GSM Handsets Lab. GSM Phone REPAIR MANUAL MODEL : LG-500 Series

GSM Handsets Lab INTRODUCTION.………………………………… 1.1 Purpose.…………………………………..… Abbreviations ……………………………… TEST SETUP ………………………………..… Setup.…………………………………..… ASSEMBLY INSTRUCTION …………………… 3.1 Disassembly of upper case ………………… 3.2 Disassembly of upper-case components … 3.3 Disassembly of lower case ………………… 3.4 Disassembly of lower case components … 3.5 Disassembly of PCB ……………………… 3.6 Assembly ……………….…………………… 4. DOWNLOAD.…………………………………… 4.1 Download Equipment ………………………… 4.2 Data Kit Download Procedure ………………… 4.3 Using Download Program …………………… 5. ENGINEERING MODE ……………… 5.1 BB Test ……………………………… 5.2 Trace Test ………………………… 5.3 S/W Version ………………………… 5.4 SIM Lock …………………………… 5.5 Call Timer …………………………… 5.6 Fact. Reset ………………………… 6. TROUBLE SHOOTING ……………… 6.1 Power Supply………………………… 6.2 Voice ……………………………… Display ……………………………… 6.4 The Other Function ………………... Appendix A.1 RF Components ……………………. A.2 Rx Test ……………………………… A.3 Tx Test ……………………………… Table of Contents

GSM Handsets Lab INTRODUCTION

GSM Handsets Lab INTRODUCTION 1.1 Purpose This manual provides the information necessary to repair, description and download the features of the LG-500 series, specially this book has the chip aim of our repair men to improve their ability. Applicability This trouble shooting is only applicable to professional engineer for repai ring mobile phone. Maintenance Limitations Maintenance limitations on the LG-500 series must be performed only b y the LGE or its authorized agent. The user may not make any changes a nd/or repairs expect as specifically noted in this manual. Therefore, note t hat unauthorized alternations or repair may affect the regulatory status of the system and may void any remaining warranty. Purpose

GSM Handsets Lab INTRODUCTION BBBaseband LDOLow Drop Output LEDLight Emitting Diode CC-CVConstant Current–Constant Voltage CLACigar Lighter Adapter DACDigital to Analog Converter DCSDigital Communication System DSPDigital Signal Processing ELElectroluminescence ESDElectrostatic Discharge FPCBFlexible Printed Circuit Board GMSKGaussian Minimum Shift Keying GPIBGeneral Purpose Interface Bus GPRSGeneral Packet Radio Service GSMGlobal System for Mobile Communications UARTUniversal Asynchronous Receiver/Transmitter IFIntermediate Frequency LCDLiquid Crystal Display PCBPrinted Circuit Board PSTNPublic Switched Telephone Network RFRadio Frequency RTCReal Time Clock SIMSubscriber Identity Module SRAMStatic Random Access Memory TATravel Adapter TDDTime Division Duplex TDMATime Division Multiple Access WAPWireless Application Protocol IPUIInternational Portable User Identity 1.2 Abbreviations Abbreviations

GSM Handsets Lab INTRODUCTION ATTENTION Boards, which contain Electrostatic Sensitive Device (ESD), are indicated by the sign. Following information is ESD handling: Service personnel should ground themselves by using a wrist strap when exchange system boards. When repairs are made to a system board, they should spread the floor with anti-static mat which is also grounded. Use a suitable, grounded soldering iron. Keep sensitive parts in these protective packages until these are used. Attention

GSM Handsets Lab TEST SETUP

GSM Handsets Lab TEST SETUP SPECTRUM ANALYZER HIGH FREQUENCY PROBE OSCILLOSCOPE PROBE COMPUTER MON UART PHONE POWER DIP S/W PIF(LG-500 용 JIG) GSM TESTSET (8960) LG 500 MOBILE RF CABLE POWER CABLE RS-232 CABLE 500 용 I/O CON. CABLE GPIB CABLE + - GPIB COM1 GPIB CABLE RF IN/OUT I/O Connector POWER SUPPLY Setup Figure

