Nokia 616 User manual

Nokia Customer Care
Copyright© 2005 Nokia Corporation, All Rights Reserved
SERVICE
MANUAL
Nokia 610 & 616
CarKit Phone (TFE-4/RV-1)
(Approved Issue 1.0 November 2003)
NMP Part No: 0275931 (Issue 1.1 December 2003)
(Issue 2.0 March 2005)
Company Confidential

TFE-4 Company Confidential
Foreword Customer Care, User Guidance
Page 2 Copyright © 2005 Nokia Corporation. Issue 2.0 Mar/2005
Company Confidential
Amendment Record Sheet
Amendment
Number Date Inserted By Comments
Issue 1.0 Nov. 03 P.Harvey Approved Issue
Issue 1.1 Dec. 03 P.Harvey Published Issue
Issue 2.0 Mar. 05 P.Harvey The introduction of the Nokia 616

Customer Care, User Guidance Foreword
Company Confidential TFE-4
Issue 2.0 Mar/2005 Copyright © 2005 Nokia Corporation Page 3
Company Confidential
Copyright © 2005 Nokia. All rights reserved.
Reproduction, transfer, distribution or storage of part or all of the contents in this
document in any form without the prior written permission of Nokia is prohibited.
Nokia, Nokia Connecting People, Nokia 610 & 616 are trademarks or registered
trademarks of Nokia Corporation. Other product and company names mentioned
herein may be trademarks or tradenames of their respective owners.
Nokia operates a policy of continuous development. Nokia reserves the right to make
changes and improvements to any of the products described in this document with-
out prior notice.
Under no circumstances shall Nokia be responsible for any loss of data or income or
any special, incidental, consequential or indirect damages howsoever caused.
The contents of this document are provided "as is". Except as required by applicable
law, no warranties of any kind, either express or implied, including, but not limited
to, the implied warranties of merchantability and fitness for a particular purpose,
are made in relation to the accuracy, reliability or contents of this document. Nokia
reserves the right to revise this document or withdraw it at any time without prior
notice.
The availability of particular products may vary by region.
IMPORTANT
This document is intended for use by qualified service personnel only.

TFE-4 Company Confidential
Foreword Customer Care, User Guidance
Page 4 Copyright © 2005 Nokia Corporation. Issue 2.0 Mar/2005
Company Confidential
Warnings and Cautions
Please refer to the product’s user guide for instructions relating to oper-
ation, care and maintenance including important safety information.
Note also the following:
Warnings:
1. CARE MUST BE TAKEN ON INSTALLATION IN VEHICLES FITTED WITH
ELECTRONIC ENGINE MANAGEMENT SYSTEMS AND ANTI-SKID BRAKING
SYSTEMS. UNDER CERTAIN FAULT CONDITIONS, EMITTED RF ENERGY
CAN AFFECT THEIR OPERATION. IF NECESSARY, CONSULT THE VEHICLE
DEALER/MANUFACTURER TO DETERMINE THE IMMUNITY OF VEHICLE
ELECTRONIC SYSTEMS TO RF ENERGY.
2. THE product MUST NOT BE OPERATED IN AREAS LIKELY TO CONTAIN
POTENTIALLY EXPLOSIVE ATMOSPHERES EG PETROL STATIONS (SERVICE
STATIONS), BLASTING AREAS ETC.
3. OPERATION OF ANY RADIO TRANSMITTING EQUIPMENT, INCLUDING
CELLULAR TELEPHONES, MAY INTERFERE WITH THE FUNCTIONALITY OF
INADEQUATELY PROTECTED MEDICAL DEVICES. CONSULT A PHYSICIAN
OR THE MANUFACTURER OF THE MEDICAL DEVICE IF YOU HAVE ANY
QUESTIONS. OTHER ELECTRONIC EQUIPMENT MAY ALSO BE SUBJECT TO
INTERFERENCE.
4. BEFORE MAKING ANY TEST CONNECTIONS, MAKE SURE ALL EQUIPMENT
IS SWITCHED OFF.
Cautions:
1. Servicing and alignment must be undertaken by qualified personnel only.
2. Ensure all work is carried out at an anti-static workstation and that an
anti-static wrist strap is worn.
3. Ensure solder, wire, or foreign matter does not enter the product as
damage may result.
4. Use only approved components as specified in the parts list.
5. Ensure all components, modules screws and insulators are correctly re-
fitted after servicing and alignment. Ensure all cables and wires are
repositioned correctly.

