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HTC Prodigy Service Manual

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Service Manual
PDA Phone Product
Prodigy
HTC Proprietary
Confidential Treatment Requested
Rev. XA
August 13, 2005
HTC Corp.
Engineering Mobility
HTC confidential
© 2001, HTC Corporation. All rights reserved.
TOTAL 84
CONT.ON. 2 PAGE NO. 1

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  • Page 1 Service Manual PDA Phone Product Prodigy HTC Proprietary Confidential Treatment Requested Rev. XA August 13, 2005 HTC Corp. Engineering Mobility HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 2 PAGE NO. 1...
  • Page 2 TITLE: Service Manual for Prodigy REV. DATE CONTENTS DEP. REVISED APP´D STGE.PER. Formal release Aug 13, 2005 Technical Johnson Yang Support HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 3 PAGE NO. 2...

  • Page 3: Table Of Contents

    EQUIREMENT 10.3 ························································································47 TEST CONNECTION 10.4 RF A . ············································································ 48 NTENNA 10.5 B ········································································ 52 LUETOOTH UNCTION 10.6 WLAN F ················································································ 56 UNCTION HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 4 PAGE NO. 3...
  • Page 4 OW TO CHECK BACKUP BATTERY C. H ········································· 82 OW TO PERFORM RESET AND RESET D. R ··············································· 82 EMOVE AIN BATTERY BEFORE URN OFF UNIT HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 5 PAGE NO. 4...

  • Page 5: Introduction

    1. Introduction This manual provides the technical information to support service activities of PDA phone (Prodigy). This document contains highly confidential information, any or all of this document should not be revealed to any third party. 2. Product Specifications 2.1 Product Configuration...

  • Page 6: Specifications Of Prodigy

    * CLI (Call line Identity) * Display own number * Network selection * Cell broadcast * Multi-party conference call * Spool Icon * Network lock HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 7 PAGE NO. 6...

  • Page 7: P Rodigy

    2 soft keys Camera shutter button Voice command/Voice recorder button Reset Switch RF button Sliding QWERTY keyboard with 39 keys + 2 soft keys HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 8 PAGE NO. 7...
  • Page 8 Generic Access profile Serial Port profile Headset profile Object Push profile DUN profile Heads-free profile Generic Object Exchange profile HID profile Co-exist with WiFi HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 9 PAGE NO. 8...
  • Page 9 Car Kit w/car stereo mute function Stereo-wired headset with microphone Mono bluetooth headset with microphone Keyboard Cradle (optional) User manual, quick start guide, Sync. S/W (CD) Travel charger HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 10 PAGE NO. 9...

  • Page 10: Labeling

    Y: Year Last Digital of the Year. WW: Week Code : 01 ~ 54 PP: Product Code ZZZZZ: Serial Number (00001 ~ 99999) Use Base 10 HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 11 PAGE NO. 10...

  • Page 11: Servicing Tools

    4. Servicing Tools This chapter provides information for the servicing tools for Prodigy. Repair Level Definition Unit Accessory test and unit swap Unit Test and ROM Re-flash Refurbishment and Module Swap +L1 L2.5 M/B Repair(connecter, button, MIC…) +L2 List of Servicing Tools...