GSM Handsets Lab TEST SETUP How to setup -S - + +S GND Power Supply Output Port - + PIF(510 용 JIG) PS Port A. Computer 1. Put GPIB card to the extended slot of personal computer. If you have a notebook PC, you need PCMCIA card for GPIB. 2. Connect the RS-232 cable between COM port of your PC and MON port or UART port of PIF. MON Port : CAL Test, Auto Test, etc. UART : S/W Download B. GSM TEST_SET(8960) 1. Connect GPIB cables (from Computer and Power Supply) to the rear panel of Connect mobile RF cable to RF In/Out port at the front panel of C. Power Supply 1. Setup : Voltage 4.0V, max Current 3A. 2. Connect GPIB cable at the rear panel. 3. Connect power cable

GSM Handsets Lab TEST SETUP How to setup PIF DIP Switch D. PIF(JIG for LG 500) 1. Connect I/O connector cable for 500 to PIF phone port. 2. Connect the power cable ro PS port of PIF. 3. Connect the RS-232 cable ro PIF MON or UART. ON OFF DC PS REMOTE H/F DIP Switch *H/F=Hands Free *PS=Power Supply

GSM Handsets Lab TEST SETUP How to setup D. PIF(JIG for LG 500) JTAG1AUDIOJTAG2 MON UART PHONE TA MON Status UART Status Power + PS - DC IN 12V TA

GSM Handsets Lab ASSEMBLY INSTRUCTION

GSM Handsets Lab ASSEMBLY INSTRUCTION

GSM Handsets Lab ASSEMBLY INSTRUCTION 3.1 Disassembly of Upper Case 1. Push the battery locker, and then remove the battery cover. 2. Pull the battery downward and lift it up. 3. Use your thumb to pull down the battery-locker hard. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION 4. Loosen the 4 screws as shown below. 5. While the Lower case is detached from the Upper case, twist the lower case to the right for disassembling a hook. Then twist it again to the left for disassembling the other hook. Finally, take out the lower case from the upper case. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION 3.2 Disassembly of Upper-Case Components 1. Release the screws and lift up the speaker holder to remove the speaker. 2. Use a '-' type driver carefully to lift up the Lower case of the vibrator spindle. Assembly : - Make sure the terminal of Speaker is being attached towards the Antenna. - When inserting the earphone cap, place its upper part into the hole first. And from the inside, use a long nose to hold and pull it. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION 3. Use a small '-'type driver to insert into the direction and lift it up to remove the battery spring. 4. Also, for the SIM-card cover, use '-'type driver to remove it. 5. Release the Volume BTN by pushing it with opposite force onto each side. And for the Recording BTN, just push one its side to release it. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION 3.3 Disassembly of Lower Case 1. Use a '-' type driver to release from the hooks on Lower case. Then, lift up the PCB for final disassembly. 2. Insert a small '-'type driver between the shield-can and cover, and lift up along the flat side of the lower case. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION 3. Lift up the rubber part of multi-key, and then the Dial BTN will be disassembled from the Lower Case. 4. While holding the Lower case with your left hand, use your right hand to twist the flip-cover to the hinges. Assembly : Leave the flip cover open and insert one side of the flip-cover into the hinge as shown below. Then twist the flip-cover when inserting the other end. DO NOT use too much force onto it. Make sure the flip is working properly, after the assembly. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION 3.4 Disassembly of Lower-Case Components 1. Use a pin to lift up the microphone to the direction as shown below. 2. Use a pin to release the Receiver. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION 3. Insert a '-'type driver between the hinge and the Lower case, and lift it up to remove the hinge. 4. See the cover from the A-direction as shown below, and assemble a pink hinge on its left and a green hinge on its right. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION 3.5 Disassembly of PCB 1. Lift up the side hooks as shown in fig.4-9. Then the main PCB and the LCD Module will be disassembled. Assembly: - Insert guide-hooks of LCD Module into guide-holes of Main PCB and push it in until it clicks. - When placing Backup-battery onto Battery-hold, make sure the battery poles are facing the right direction. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION 2. Use a '-'type driver to push away the antenna hook, and then disassemble the Antenna. Assembly : Push the Antenna into the hole until it clicks. Disassembly/Reassembly