Customer Care, User Guidance Foreword
Company Confidential TFE-4
Issue 2.0 Mar/2005 Copyright © 2005 Nokia Corporation Page 5
Company Confidential
For your safety
QUALIFIED SERVICE
Only qualified personnel should install or repair Nokia equipment.
ACCESSORIES
Use only approved accessories. Do not connect incompatible products.
CONNECTING TO OTHER DEVICES
When connecting to any other device, read its user’s guide for detailed safety instruc-
tions. Do not connect incompatible products.
ESD protection
Nokia requires that product service points have sufficient ESD
protection (against static electricity) when servicing products.
Any product of which the covers are removed must be handled
with ESD protection. The SIM card can be replaced without ESD
protection if the product is otherwise ready for use.
To replace the covers ESD protection must be applied.
All electronic parts of the product are susceptible to ESD. Resis-
tors, too, can be damaged by static electricity discharge.
All ESD sensitive parts must be packed in metallized protective
bags during shipping and handling outside any ESD Protected Area
(EPA).
Every repair action involving opening the product or handling the
product components must be done under ESD protection.
ESD protected spare part packages MUST NOT be opened/closed
out of an ESD Protected Area.
For more information and local requirements about ESD protec-
tion and ESD Protected Area, contact your local Nokia After Mar-
ket Services representative.

TFE-4 Company Confidential
Foreword Customer Care, User Guidance
Page 6 Copyright © 2005 Nokia Corporation. Issue 2.0 Mar/2005
Company Confidential
Care and maintenance
The product is a product of superior design and craftsmanship and should be treated
with care. The suggestions below will help you to fulfil any warranty obligations and
to enjoy this product for many years.
Keep dry. Precipitation, humidity and all types of liquids or moisture can contain min-
erals that will corrode electronic circuits.
Do not use or store in dusty, dirty areas. Its moving parts can be damaged.
Do not store in hot areas. High temperatures can shorten the life of electronic devices,
damage batteries, and warp or melt certain plastics.
Do not store in cold areas. When it warms up (to its normal temperature), moisture
can form inside, which may damage electronic circuit boards.
Do not drop, knock or shake. Rough handling can break internal circuit boards.
Do not use harsh chemicals, cleaning solvents, or strong detergents to clean the prod-
uct.
Use only the supplied or an approved replacement antenna. Unauthorised antennas,
modifications or attachments could cause damage and may violate regulations gov-
erning radio devices.
All of the above suggestions apply equally to all the component parts of this product.

Customer Care, User Guidance Foreword
Company Confidential TFE-4
Issue 2.0 Mar/2005 Copyright © 2005 Nokia Corporation Page 7
Company Confidential
Company Policy
Our policy is of continuous development; details of all technical modifications will be
included with service bulletins.
While every endeavour has been made to ensure the accuracy of this document, some
errors may exist. If any errors are found by the reader, NOKIA MOBILE PHONES Busi-
ness Group should be notified in writing.
Please state:
Title of the Document + Issue Number/Date of publication
Latest Amendment Number (if applicable)
Page(s) and/or Figure(s) in error
Please send to:
NOKIA CORPORATION
Nokia Mobile Phones Business Group
Nokia Customer Care
PO Box 86
FIN-24101 SALO
Finland

TFE-4 Company Confidential
Foreword Customer Care, User Guidance
Page 8 Copyright © 2005 Nokia Corporation. Issue 2.0 Mar/2005
Company Confidential
Overall Manual Contents
1 - General Information
2 - Parts Lists & Component Layouts
3 - Service Software & Service Concepts
4 - Service Tools
5 - Disassembly & Assembly Instructions
6 - Troubleshooting
7 - Installation
8 - Technical Information
8a Junction Board TF5
8b Engine Board TF4
9 - Schematics and Component Finder

