Motorola g520 Service Manual
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Motorola g520 Service Manual

Motorola g520 Service Manual

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g520
Level III Service Manual

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Summary of Contents for Motorola g520

  • Page 1 Level III Service Manual...
  • Page 2 ©2002 by Motorola, Inc. All rights reserved.

  • Page 3: Table Of Contents

    CONTENTS Page Number SECTION 1: GENERAL Introduction Motorola service policy for g520 in warranty General Safety Information SECTION 2: g520 DESCRIPTION Specifications g520 Overview Connector Pinout Talk time, Weight and Volume Matrix SECTION 3: FEATURE LIST List of Features available...
  • Page 4 SECTION 6: REPAIR AND TEST PROCEDURES Repair Introduction Mechanical repairs Basic modular troubleshooting Software Upgrade Testing on HP 8922 Testing on Go / NoGo Tester SECTION 7: ACCESSORIES Accessory Statement SECTION 8: GLOSSARY OF TERMS List of Abbreviations...

  • Page 5: Section 1: General

    SECTION 1: GENERAL European Customer Services...

  • Page 6: Introduction

    The scope of this document is to provide the reader with basic information relating to the g520 and also to provide procedures and processes for repairing the units up to and including Level 2 repair.

  • Page 7: Motorola Service Policy For G520 In Warranty

    Only shops authorized to carry out repairs will be able to purchase spare parts. Orders for spare parts should be placed with the Accessories and Aftermarket Division (AAD) of Motorola. Refer to the latest version of CSB 260 for details.

  • Page 8: General Safety Information

    In standby mode the mobile telephone will automatically transmit to acknowledge a call if it is not turned off. • Refer to the appropriate section of the product user manual for additional pertinent safety information • All equipment should be serviced only by a Motorola qualified technician. European Customer Services...

  • Page 9: Section 2: G520 Description

    SECTION 2: g520 DESCRIPTION...

  • Page 10: Specifications

    Specifications of g520 General Function Specification Frequency Range GSM PCS 1850.2 - 1909.8 MHz Tx 1930.2 - 1989.8 MHz Rx Channel Spacing 200 kHz Channels 174 GSM/374 DCS carriers with 8 channels per carrier Modulation GMSK at BT = 0.3...

  • Page 11: G520 Overview

    Overview The g520 is marketed as a ‘ price beater’ unit in its class. It is now designed with a new chip set to allow the unit to operate at a lower working voltage and therefore prolong battery life, in both Standby and Talk time.

  • Page 12: Connector Pinout

    2.3 Connector Pinout 1- Ext B+ 2- Ground 3- Man Test 4- Uplink 5- Not Connected 6- Downlink 7- DSC_EN_B 8- UTXD 9- Ground 10- UTXD_IN 11- Ground Talk Times, Weight and Volume Matrix White holographic film on display...

  • Page 13: Section 3: Feature List

    SECTION 3: FEATURE LIST...

  • Page 14: List Of Features Available

    List of Features Available Below are the list of Menu functions available at present. Menu Generation Menu Network Phone Book Selection Generation Menu Generation Menu Call Related Call Meters Generation Menu Features 5th Generation Menu Generation Menu Messages Phone Setup...

  • Page 15: Call Related Features

    CALL RELATED FEATURES Show battery meter 1.Show ID on next call Restrict my 2.Restrict ID on next call Phone number Call Diverting 1.On Talk and Fax 2.Off Call waiting 1.On 2.Off 1.Int’ l Calls Call Barring Bar outgoing calls 2.Int’...

  • Page 16: Messages

    Messages Call Voicemail Received messages Go to Next message Delete Message Return Call 1.Send Message Edit Message 2.Store Message Reply to message Delete all messages Outgoing Messages Go to next message Send message 1.Send message Edit message 2.Store message Delete message 1.On...

  • Page 17: Phone Setup

    PHONE SETUP Adjust Ring volume 1.On Ringer On or Off 2.Off Standard Tone Set Ringer Tone Music Tone Set Ringer Tone 2 1.On Automatic Lock Phone Lock 2.Off Lock Now Change Unlock mode Change SIM PIN2 Code 1.On 2.Off Require SIM card pin 3.Change SIM pin Code...

  • Page 18: Network Selection

    NETWORK SELECTION Available 1.Register Now Networks 2.Make Preferred Registration 1.Automatic Search Network Search Preferences 2.Manual Search 1.Slow Search 2.Medium Search Frequency of 3.Fast Search Search 4.Continuous Search Preferred 1.Choose From Available Add network Networks 2.Choose From Known to List 3.Add new Network Code...

  • Page 19: Accessory Setup

    ACCESSORY SETUP Note: THIS MENU IS ONLY AVAILABLE WITH EITHER HEADSET PLUGGED IN OR WHEN INSTALLED IN A CAR KIT. 1.On Automatic answer 2.Off European Customer Services...