GSM Handsets Lab ASSEMBLY INSTRUCTION Assembly 3.6 ASSEMBLY 1. Hang the Main PCB onto the hook on Lower case and push it down. 2. Connect the lead wire of Speaker and Vibrator to the Main PCB. Make sure that the poles are facing right directions. 3. As shown below, insert Lower case to the hooks on the top of Upper case. 4. Finally, tighten the cases with 4 screws.

GSM Handsets Lab DOWNLOAD

GSM Handsets Lab DOWNLOAD Download Setup 4.1 Download Equipment 1. Data Kit 2. Desktop or Notebook PC 3. Download Monitor Program 4. LG-500 mobile phone Data Kit for LG 500 To RS-232 Port

GSM Handsets Lab DOWNLOAD 4.2 Data Kit Download Procedure General Purpose: This document gives a guideline for upgrading software of LG-500 GSM/DCS Dual-band mobile phone using UART port. Download Environment: In order to download software of LG-500, the following working environments should be prepared : LG-500 Data Link Kit, DK-10G that is connected to COM1 or COM2 serial port in the Desktop or Notebook PC. LG-500 Data Kit Download Monitor Program that is copied to Desktop PC or Notebook PC. Target SW* downloaded to LG-500 mobile phone. Warning You MUST use the Data Link Kit (DK-10G) and UART Download Monitor program that are provided from LGE. Otherwise downloading process won't work properly. How to download

GSM Handsets Lab DOWNLOAD 4.3 Using Download Program 1. Unzip LG-500 UART Download monitor program (monitor632.zip) in PC. 2. Execute monitor632.exe. And then select the "Target" Menu shown below. Then, choose "Connect" in the Target Menu. Using Download Program

GSM Handsets Lab DOWNLOAD 3. A table will be displayed as shown below. Then press the arrow-button and choose a correct serial port. And press "OK" button. Using Download Program

GSM Handsets Lab DOWNLOAD 4. As the following window shown in Fig A is displayed, connect LG-500 Phone to Data Link Kit, DK-10G and power on LG-500. If the connection is succeeded, the following screen will show the contents as shown Fig B. Fig B Fig A Using Download Program

GSM Handsets Lab DOWNLOAD 5. Click on "Flash" on the top menu and select "Erase and Program Appli Only" item as shown in Fig 5. Using Download Program

GSM Handsets Lab DOWNLOAD 6. Finally choose the target SW that you want to download. And then you can see the following window in Fig 6. Using Download Program

GSM Handsets Lab DOWNLOAD 7. If the downloading procedure is succeeded, then the following window is shown. Using Download Program

GSM Handsets Lab ENGINEERING MODE Enter : 2945# * This mode is used to certify that which part is needed to repair so simply. This part is consist of Baseband test, Trace test, SW version and so on. A. About Engineering Mode Engineering mode is designed to allow a service man/engineer to view and test the basic functions provided by a handset. B. Access Codes The key sequence for switching the engineering mode on is 2945#*#. Pressing END will switch back to non-engineering mode operation. C. Key Operation Use Up and Down key to select a menu and press 'select' key to progress the test. Pressing 'back‘ key will switch back to the original test menu.