Nokia Customer Care
Nokia 610 & 616 CarKit Phone (TFE-4/RV-1)
Issue 2.0 Mar/2005 Copyright ©2005 Nokia Corporation. Page 1-1
Company Confidential
1 - General Information

TFE-4/RV-1 Company Confidential
General Information Nokia Customer Care
Page 1-2 Copyright © 2005 Nokia Corporation. Issue 2.0 Mar/2005
Company Confidential
Table of Contents
Description Page No.
Abbreviations ................................................................................................................................... 3
The Product ........................................................................................................................................ 3
Product Features ....................................................................................................................... 4
Radio Unit TFE-4/RV-1 .................................................................................................... 4
Display Unit SU-11/21 ..................................................................................................... 4
Input Device CUW-3 ........................................................................................................ 4
Call and message handling ............................................................................................. 4
Voice recording .................................................................................................................. 4
List of Units and Modules ......................................................................................................5
Interconnection Diagrams ..................................................................................................... 6
System Characteristics ............................................................................................................ 6
Mechanical Characteristics ................................................................................................... 7
Electrical Characteristics ........................................................................................................ 7
External Signals and Connections ....................................................................................... 7
Environmental Conditions ...................................................................................................... 8
Vibration ............................................................................................................................. 8
Temperature ...................................................................................................................... 8
List of Figures
Figure 1: Radio Unit TFE-4 ........................................................................................................... 3
Figure 2: Interconnection Diagram ............................................................................................ 5
List of Tables
Table 1 : Units and Modules .......................................................................................................... 5
Table 2 : General RF Specifications ............................................................................................. 6
Table 3 : Mechanical Characteristics .......................................................................................... 7
Table 4 : Supply voltages ............................................................................................................... 7
Table 5 : Power Consumption ....................................................................................................... 7
Table 6 : List of external connectors ........................................................................................... 7
Table 7 : Vibration conditions ....................................................................................................... 8
Table 8 : Temperature ranges ........................................................................................................ 8

Nokia Customer Care General Information
Company Confidential TFE-4/RV-1
Issue 2.0 Mar/2005 Copyright © 2005 Nokia Corporation. Page 1-3
Company Confidential
Abbreviations
The Product
The TFE-4/RV-1 system is a fully functional car phone that depending on the user’s
mobile phone capabilities can operate in the following modes:
• As a fully functional car phone accessing the SIM card of a compatible Bluetooth
phone using Bluetooth SIM Access Profile, provides the full feature set.
• As a fully functional car phone accessing the SIM card in the Radio Unit of the
system, provides the full feature set.
• As a fully functional car kit accessing a compatible mobile phone using Bluetooth
Handsfree Profile. However, this offers a reduced feature set.
Figure 1: Radio Unit TFE-4
ASIC Application Specific Integrated Circuit ID Input Device
BT Bluetooth I/f Interface
DU Display Unit (SU-11/21) JB Junction Board (TF5)
EB Engine Board (TF4) PWB Printed Wired Board
GPRS General Packet Radio System RU Radio Unit (TFE-4/RV-1)
HD Headset SIM Subscriber Identity Module
HF Hands Free SW Software
HW Hardware UI User Interface
Figure 1: Radio Unit TFE-4
3
4
2
6
5
1

