HTC Sapphire User manual

Doc. No. DOC-00051810 REV.
Issued Date 2008/12/29
. Revised Date 2009/01/14 AX02
Doc. Title Sapphire Service Manual Page 1 of 91
HTC CONFIDENTIAL
SM-TP008-1125
HTC Corporation.
Sapphire
Service Manual
UHTC Proprietary
Confidential Treatment Requested
Rev. AX02
HTC Corporation.
Engineering Mobility

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Issued Date 2008/12/29
. Revised Date 2009/01/14 AX02
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HTC CONFIDENTIAL
SM-TP008-1125
HTC Corporation.
REVISION CONTROLTABLE
REV DATE CONTENTS DEPT REVISED STAGE
AX01 2008/12/29 Fist Draft PSE Marc DVT
AX02 2009/01/14 Add product picture at page 1 PSE Marc CVT

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HTC CONFIDENTIAL
SM-TP008-1125
HTC Corporation.
1. INTRODUCTION ....................................................................................................................................................................4
1.1 PRODUCT FEATURES .......................................................................................................................................................5
1.2 PRODUCT OVERVIEW .......................................................................................................................................................7
2. DEVICE DISASSEMBLING AND ASSEMBLING PROCEDURE ................................................................................13
2.1 DISASSEMBLING PROCEDURE........................................................................................................................................13
2.2 ASSEMBLING PROCEDURE.............................................................................................................................................23
3. ROM RE-FLASH PROCEDURE........................................................................................................................................32
3.1 ROM UPGRADE THRU RUU (RE-FLASH UPGRADE UTILITY)........................................................................................32
3.2 ROM IMAGE UPGRADE THRU SD CARD..........................................................................................................................36
4. DIAGNOSTIC PROGRAM..................................................................................................................................................38
4.1 LIST OF DIAGNOSTIC /WINCE TEST ITEMS ..................................................................................................................38
5. POWER MEASUREMENT TEST ......................................................................................................................................51
5.1 MAIN BOARD LEAKAGE CURRENT TEST PROCEDURE ...................................................................................................51
5.2 BATTERY RUNDOWN TEST PROCEDURE.........................................................................................................................56
6. COSMETIC INSPECTION CRITERIA...............................................................................................................................58
6.1 CLASSES DEFINITION OF INSPECTIVE AREA...................................................................................................................58
6.2 DISPLAY INSPECTION .....................................................................................................................................................59
6.3 MAIN UNIT INSPECTION ..................................................................................................................................................61
7. GENERIC TROUBLESHOOTING .....................................................................................................................................62
8. GENERIC LABELING PLAN..............................................................................................................................................67
9. GENERIC SPARE PART LIST AND PHOTOS................................................................................................................83
9.1 SPLFOR REPAIR ...........................................................................................................................................................83
9.2 BOARD LEVEL 2.5 REPAIRS...........................................................................................................................................85
9.3 FRU M/BADDITIONAL PARTS LOCATION........................................................................................................................89
10. RF ANTENNA SPECIFICATION...................................................................................................................................90

Doc. No. DOC-00051810 REV.
Issued Date 2008/12/29
. Revised Date 2009/01/14 AX02
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HTC CONFIDENTIAL
SM-TP008-1125
HTC Corporation.
1 Introduction
This manual provides the technical information to support the service activities of this product.
This document contains highly confidential information, so any or all of this document should not be revealed to
any third party.
zChapter 1: Introduction-This Chapter is about Products features and basic Product function. After
reading this chapter, you will know what feature the product has and basic hardware
operation. Also you will know how to perform soft-rest and hard-rest in this chapter.
zChapter 2: Device Disassembling andAssembling Procedure- After reading this chapter, you will
learn how to disassemble and assemble the product. Also, you will know what tools to
use and the torque. Please follow the instruction to disassemble the unit to prevent
from damaging the unit.
zChapter 3: ROM Re-flash Procedure- After reading this chapter, you will learn how to perform
the ROM image re-flesh by using RUU and SD-Card. Also you can find the steps of
enter the boot loader mode.
zChapter 4: DIAGNOSTIC PROGRAM- After reading this chapter, you will learn
zHow to use the diagnostic program to perform unit function test
zHow to test some functions in Windows Mobile mode (ex. WLAN, Bluetooth, and
USB etc…)
zChapter 5: Power measurement test- After reading this chapter, you will learn how to use MB
leakage test procedure and battery run-down test (Battery Capacity Measurement).
zChapter 6: Cosmetic Inspection Criteria- After reading this chapter you will learn the appearance
quality inspection criteria, ex. Display, bezel, and housing etc…
zChapter 7: Generic Troubleshooting- After reading this chapter, you will learn how to do generic
trouble-shooting.
zChapter 8: Generic Labeling Plan- In this chapter, you will find generic labels for reference, ex.
Regulation label, and battery label etc…
zChapter 9: Generic Spare Part List and Photos- In this chapter, you will find Spar parts reference
list and photos for repairing, including unit and Board level.
zChapter 10: RF Antenna Specification- Reference Spec for RF test.