  • Page 20: Section 4: Disassembly & Parts

    SECTION 4: DISASSEMBLY & PARTS...

  • Page 21: Dissasembly Introduction

    4.1 Disassembly Introduction The g520 is held together by 5 screws as other Modulus products; 1 of these screws is placed beneath the IMEI label. Care should be taken whilst removing the display flex cable as this can be torn or broken without too much stress being applied.
  • Page 22 2. Remove battery by 1. Remove battery door pushing and lifting at by pressing down on clip the same time. while pulling towards you. 3. Press down and pull SIM 4. Unscrew antenna and door to right and lift. Then remove.
  • Page 23 5. Unscrew all 5 screws, 6. Lift off back housing remembering the one beneath from PCB. the label in the center. 7. Pry the alert from 8.Remove keypad the back housing. PCB from board European Customer Services...
  • Page 24 9. Remove the keypad 10. Fit a blade under the speaker and from the front housing. carefully lift it from the front housing. European Customer Services...

  • Page 25: Exploded Parts Diagram

    Exploded Parts Diagram SWF3076DA European Customer Services...

  • Page 26: Replacement Parts

    Replacement Parts Xcvr Item Number SWF3076DA Frnt Hsng Assy 0103892K01 Lens tape not available Keypad 3809378T02 Speaker 5009150J04 Lens 6103893K02 Rear Hsng 0109482U02 Alert 5009005J09 Stubby Antenna 8504892Z02 Screw 0309315B02 Speaker Gasket 3203997K01 Keypad Domes 4009410U05 Microphone 5009536H15 Display...

  • Page 27: Section 5: Sim Cards And Security

    SECTION 5: SIM CARDS AND SECURITY European Customer Services...

  • Page 28: Manual Test Mode

    5.1 Manual Test Mode The GSM Motorola g520 is equipped with a manual test mode capability. This capability allows service personnel to take control of the unit, and by entering certain keypad commands, make the unit performs desired functions.
  • Page 29 4. Insert card into replacement unit, or unit with new main RF / Logic PCB. 5. Turn unit on wait till ‘ Clone’ appears. 6. Enter 03# ‘ Please wait’ will be displayed while data is transferred. 7. Repeat steps 1 – 6 but enter 022# at step 2 to transfer data on to Clone card.

  • Page 30: Gsm Test Commands

    GSM Test Commands This is a list of Level 1 and 2 Test commands available to g520 Table 6.1 Test commands GSM Test Commands Key Sequence Test Function/Name #(hold down for 2 seconds) Enter manual test mode Exit manual test mode...

  • Page 31: Identity And Security

    The mechanical Serial Number (MSN) is an individual unit identity number and will remain with the unit throughout the life of the unit. The MSN can be used to log and track a unit on Motorola’ s EPPRS system. The MSN is divided into 4 sections.

  • Page 32: Section 6: Repair And Test Procedures

    SECTION 6: REPAIR AND TEST PROCEDURES European Customer Services...

  • Page 33: Repair Introduction

    6.1 Repair Introduction The g520 is divided into 3 main sections when it comes to part replacability: the housings which contain the alert, speaker, the main PCB which contains RF / Logic circuitry and the keypad; and finally the display which connects to the main PCB via a ZIF connector. If the RF / Logic board is faulty then the entire unit must be replaced since there is no replacement PCB available.

  • Page 34: Repair Chart

    Repair Chart Table 2. GSM g520 Cellular Telephone: Troubleshooting and Repair Chart. (Assembly Replacement Level). SYMPTOM PROBABLE CAUSE VERIFICATION AND REMEDY Personal telephone will not turn a) Battery pack either discharged Measure battery. If the battery voltage is <4.00 V dc,...
  • Page 35 SYMPTOM PROBABLE CAUSE VERIFICATION AND REMEDY 4. Incoming call alert transducer a) Faulty alert Transducer / Main Replace Logic/RF Board Assembly (refer to audio distorted or volume is too RF / Logic PCB defective symptom 1c). Verify that the fault has been cleared low.

  • Page 36: Software Upgrade

    SYMPTOM PROBABLE CAUSE VERIFICATION AND REMEDY 9. Internal Charger not working a) Faulty charger circuit on main Test a selection of batteries in the rear Board. pocket of the desktop charger. Check LED display for the charging indications. If these are charging ok, then the internal charger is at fault.

  • Page 37: Testing On Hp8922

    Down Converter RF Cable g520 under Test Note: To test the PCB on its own without a housing or SIM card the unit must first be put into test mode and then into Tx or Rx mode using the applicable manual test commands. Ensure that a battery is installed during this, since the battery acts as a SIM card presence detect for the unit.