TFE-4/RV-1 Company Confidential
General Information Nokia Customer Care
Page 1-4 Copyright © 2005 Nokia Corporation. Issue 2.0 Mar/2005
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Product Features
(1) Radio Unit TFE-4/RV-1
• Car phone (E)GSM 900 / 1800
• External antenna interface
• Bluetooth (BT)
• CSD, HSCSD, GPRS support via BT I/f
• 12V power supply from car battery
• Ignition sense interface
• Car radio mute interface
• BT SIM Access Profile and BT Handsfree Profile
• Internal SIM reader
• User guided system set up
(2) Display Unit SU-11/21
• Monochrome display with 84 x 24 pixel resolution plus 1 status line with fixed
icons
• Active display area 54.7 x 18.7 mm
• Height of capital letter: up to 14 pixel (8.45 mm) SU-11, 9 pixel (5.43 mm) SU-21
• Flexible installation possibilities due to ball joint fixation
• User adjustable background lighting
(3) Input Device CUW-3
• 4 function keys: send, voice activation, end/back/clear, mode switch buttons
• Turn/push wheel for left/right scrolling and menu/select function
Call and message handling
• Voice dialing (SDND), 12 names per user (2x)
• Voice commands (shortcuts to predefined applications, e.g. connect BT headset),
3 commands per user (2x)
• Call from phonebook/last dialed list/call registers
• Favorite list dialing (trained name tags)
• Number dialing
• Accept/reject incoming call
• Ring tone + speaker volume adjustment
•ReadSMS
• Write SMS (with HSU-4 Handset only)
• Send predefined SMS templates
• Voice call back to SMS sender
• Audio routing to headset (BT/headset) for privacy mode
• Silent mode
Voice recording
• Record and playback voice memos/notes
• Easy tracking and replay of up to 10 voice memos

Nokia Customer Care General Information
Company Confidential TFE-4/RV-1
Issue 2.0 Mar/2005 Copyright © 2005 Nokia Corporation. Page 1-5
Company Confidential
List of Units and Modules
Table 1: Units and Modules
Fig.1
Item Name of unit/module Type code
Material code Notes
610 616
Nokia 610 / 616
CarKit Phone Sales Pack
(TFE-4)
0051904
0051903
0051901
0051902
0086220
0086407
--------
--------
--------
--------
--------
--------
Basic E&A incl. France, Czech, Slovak,
SA and Poland.
Ukraine.
Russia.
Australia
Turkey.
New Zealand.
(RV-1) --------
--------
--------
--------
--------
--------
0518085
0520450
0520451
0520452
0520454
0520455
Basic E&A incl. France, Czech, Slovak,
SA and Poland.
Turkey.
Russia.
Ukraine.
APAC/Australia.
APAC/New Zealand
(1) Radio Unit TFE-4 0514206
0514203
0514205
0514204
--------
--------
--------
--------
Basic E&A
Turkey and Ukraine
Russia and Poland
Australia and New Zealand
RV-1 -------- 0518084
Engine Board TF4 0201914
Junction Board TF5 0051905 0201916
Mechanics assembly parts TFE-4 0262837 TFE-4 RU assembly module
(3) Input Device CUW-3 0650058
(2) Display Unit SU-11 0650075
0650076
0700112
--------
--------
--------
Language pack A
Language pack B
Language pack C (Orange)
SU-21A
SU-21B
SU-21C
SU-21D
--------
--------
--------
--------
0700119
0700720
0700721
0700124
Language pack A
Language pack B
Language pack C
Language pack D
Variant independent
(4) Handsfree Loudspeaker SP-2 0692013
(5) Handsfree Microphone HFM-8 0690016
(6) Power Cable PCU-4 0630478
Mounting plate MKE-1 0260076 For RU and handset
Compatible Enhancements
•Car Handset HSU4 For privacy calls and SMS writing
•Wireless Headset HDW-2 For privacy calls
•Wireless Headset HS-11W For privacy calls
•Wireless Clip-on Headset HS-3W For privacy calls
•Wireless Clip-on Headset HS-21W For privacy calls
•Wireless Boom Headset HS-4W For privacy calls
•Wireless Image Headset HS-13W For privacy calls