GSM Handsets Lab ENGINEERING MODE 5.1 Baseband Test [MENU 1] A. LED Test [1-2] This menu is to test the indicator LED on top left hand corner of a handset and backlight LED in the LCD module. Auto Test [1-2-1] Indicator On [1-2-2] : Green light turns on and menu is changed to “Indicator Off”. Back Light On [1-2-3] : Back Light turns on and menu is changed to “Indicator Off”. Back Light Degree [1-2-4] : This controls brightness of Backlight. When entering into the menu, the present backlight-value in the phone is displayed. Use Left/Right key to adjust the level of brightness. The value of the brightness set at last will be saved. B. LCD Test [1-3] This menu is to test the LCD module. Auto Test [1-3-1] Font [1-3-2] Icons [1-3-3] Animation [1-3-4] LCD Parameters [1-3-5] Reset Period [1-3-6]

GSM Handsets Lab ENGINEERING MODE C. Keypad Test [1-4] D. Melody Test [1-5] Auto Test [1-5-1] Melody Pattern [1-5-2] Melody Volume [1-5-3] E. Vibrator [1-6] F. Battery Test [1-7] G. Serial Port Test [1-8] H. Audio Gain Test [1-9] Receiver [1-9-1] : Voice[ ], Keytone[ ], Echo Control[ ] Earmic [1-9-2] : Voice[ ], Keytone[ ], Echo Control[ ] Loudspeaker [1-9-3] : Voice[ ], Keytone[ ], Echo Control[ ] Handsfree [1-9-4] : Voice[ ], Keytone[ ], Echo Control[ ] Default value [1-9-5] I. Deep Sleep Test [1-10]

GSM Handsets Lab ENGINEERING MODE 5.2 Trace Test [MENU 2] S/W Version [MENU 3] : This displays software version stored in the phone. 5.3 Eng Mode [MENU 4] 5.4 SIM Lock [MENU 5] 5.5 Call Timer [MENU 6] A. All Calls [6-1] : This displays total conversation time. User cannot reset this value. B. Reset settings [6-2] : This resets total conversation time to this, [00:00:00]. 5.6 Fact. Reset [MENU 7] This Factory Reset menu is to format data block in the flash memory and this procedure set up the default value in data block. Attention Fact. Reset (i.e.Factory Reset) should be only used during the Manufacturing process. Servicemen should NOT progress this menu, otherwise some of valuable data such as Setting value, RF Calibration data, etc. cannot be restored again.

GSM Handsets Lab Trouble Shooting Power Supply 6.1 Power Supply Failure : Power-ON button is not working. Solution : - Check the voltage level of battery. - If voltage level < 3.32V, Charge the battery. - If voltage level > 3.32V, Go on to the next page. + - TOP

GSM Handsets Lab Trouble Shooting Power Supply Failure : Power-ON button is not working. Solution : - Check the level of U605.8 (ONnOFF) - If voltage level is low(<2V), Power-On sequence is not executed properly.Try again. - If voltage level is high(>3V),check the LCD module and backlights. U605 8

GSM Handsets Lab Trouble Shooting Audio 6.2 Audio Failure : MIC is not working. Solution : - Connect the phone to the test network and make a call. - Check the signal level at point R601(upper side) If voltage level << 2.5V, Check the connectivity of R601, R602. Go on to the next page. R601 R602

GSM Handsets Lab Trouble Shooting Audio Failure : MIC is not working. Solution : - Check the signal level at the U601.5 and U602.5 after putting audio signal in MIC. A few hundreds of mV levels have to be measured. If not, replace U601 or U602. Go on to the next page. U601 U

GSM Handsets Lab Trouble Shooting Audio Failure : MIC is not working. Solution : - Check the connectivity of MIC component. Replace the MIC. Try again. MIC Contact PAD MIC

GSM Handsets Lab Trouble Shooting Voice Failure : Receiver is not working. Solution : - Connect the phone to the test network and make a call. - Check the signal level at the point U604.4 after putting audio signal in MIC. A few hundreds of mV levels have to be measured. If not, replace U604. Go on to the next page. 4 U604

GSM Handsets Lab Trouble Shooting Voice Failure : Receiver is not working. Solution : - Check the connectivity of receiver component. Replace the receiver. Try again. Receiver Contact PAD Receiver

GSM Handsets Lab Trouble Shooting Voice Failure : Melody is not heard. Solution : - Check the connectivity of speaker. Go on to the next page.