  • Page 38: Testing On Go / Nogo Tester

    Testing on Go / NoGo tester The set up for the GO / NOGO tester must be set up as shown above. The tester must be set up following GSM specifications. Note, the D520 is shown in the illustration.

  • Page 39: Section 7: Accessories

    SECTION 7: ACCESSORIES European Customer Services...

  • Page 40: Accessory Statement

    7.1 Introduction Most of the accessories are compatible with the previous models. Accessories available with compatibility to C / D160 Part Number Name SYN 7167A AA Door With Belt Clip SHN 6936A AA Battery Door W/ Stud for Belt Clip...

  • Page 41: Section 8: Glossary Of Terms

    SECTION 8: GLOSSARY OF TERMS European Customer Services...

  • Page 42: List Of Abbreviations

    8.1 List of Abbreviations Those marked ** are Motorola specific abbreviations. A Interface Interface between MSC and BSS Authentication algorithm Stream cipher algorithm ciphering key generating algorithm Access Burst A-bis Interface between BSC and BTS ACCH Associated Control Channel...
  • Page 43 CSPDN Circuit Switched Public Data Network Closed User Group Call Waiting Dummy Burst Distributed Base Station ** DCCH Dedicated Control Channel Detach Decision Feedback Equalizer DISC Disconnect Data Link (layer) Control Channel (ISDN terminology applied to mobile service) Signaling channel...
  • Page 44 Information (frames) International Alphanumeric 5 Identification IMEI International Mobile Equipment Identity Immediate assignment message IMSI International Mobile Subscriber Identity Intelligent Network INDY Iridium 9500 handset International Switching Center Iridium Subscriber Unit ISDN Integrated Services Digital Network ISUP ISDN User Part...
  • Page 45 Norme European de Telecommunications Network Management Network Management Center O&M Operations and Maintenance OACSU Off Air Call Set-Up Outgoing Calls Barred OMAP Operations and Maintenance Application Part (previously was OAMP) Operations and Maintenance Center OMCR Operations and Maintenance Center -Radio Part...
  • Page 46 SRES Signed RESponse (authentication) Supplementary Service System Simulator Signaling Transfer Point SYSGEN SYStem GENeration Terminal Adapter Timing Advance TCAP Transaction Capabilities Application Part Traffic Channel TCH/F A full rate TCH TCH/FS A full rate speech TCH TCH/HS A half rate speech TCH...
  • Page 47 - RF SCHEMATICS RX SIGNAL PATH TX SIGNAL PATH MIX_275 MAIN VCO SIGNAL PATH TUNING VOLTAGES GSM_LNA275 13 MHz REFERENCE CLOCK TXVCO_EN VCO_275 DATA BUS ADDRESS BUS Q501 Q502 TEXT REFERENCE SIGNALS FL459 DCS_SEL GSM_SEL FL400 RX_DCS_*GSM TX_GSM_*DCS Q410...
  • Page 48 - AL SCHEMATICS RX SIGNAL PATH TX SIGNAL PATH MAIN VCO SIGNAL PATH TUNING VOLTAGES PWR_SW LBTO 13 MHz REFERENCE CLOCK DATA BUS ADDRESS BUS TEXT REFERENCE SIGNALS KBR2 URXD UTXD (WAS SCI_TX) EMU1 TRST* KBR1 (WAS SCI_RX) TRST*...
  • Page 49 - BLOCK DIAGRAM - PAGE 1/2 KBR0, KBR1, KBR2 H2, H1, H3 C4, C14, F10,H4, K5, K13, P13 KBC0, KBC1, KBC2 J5, J3, J2 to Keyboard KEYPAD A9, A10, C5, G12, K6, K10, M8, M11 BKLITE_CNTL WHITE_CAP DISPLAY MAGIC SPI...
  • Page 50 - BLOCK DIAGRAM - PAGE 2/2 A100 Osc. LOCAL 800MHz discrete RF_V2 OSCILLATOR circuty Q262 U201 PCS LNA RX MID CHANNELS MAGIC CR259 RX_EN SW_V1 U504 PCS: CH 661 -- 1960MHz MIX_275 ( SCLK_OUT ) BCLKR 1930-1990MHz 1930-1990MHz MIX_275...
  • Page 51 - BOARD LAYOUT...
  • Page 52 - SIGNAL FLOW MIX_275 VCO_275 SW_VCC RF_V2 RF_V1 RF_V2 EEPROM CS RAM Byte Control LB+ RAM Byte Control 1 EEPROM 0E SH202 13MHz_CLK WHITECAP U201 Y201 MAGIC JEKYLL MAGIC_13MHz MAGIC U700 SH700 J665 SIM_CONN WHITE_CAP 1617 SH201 SH481 SH600...

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