TFE-4/RV-1 Company Confidential
General Information Nokia Customer Care
Page 1-6 Copyright © 2005 Nokia Corporation. Issue 2.0 Mar/2005
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Interconnection Diagram
Figure 2: Interconnection Diagram
System Characteristics
Table 2: General RF Specifications
Parameter Unit
Cellular System EGSM900, DCS1800
RX Frequency Band EGSM: 925 - 960 MHz
DCS1800: 1805 - 1880 MHz
TX Frequency Band EGSM: 880 - 915 MHz
DCS1800: 1710 - 1785 MHz
Output Power EGSM900: +5 ...+33 dBm / 3.2 mW ... 2 W
DCS1800: +0 ...+30 dBm / 1.0 mW ... 1 W
Number of RF Channels EGSM: 174
DCS1800: 374
Channel Spacing 200 kHz
Number of TX Power Levels EGSM900: 15
DCS1800: 16
Typical receiver sensitivity, static channel -106 dBm, EGSM900 TCH/FS at 2%BER
-106 dBm, DCS1800 TCH/FS at 2%BER
Frequency Error, Static Channel < 0.1 ppm
RMS Phase Error < 5.0 o
Peak Phase Error < 20.0 o
Car Battery
Ignition
Car Radio Mute
Radio Unit
SIM
HF
Speaker
HF Mic
Display
Unit
Input
Device
Antenna

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Company Confidential TFE-4/RV-1
Issue 2.0 Mar/2005 Copyright © 2005 Nokia Corporation. Page 1-7
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Mechanical Characteristics
Electrical Characteristics
External Signals and Connections
Table 3: Mechanical Characteristics
Unit Type Code Dimensions (mm)
(W x H x D)
Weight
Engine Board Size TF4 43 x 126 x 9.2 ********
Junction Board Size TF5 98.6 x 128 x 15 ********
Radio Unit TFE-4/RV-1 140 x 106 x 41 305 g
Input Device CUW-3 56 x 35 x 24 16.7 g w/o cable
Display Unit XDW-1R
SU-11
79 x 64 x 44
73 x 57 x 30
NA
45.5 g w/o cable
Handsfree Speaker SP-2 86 x 85 x 60 238 g w/cable
Handsfree Microphone HFM-8 43 x 24 x 13 37 g w/cable
Table 4: Supply Voltage
Line
Symbol
Parameter Type Min. Typical /
Nominal
Max. Unit / Notes
VBAT Input from a car battery Power In 10.8
9
13.5 16
16
27
V DC (full functionality)
V DC (reduced functionality)
V DC (not working max DC)
1.5
1
A DC (working)
mA DC (sleep mode)
Table 5: Power Consumption
Condition Current
Active (call) < 1.5 A
Standbye < 300 mA
Off < 1 mA
Table 6: List of external connectors
Connector Name Conn. Manufacturer NMP code / Notes
TFE-4, N610
GSM antenna connector X209 CONN_ANT_3412 SM ANT CONN RF FME 50R 400V 3GHZ
Display Unit connector X103 CON_SS_641010_NF_K Modular Jack 10POL 90deg UNSH
Car connector X104 Molex 43045-0421 Micro-Fit 3.0 2x2
Speaker connector X105 SMK LGY2501-0500E 3.5 mm jack
Microphone connector X106 SMK LGK2509-0600E 2.5 mm jack
Input device X107 CON_SS_641010_NF_K Modular Jack 10POL +K2 Key 1.5A 90deg
RV-1, N616
GSM antenna connector X101 IMS 3412.72.1610.001 Antenna connector FME
RS232 Interface X102 Stewart SS-641010-NF-K1 Modular connector RJ-45 K1
Display Unit connector X103 Stewart SS-641010-A-NF-RMK4 Modular connector RJ-45 RMK4