GSM Handsets Lab Trouble Shooting Voice Failure : Melody is not heard. Solution : - Check the signal level at the point U605.5 (VCC). If voltage level << 3V, replace the LDO(U605). Go on to the next page. U605 5

GSM Handsets Lab Trouble Shooting Voice Failure : Melody is not heard. Solution : - Check the melody signal level at the point U or U A few hundreds of mV levels have to be measured. If not, replace Melody IC (U603). - Replace the speaker. Do not repaired U

GSM Handsets Lab Trouble Shooting Display 6.3 Display Failure : LCD display is not working. Solution : - Normal state contact of LCD module with LCD connector on PCB. - Check “Is LCD connector well soldered onto PCB?” If not, re-soldering LCD connector. Go on to the next page. Disassemble LCD module Contact PADLCD connector Contact Pin

GSM Handsets Lab Trouble Shooting Display Failure : LCD display is not working. Solution : - Check “Are R719 & R720 well soldered onto PCB?” If not, re-soldering R719 and R720. Go on to the next page. R720 R719

GSM Handsets Lab Trouble Shooting Display Failure : LCD display is not working. Solution : - Check “Are R725~R729 well soldered onto PCB?” If not, re-soldering R725~ R Replace the LCD module. R727 R726 R725 R728 R729

GSM Handsets Lab Trouble Shooting The Other Function 6.4 The Other Function Failure : Vibrator is not working. Solution : - Check in the Engneering mode [2945#*16]. - Check whether J701 is well connected to the vibrator lines or not. If not, resoldering… & Try again. Go on to the next page. Vibrator (J701)

GSM Handsets Lab Trouble Shooting The Other Function Failure : Vibrator is not working. Solution : - Check the R732 voltage level. (high=approx. 3V) If not, replace R Check “Is the R731 well mounted?” If not, re-mount R709 - Check the T702 collector level. (under 100mV) If not, replace T731. Go on to the next page. R731 T702 C R732 + V -

GSM Handsets Lab Trouble Shooting The Other Function Failure : Vibrator is not working. Solution : - Check the signal level at the point R730, L701. (about 1V) If not, replace R703 or L701 - Replace J701(Vibrator) L701 R730 + V -

GSM Handsets Lab Trouble Shooting The Other Function Failure : LED (Keypad Backight) is not emitted. Solution : - Check “Are R709 & R710 well mounted?” If not, re-mount R709 and R Check the T701.4 voltage level. (high=approx. 3V) If not, replace T701… Try again. Go on to the next page. R709 T701 4 R710

GSM Handsets Lab Trouble Shooting The Other Function Failure : LED (Keypad Backight) is not emitted. Solution : - Check LED pin 1 voltage (= battery voltage) If not, replace battery. - Replace D701~D708, one by one. D701D705D703 D704 D706D708 D707 D

GSM Handsets Lab Trouble Shooting The Other Function Failure : LED (LCD Backight) is not emitted. Solution : - Check “Are R723 & R724 well mounted?” If not, re-mount R723 and R Check the T704.6 voltage level. (high=approx. 3V) If not, replace T704… Try again. Go on to the next page. R724 T704 R723 6

GSM Handsets Lab Trouble Shooting The Other Function Failure : LED (LCD Backlight) is not emitted. Solution : - Check “Are R780~R783 well mounted?” If not, re-mount R780~R Replace D711~D714, one by one. D711 1 D713 D712 D714 R780 R783 R781 R782

