert and tighten the 4 flip assembly screws to torque setting of 1 0 inch pounds 11 Slide the flip assembly cover onto the flip assembly 12 Replace flip assembly transceiver board rear...

Page 36: ...nd flip CLI lens assembly as described in the procedures 2 Remove the camera assembly boot see Figure 19A 3 Use the disassembly tool to gently pry the display assembly out of it s space in the flip assembly see Figure 19B 041191o 041193o Figure 19 Display Assembly Removal G The flexible printed cable FPC flex is easily damaged Exercise extreme care when handling A Camera Boot Display Assembly B ...

Page 37: ...eplace carefully slide the flex cable through the slot in the flip housing 6 Carefully lower the display assembly into place in the flip assembly 7 Place the camera boot over the camera assembly 8 Replace the flip CLI lens assembly flip assembly antenna SIM battery and battery cover as described in the procedures 041194o Figure 20 Removing the Flex Cable Assembly ...

Page 38: ...ver battery SIM antenna flip assembly flip display assembly as described in the procedures 2 Unseat the CLI display flex cable on the display assembly see Figure 16 G The flexible printed cable FPC flex is easily damaged Exercise extreme care when handling 041192o Figure 21 Removing the CLI display flex socket connector ...

Page 39: ...e display module 7 To replace place the CLI display flex connector into the ZIF connector 8 Close the ZIF connector latch to secure the flex cable 9 Lower the CLI display onto the display assembly 10 Carefully and gently press the display flex connector into its socket 11 Replace the camera assembly flip CLI display assembly flip assembly antenna SIM battery and battery cover as described in the p...

Page 40: ...nu and stored memory such as phone books or even just program a unit with basic user information such as language selection V635 telephones use TrueSync synchronization software to effect a personality transfer Identification Each Motorola GSM device is labeled with a variety of identifying numbers The following information describes the current identifying labels Mechanical Serial Number MSN The ...

Page 41: ...on types or individual units The full IMEI structure is listed in Table 2 Where TAC Type Allocation Code formerly known as Type Approval Code NN Reporting body identifier XXXX Type Identifier YY YY is set to 00 from 01 01 2003 until 31 03 2004 ZZZZZZ Individual unit serial number A Phase 1 0 Phase 2 check digit defined as a function of all other IMEI digits Other label number configurations presen...

Page 42: ...eplace the battery as described in the procedures 6 Press to turn the phone ON Manual Test Mode Commands Table 3 Manual Test Commands Key Sequence Test Function Name Remarks Menu 048263 Enter manual test mode End Key Exit manual test mode 54 Suspend Required for all Test Mode Operations 0 0 0 Select tone 0 0 0 1 Select tone 1 0 0 2 Select tone 2 0 0 3 Select tone 3 0 0 4 Select tone 4 0 0 5 Select...

Page 43: ...Set band DCS 1800 10 0 5 10 0 6 Set dual band GSM 900 1800 10 1 0 Read band 3 GSM 4 DCS 5 PCS 6 GSM DCS 18 0 Initialize non volatile memory Master Reset 18 1 Initialize non volatile memory Master Clear 55 2 001 Test Display All pixels ON 55 2 000 Test Display All pixels OFF 55 2 002 Test Display Checkerboard pattern A 55 2 003 Test Display Checkerboard pattern B 55 2 004 Test Display Border pixels...

Page 44: ...attery connectors Press and hold the PWR button If unit turns on and stays on disconnect the dc power source and reassemble with the new keyboard assembly 2 Telephone exhibits poor reception or erratic operation such as calls frequently dropping or weak or distorted audio a Antenna assembly defective Check to make sure that the antenna pin is properly connected to the transceiver board assembly If...

Page 45: ...ex connector is at fault proceed to d If connection is not at fault proceed to b b 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 cleared proceed to c c Antenna assembly defective Check to make sure the antenna is installed correctly If the antenna is installed correctly substitut...

Page 46: ...ing Faulty charger circuit on transceiver board assembly Test a selection of batteries in the rear pocket of the desktop charger Check LED display for the charging indications If these are charging properly then the internal charger is at fault Replace the transceiver board assembly refer to 1c Verify that the fault has been cleared and reassemble the unit with the new transceiver board assembly 1...

Page 47: ...47 Level 1 and 2 Service Manual Part Number Charts Part Number Charts The following charts are provided as a reference for the parts associated with V635 telephones Related Publications Motorola V635 User s Guide English 68XXXXXX79 ...

Page 48: ...48 November 16 2004 6809490A75 O Part Number Charts V635 Exploded View Diagram 041171o Figure 24 Exploded view diagram 1 2 3 4 5 6 7 11 8 9 10 12 13 14 16 17 19 22 23 25 28 21 18 20 24 26 27 15 ...

Page 49: ...d Medallion Assembly 19 Popple Dome Sheet 5 Camera Boot 20 Acoustic Gasket 6 96 x 90 CSTN CLI Display 21 Microphone Grommet 7 1 3 MP Camera Assembly 22 Microphone 8 Housing Base Knuckle Right 23 Transceiver Board 9 Hinge 24 Antenna 10 Flip Flex Assembly 25 Rear Chassis Assembly 11 176 x 220 TFT Main Display 26 RF Grommet 12 Flip inner Housing Assembly 27 Knuckle Screws long 2X 13 Housing Base Knuc...

Page 50: ...11 Data Cable CE Bus USB S9642 Bluetooth Car Kit Asia Americas S9643 Bluetooth Car Kit Euro SYN0945 Bluetooth Headset Green HS820 CHYN4590 Bluetooth Headset Genie HS801 SYN9826 Bluetooth Headset Paladin HS810 SYN9820 Bluetooth Helmet Headset HS830 SYN0717 Bluetooth PC USB Adapter SYN0736 Bluetooth Speaker Quadrant HF800 SYN1107 Bluetooth Headset Paladin HS850 SYN0986 Bluetooth Headset HS805 SYN108...

Page 51: ...d 2 Service Manual Part Number Charts SPN4940 Travel Charger CE Bus Mid Rate Switcher US SPN5037 Travel Charger CE Bus Mid Rate Switcher US SPN5049 Travel Charger CE Bus Rapid Switcher US Table 6 V635 Accessories Continued Kit Number Description ...

Page 52: ...52 November 16 2004 6809490A75 O Part Number Charts V635 ...

Page 53: ...flip assembly cover removing and replacing 34 flip assembly removing and replacing 32 H headphone speaker jack removing and replacing 30 I identification 40 international mobile station equipment identity 41 mechanical serial number 40 product 5 IMEI 41 in use indicator 16 indicators alert setting 16 battery level 16 in use 16 menu 16 message waiting 16 roam 16 service indicator status light 15 si...

Page 54: ...sembly 31 real time clock battery 28 rear housing 24 SIM 22 transceiver board assembly 26 volume smart buttons 29 roam indicator 16 S serial number mechanical 40 service manual about 6 revisions 7 scope 6 service policy 7 customer support 7 out of box failure 7 product support 7 service procedure ordering replacement parts 8 shut down upon battery removal 18 signal strength indicator 16 SIM Applic...

Page 55: ......

Page 56: ... Motorola Inc All other product or service names are the property of their respective owners Reg U S Pat Tm Off 2004 Motorola Inc All rights reserved Personal Communications Sector Sawgrass International Concourse 789 International Parkway Mailstop S2C Sunrise FL 33325 6222 6809490A75 6809490A75 O ...

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