  • Page 12: Disassembling

    5. Tweezers. Remove the Stylus, mini-SD Card slot Filler, and protection rubber of antenna connector. Next, Remove the battery cover by releasing lock switch HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 13 PAGE NO. 12...
  • Page 13 Remove main battery from unit Use the plastic stick to Insert and gently twist into the gap between back housing and antenna cover. Unlock the inside hook HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 14 PAGE NO. 13...
  • Page 14 Take care of disassembling Antenna cover during the process, it is easy to damage the hook of Antenna cover Antenna cover is removed HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 15 PAGE NO. 14...
  • Page 15 Release 4 screws from back housing To insert plastic stick into the gap of top of back housing Unlock hook HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 16 PAGE NO. 15...
  • Page 16 There are 3 hooks at right side Another 3 hooks at left side Disassembly back housing HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 17 PAGE NO. 16...
  • Page 17 There are 2 parts on the back housing, 1. Flash light 2. Vibrator Use Plastic stick to unlock hooks of flash light module Use tweezes to remove Vibrator HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 18 PAGE NO. 17...
  • Page 18 Flash-light module and Vibrator are removed Following need to be assembled 1. Camera 2. Speaker 3. Speaker 4. Keyboard FPC cable Remove Camera HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 19 PAGE NO. 18...
  • Page 19 Disassembly speakers Both side speakers are removed Disconnect keyboard FPC cable Shift the slide tray as left picture HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 20 PAGE NO. 19...
  • Page 20 Use plastic stick to raise main board The main board is connected with Rigid-Flex Board Disconnect the FPC cable The main board is released HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 21 PAGE NO. 20...
  • Page 21 Make sure sponges and Mylar, Gasket,… are stuck in the main board Shift the slide tray back Disassembly 4 screws on both sides. Disassembly slide tray of keyboard HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 22 PAGE NO. 21...
  • Page 22 Remove 8 screws Disassembly keyboard Keyboard and keypad are moved HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 23 PAGE NO. 22...
  • Page 23 Remove 4 screws Use plastic stick to unlock the hook There are 6 hooks at both side, and 2 hooks at top and bottom side HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 24 PAGE NO. 23...
  • Page 24 Let FPC cable through the space of Housing case, Separate housing and front Bezel Remove protect tapes from the Rigid-Flex Board Remove 2 screws of top side HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 25 PAGE NO. 24...
  • Page 25 Remove 2 screws of bottom side Disconnect LCM FPC cable Disassembly Rigid-Flex Board Disassembly LCM to front Bezel HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 26 PAGE NO. 25...
  • Page 26 Disassembly Receiver Disassembly process is done The Unit Disassembly is done HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 27 PAGE NO. 26...

  • Page 27: Assembling

    Make sure sponges and Mylar, Gasket,… are stuck in the main board Assembly Receiver to front Bezel Assembly 5 ways keypad to front Bezel Assembly LCM to front Bezel HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 28 PAGE NO. 27...
  • Page 28 Install 2 screws to fix bottom side of Rigid-Flex Board Assembly LCM FPC cable Stick tape to protect LCM connector and bottom side of Rigid-Flex Board HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 29 PAGE NO. 28...
  • Page 29 Assembly housing Use finger and thumb to press the hook Make sure no gap HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 30 PAGE NO. 29...
  • Page 30 Shift the slide pillar in the place Assembly Qwerty keypad Stick FPC keyboard to metal support holder HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 31 PAGE NO. 30...
  • Page 31 Assembly keyboard Install 8 screws to fix keyboard Assembly the tray of keyboard HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 32 PAGE NO. 31...
  • Page 32 Install 4 screws on both sides Shift the position as left picture Assembly Microphone rubber Connect FPC cable HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 33 PAGE NO. 32...
  • Page 33 Make sure mini-USB connector and Audio jack is in place Take card the volume control switch while put the main board into the tray of keyboard HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 34 PAGE NO. 33...
  • Page 34 1. Keyboard FPC cable 2. Camera 3. Speaker 4. Speaker Assembly flash-light module to back housing Assembly Vibrator to back housing Assembly Back housing HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 35 PAGE NO. 34...
  • Page 35 Use finger and thumb to press the hook Assembly Antenna cover, two hooks must be paired first Push the Antenna cover from top side HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 36 PAGE NO. 35...
  • Page 36 Put back the battery cover. Assembly is done Now The unit is ready for performing TEST. The Unit Assembly is done and ready for further tests. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 37 PAGE NO. 36...

  • Page 37: Notification Once Backup Battery , M//Breplacement

    5.3 Notification once Backup battery, M//B replacement If you are authorized by HTC for board level component replacement, and if you perform M/B replacement, must take care for following notice: Golden cap replacement. In case of back up battery defective and need...

  • Page 38: Equipment Of Problem Diagnostics

    CPU: Pentium 166MHz or above Memory: 64MB~128MB 6.3 Software Requirement Microsoft Active Sync version 4.0 above Diagnostic Program loaded on Mini SD card. ( encoded by HTC) HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 39 PAGE NO. 38...

  • Page 39: Diagnostic Programs

    Clear talk time recode in WinCE system information Diag to SD Copy Diag program to another encoded SD card Device info Check unit information Write system SN HTC internal use only USB Test HTC internal use only SIR Test HTC internal use only...

  • Page 40: Test Items Operation

    How to Enter Test Mode (not final confirmed yet) >Insert mini-SD card (with Diagnostic program pre loaded sent by HTC) into Min- SD slot >Power on the unit. While press and hold the Capture button and Reset the unit with stylus, release Reset button first about 1 second to enter test Mode.