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1.1 Product Features

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. Revised Date 2009/01/14 AX02
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HTC CONFIDENTIAL
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HTC Corporation.

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. Revised Date 2009/01/14 AX02
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Product overview
zFront side
zAccessories

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# ITEM FUNCTION
1 AC ADAPTER RECHARGES THE BATTERY.
2 USB SYNC CABLE CONNECTS TO A PC AND SYNCHRONISES
DATA.

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zInstall the SIM card
1. Make sure your device is turned off.
2. Press the back cover latch down and gently slide the back cover towards yourself. Once the back
cover pops out, remove it by lifting it up from the bottom end.
3. If you have installed the battery, remove it by lifting it up from the bottom end.
4. Insert the SIM card into the slot with its gold contacts facing down and its cut-off corner facing toward
outside of the slot.
5. Install the battery by inserting it with its exposed copper part aligned with the protruding copper
conductor on the upper right side of the battery compartment. Insert the upper part of the battery first,
then gently push the battery into place.
6. Replace the back cover by gently sliding back in until it snaps in place.

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zInstall the SD card
If you need more storage for your device, you can
install an SD card into the slot on the upper part
of the device. To install the SD card, gently insert
the card into the slot (with its gold contacts
facing down) until it snaps in place.
To remove the SD card, make sure that no
application is accessing the card. Press the card
to pop it out slightly and gently pull the card out
of the slot.
zCharge the battery
New batteries are shipped partially charged. Before you start using your device, you have to install and
charge the battery. Some batteries perform best after several full charge/discharge cycles. You can
charge the battery in two ways:
• Connect your device directly to an
electrical outlet using the AC adapter.
• Plug the sync cable to the USB port on
your PC and to the sync connector on
your device.
When your device is turned off, charging is indicated by a solid amber light on the LED
indicator.
When your device is turned on, charging is indicated by a solid amber light on the LED
indicator as well as a charging icon ( ) on the Today screen.
After the battery has been fully charged, the LED indicator becomes green and a full
battery icon
( ) appears on the Today screen.

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. Revised Date 2009/01/14 AX02
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zTo perform a soft reset
• Use the stylus to press the RESET button found on the back of the device. Your device restarts and displays
the Today screen.
zTo perform a hard reset
Warning! Your device will be set back to factory default settings. Please ensure any additional installed
programs and/or user data have been backed up before a hard reset is performed.
1. Hold the Soft1 and Soft2 Key and Press the RESET Button at the same time
2. Press SEND Button to confirm hardware reset
3. Press OK Button to double confirm hardware reset

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2 Device Disassembling and Assembling Procedure
2.1 Disassembling procedure
1. PHILLIPS SCREW-DRIVER 00X50
2. FLAT PLASTIC STICK
(P/N:RTT-00006)
3. CLEANING CLOTH
4. PLASTIC TWEEZERS
5. ESD WRIST STRAP.
1. Remove the battery cover
2. Remove the battery

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3. Unfasten the screws at the
location indicated.
4. Remove the antenna by
inserting the plastic stick in
to the gap
5. Use the flat plastic stick to
slide through the gap
between keyboard upper
cover and keyboard bottom
cover.

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6. Disassemble speaker from
keyboard bottom cover.
7. Unfasten the screws at the
location indicated

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8. Disassemble LCM FPC
connector from the Main
board.
9. Disconnect the Vibrator
cable
10. Disconnect the FPC
connector from the Upper
board.

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11. Unfasten the screws at the
location indicated
12. Turn over the upper board.
13. Disassemble the cable.
14. Disconnect the volume
FPC from Rigid-Flex board.

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15. Remove the volume FPC
from the chassis
16. Disassemble the camera
module from the upper
board.
17. Disconnect the AP key FPC
connector

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18. Disconnect the Rigid-Flex
board connector form the
Main board as shown.(1)
19. Use the white stick to
separate it
20. Unfasten the screws at
location indicated (blue)
21. Disconnect the Main FPC
from Main board and
remove it

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22. Remove the Main Board
from Chassis
23. Unplug the cable from the
Main Board.
24. Remove the Mylar
25. Release the hook from the
Main Board to separate the
switch