GSM Handsets Lab Trouble Shooting The Other Function Failure : Charging is not working. Solution : - Check “Is the battery pack well connected to the phone?” If not, reassemble battery pack. - Check the battery voltage level. (3.2~4.2V) “YES” Check indicator LED. “NO” Check TA, CLA, DTC. + -

GSM Handsets Lab Trouble Shooting The Other Function Failure : Charging is not working. Check indicator LED. Solution : Check indicator LED. - Check the indicator LED (state:ON) when charger is connected. If not, replace the battery. - Check whether Indicator LED has ON state within 3 minutes or not. If not, replace the battery. Go on to the next page. Indicator LED

GSM Handsets Lab Trouble Shooting The Other Function Failure : Charging is not working. Check TA, CLA, DTC Solution : Check TA, CLA, DTC - Check TA, CLA, DTC voltage (5.2V, 800mA) If not, replace TA, CLA and DTC. Go on to the next page. Travel Charger Cigar Jack Adatpor Desk Top Charger

GSM Handsets Lab Trouble Shooting The Other Function Failure : Charging is not working. Solution : - Check the T501 voltage level. (0.65~0.9V) If not, replace T Check the D501 voltage level. (<0.3V) If not, replace D501. Go on to the next page. T501 D < 0.3V V +- V

GSM Handsets Lab Trouble Shooting The Other Function Failure : Charging is not working. R508 J503 Solution : - Check the R508 voltage level. (<0.12V) If not, replace R Check “Are the J502, J503 well connected to PCB?” If not, re-mount J502 or J Upgrade Software to the latest version. R V J502 (I/O Connector)

GSM Handsets Lab Trouble Shooting Solution : - “no RSSI or weak signal” Check contact between antenna spring and pad at PCB. : Stretching the spring to the direction of PCB pad. Go on to the next page. Antenna padAntenna spring Failure : Receiving Signal Failure. The Other Function

GSM Handsets Lab Trouble Shooting Failure : Receiving Signal Failure. Solution : - Upgrade Software to the latest version & Test again… - (If possible) RF Calibration & Test again… MON UART PHONE POWER DIP S/W PIF(LG-500 용 JIG) LG The Other Function

GSM Handsets Lab. 65 Appendix. A.1 RF Components RF Components SW300 U302 U402 U403 U401 BPF400 BPF401 BPF404 U400 BPF403IC300BPF402 N300 BPF400,403:DCS SAW filter BPF401,402:GSM SAW filter BPF404:IF SAW filter SW300:Ant. Switch U400:VCTCXO U401:PLL U402:TRF6053 (Main chip) U403:TXVCO U301:Dual PAM IC300:APCIC N300:Directional coupler

GSM Handsets Lab. 66 Appendix. A.2 Rx Test Rx Test Transceiver (TRF6053) VCTCXO + IFXIF / VCO_TANK+ VCO_TANK- MIX_LO AFC RXIN RXIP RXQN RXQP PFD IF /N LF /65 PFD RF1 /N LF /65 PFD RF2 /N LF /13, /65 IF Output Divider Power Down Control Serial Interface 22-bit Data Register EGSM DCS 1225MHz MHz 564MHz Antenna Switch (SHS-L090DE) RF Filter IF Filter IRF Synthesizer (XRF2253) LNA 564MHz 1225MHz for GSM MHz for DCS GSM : CH40, -60dBm DCS : CH700, -60dBm Receiver RF Levels -63dBm -65dBm-50dBm-55dBm -40dBm-46dBm -63dBm -65dBm-50dBm -55dBm-63dBm -10dBm

GSM Handsets Lab. 67 Appendix Rx Test Test Points of Rx Levels

GSM Handsets Lab. 68 Appendix Rx Test Test Points of Rx Levels U401 : PLL

GSM Handsets Lab. 69 Appendix. Tx Test A.3 Tx Test Transmitter RF Levels

GSM Handsets Lab. 70 Appendix. Tx Test Test Points of Tx Levels 2 1 U401 : PLL