  • Page 41: Certification Flow

    Replace M/B Fail Whole unit charge test Fail Whole unit discharge test ? Fail Run down test ? Battery is NG Battery is OK HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 42 PAGE NO. 41...

  • Page 42: Current Consumption Measurement

    (A) and current meter (B) Note : black cable to power supply (A) and red cable to current meter (B) HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 43 PAGE NO. 42...
  • Page 43 6. Ready for testing (Don’t turn on power at the moment) 7. Turn on power supply ( 4V) 8. Turn on current meter ( 2A) HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 44 PAGE NO. 43...
  • Page 44 “ sleep mode” The criteria is as follows <= TBD Unit is turn off and no display HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 45 PAGE NO. 44...

  • Page 45: Whole Unit Charge And Discharge Test

    The charge light must be off, but the LCD screen must still on display. If it is failed in discharge test, replace another good battery for double check. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 46 PAGE NO. 45...

  • Page 46: Battery Performance On Unit With Run Down Program

    2 minutes. -> After one hour later the program will stop, open the log file of PowerCap.txt. Please check battery remaining capacity. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 47 PAGE NO. 46...
  • Page 47 (during 4 hrs, from 0% to 100%) Execute Rundown test for 1 hour Check test result PowerCap.txt Capacity >=TBD Battery is bad Battery is Good Replace main battery HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 48 PAGE NO. 47...

  • Page 48: Lcm Inspection Criteria

    3. Test Jig. 4. Shielding Box 5. RF golden sample 6. RF cable 10.3 RF test connection (following is a example of HTC RF test solution) HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 49 PAGE NO. 48...
  • Page 49 TX Phase RMS Error -104 TX Phase Peak Error -104 TX Frequency Error -104 Check TX Power -104 Check TX Power -104 Check TX Power HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 50 PAGE NO. 49...
  • Page 50 TX Phase RMS Error -104 TX Phase Peak Error -104 TX Frequency Error -104 Check TX Power -104 Check TX Power -104 Check TX Power -104 HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 51 PAGE NO. 50...
  • Page 51 TX Phase RMS Error -104 TX Phase Peak Error -104 TX Frequency Error -104 Check TX Power -104 Check TX Power -104 Check TX Power -104 HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 52 PAGE NO. 51...
  • Page 52 TX Phase RMS Error -104 TX Phase Peak Error -104 TX Frequency Error -104 Check TX Power -104 Check TX Power -104 Check TX Power -104 HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 53 PAGE NO. 52...

  • Page 53: Bluetooth Function Test

    -> Turn on Bluetooth for both devices ->Choose “Bluetooth Setting” for both devices. ->Enable “Turn on Bluetooth” ->Enable “Make this device discoverable to other devices” for both devices. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 54 PAGE NO. 53...
  • Page 54 (Test_519) and showing in the page -> In Host device, Tap “ Test_519” -> Tap “ NEXT” -> In Host device, Input passkey “ 0000” -> Tap “NEXT” HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 55 PAGE NO. 54...
  • Page 55 -> In Host device (Test_270), choose a file ( for example: Image_00001, then press and hold the file until appear sub-icon -> Tap “Beam file” HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 56 PAGE NO. 55...
  • Page 56 Do you want to accept “ Image_0001? -> Tap YES ->In UUT(Test_519), it must successful get a file “ Image_00001” in the folder of My document. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 57 PAGE NO. 56...

  • Page 57: Wlan Function Test

    (Choice AP device) (Check WLAN performance) ->Tap Start->Internet Explorer. ->Enter web address: :http://htcscm10.htc.com.tw/SDO/ WLAN.ASP (Select Internet Explorer) (Enter web address) HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 58 PAGE NO. 57...
  • Page 58 (Download file for 1Mbytes) ->After download finished, please check the playing status in windows media to ensure the function is normal. (File download) (Play in Windows media) HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 59 PAGE NO. 58...

  • Page 59: Firmware Of Os/ Radio Upgrade

    You could decide how many mini-SD cards you need for this purpose depend on your needed. You can send PO to HTC for purchasing the encoded mini-SD card, material description is as follows “128 MB mini-SD card for ROM image download, level 1, Prodigy”...
  • Page 60 Following display will show on screen: c. Type Next HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 61 PAGE NO. 60...
  • Page 61 The screen will show on display, click NEXT e. Follow the instruction on PC and make sure Active Sync connection is established before go to NEXT HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 62 PAGE NO. 61...
  • Page 62 Click Update g. Click NEXT HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 63 PAGE NO. 62...
  • Page 63 Click NEXT and wait until process completed. i. Start to re-flash unit HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 64 PAGE NO. 63...
  • Page 64 Once completed, Display will show as below in PC, and unit will be auto re-boot HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 65 PAGE NO. 64...
  • Page 65 11.2 Upload ROM image from master unit to HTC encoded mini-SD card System Requirement: -Windows 2000 above -USB Cable or Cradle -ActiveSync. Version 4.0 above -MTTY.exe -Master Unit with most updated Rom Code -128 MB encoded mini-SD card. Caution: The unit must have at least 70% of battery capacity before starting the re-flash process.
  • Page 66 Connect USB cable to unit and PC, Execute MTTY.exe and set into USB Port, Here is an example, actually display depend on MTTY.exe version. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 67 PAGE NO. 66...
  • Page 67 Insert HTC encoded 128 MB mini-SD card into mini-SD slot e. On the PC side, Select OK and press ENTER. Following display will show on PC HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 68 PAGE NO. 67...
  • Page 68 PC. CAUTION! DO NOT REMOVE THE USB CABLE FROM THE PC OR PDA, FAIL TO DO SO MAY CAUSE DEVICE UNIT FAIL TO BOOT. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 69 PAGE NO. 68...

  • Page 69: Use Pre - Loaded Sd Card To R E - Flash Unit

    Reset the unit and enter the boot-loader mode, by pressing Record button simultaneously and Reset the unit. Display will show as below…. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 70 PAGE NO. 69...
  • Page 70 Take out the mini-SD card and RESET the device (unit). Now the upgrade procedure is Done. Note : Due to security issue, it is not allowed to re-flash different customer ID . HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 71 PAGE NO. 70...

  • Page 71: Classification Of Non Confirmity

    Ｃ．Battery Pack Does not Recharge Ａ．No sound from Speaker or Distorted sound 8．Sound Ａ．No recorded sound or distorted sound 9．Recording １0．Others Ａ．Housing Cosmetic damage HTC confid ential © 2001, HT Corporation. All rights reserved. TOTAL 84 CONT.ON. 72 PAGE NO. 71...
  • Page 72 (2) Check the connection of LCM FPC whether is properly connected. (3) Try with another LCM. (4) Try with another Main Board. (5) Replace LCM if necessary (6) Replace Main Board if necessary. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 73 PAGE NO. 72...
  • Page 73 (5) Replace Main Board if necessary. (6) Once the defective part has been identified, verify it again with the defective part whether the symptom could be duplicated. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 74 PAGE NO. 73...
  • Page 74 (6) Try with another Main Board if necessary. (7) Once the defective part has been identified, verify it again with the defective part whether the symptom could be duplicated. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 75 PAGE NO. 74...
  • Page 75 (1) Make sure the Battery lock is closed properly. Data introduced by User might be lost when Battery has drained completely. (2) Connect to the AC Adapter and see if it takes charge. Also check AC Adapter condition. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 76 PAGE NO. 75...
  • Page 76 (5) Try with another Main Board or Replace Main Board if necessary. (6) Once the defective part has been identified, verify it again with the defective part whether the symptom could be duplicated. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 77 PAGE NO. 76...
  • Page 77 Backup battery malfunction 10－B． Check backup battery status in unit Charge the unit until backup battery to 100% Remove main battery for 30 second HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 78 PAGE NO. 77...

  • Page 78: Spare Part List

    Power on the unit, The screen must display in main page ( Today page) 14. Spare part list 14.1 Unit spare part list (No final version yet) HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 79 PAGE NO. 78...
  • Page 79 HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 80 PAGE NO. 79...
  • Page 80 HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 81 PAGE NO. 80...

  • Page 81: Board Level Spare Part List

    14.2 Board Level Spare Part List HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 82 PAGE NO. 81...

  • Page 82: Appendix

    Or could be incompatibility issue. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 83 PAGE NO. 82...
  • Page 83 *Note: Nevertheless, the above symptoms could be solved by a warm- reset or cold- reset, make sure the warm /cold reset has been executed and try to reproduce the symptom reported. HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. 84 PAGE NO. 83...

  • Page 84: How To Check Backup Battery

    Send Key to turn back manufacture default setting D. To remove main battery, it is requested that turn off the unit before removing main battery HTC confidential © 2001, HTC Corporation. All rights reserved. TOTAL 84 CONT.ON. F PAGE NO. 84...

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