TFE-4/RV-1 Company Confidential
General Information Nokia Customer Care
Page 1-8 Copyright © 2005 Nokia Corporation. Issue 2.0 Mar/2005
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Environmental Conditions
The transceiver is not protected against ingress of water. The transceiver may be instantaneously sub-
jected to splashed or condensed water. Longer-term contact with water will cause permanent damage.
Vibration
Temperature
Car connector X104 Molex 43045-0421 Micro-Fit 3.0 2x2
Speaker connector X105 SMK LGY2501-0500E 3.5 mm jack
Microphone connector X106 SMK LGK2509-0600E 2.5 mm jack
Input device, Handset
and Headset connector
X107 Stewart SS-641010-NF-K2 Modular connector RJ-45 K2
Table 7: Temperature ranges
Parameter Requirement Test Reference Duration Acceptance
Criteria
Vibration
(random)
Operational
10Hz-7m2/s3
50Hz-3,5m2/s3
60Hz-1,75m2/s3
1000Hz-0,06m2/s3
combined with gradual
change of temperature
1 cycle during 8h
DIN 72300-3 (draft)
Env.Hdbk. 4A: Climatic
and Mechanics
IEC 68-2-64
8h/axis Normal
Performance
or Reduced
performance
Bump
Operational
halfsine
6ms
25g
IEC68-2-29 Eb
Env.Hdbk. 4A: Climatic
and Mechanics
1000 shocks
per 6 directions
Normal
Performance
Shock Non-
operational
halfsine
6ms
100g
IEC68-2-27 3 shocks per
6 directions
Normal
Performance
Table 8: Temperature ranges
Condition Temperature range Notes
Normal Operation -10°C to +55°CSpecifications fulfilled
Reduced Operation -20°C to +70°COperational only for short periods.
Intermittent Operation -30°C to +80°COperation not guaranteed but an attempt to operate
will not damage the phone.
Storage -30°C to +80°CNon operational, 72 h
Table 6: List of external connectors
Connector Name Conn. Manufacturer NMP code / Notes

Customer Care, User Guidance
Nokia 610 & 616 CarKit Phone (TFE-4/RV-1)
Issue 2.0 Mar/2005 Copyright © 2005 Nokia Corporation Page 2-1
Company Confidential
2 - Parts List & Layouts

TFE-4/RV-1 Company Confidential
2 - Parts List Nokia Customer Care
Page 2-2 Copyright © 2005 Nokia Corporation Issue 2.0 Mar/2005
Company Confidential
Table of Contents
Page No
Exploded view of TFE-4 Radio Unit .......................................................................... 3
Assembly Parts List .......................................................................................... 4
Parts List Module for TF4 Module (EB) .................................................................... 4
Component layout diagram Bottom ........................................................... 12
Component layout diagram Top ................................................................... 13
Parts List for TF5 Module (JB) .................................................................................... 14
PWB component differences for N616 ...................................................... 21
Component layout diagram for Bottom of TFE-5 ................................... 22

Nokia Customer Care 2 - Parts List
Company Confidential TFE-4/RV-1
Issue 2.0 Mar/2005 Copyright © 2005 Nokia Corporation Page 2-3
Company Confidential
Exploded view of TFE-4 Radio Unit

TFE-4/RV-1 Company Confidential
2 - Parts List Nokia Customer Care
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Company Confidential
Assembly Parts List
Parts List for TF4 Module (EB)
PWB Components (tf4-07a)
Item Qty Description
I001 1 ‘A’ Cover
I002 1 Warranty Sealing label
I003 9 Screw 2.5 dia. x 20
I004 1 SIM Cover
I005 1 Spring SIM Connector (not illustrated)
I006 1 Engine Unit (TF4 Module (EB))
I007 1 Frame
I008 1 Data Cap
I009 2 Screw 3 dia. x 5 T10
I010 1 Junction Module (TF5 Module (JB))
I011 1 Heatsink
I012 1 ‘B’ Cover
I013 1 Type Label
Item Location
Side, Grid ref Description and value Type
A800 Top D 5 PA-SHIELD ASSY DMC02107 HDA13 ~ ~ ~ SHIELD_DMC02107
B200 Top P 3 CRYSTAL 32.768KHZ+-30PPM 9PF 32.768kHz ~ ~ CRYSTAL_CX_4V
B601 Top J 8 CRYSTAL 26.0MHZ+-8PPM CL=15.5 26MHz ~ ~ CRYSTAL_TSX_8A
C102 Top Y 5 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C104 Top T 5 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C105 Top Y 3 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C106 Top X 3 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C107 Top Y 4 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C108 Top Y 5 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C109 Top Y 6 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C110 Top T 2 Chipcap X7R 10% 50V 1n0 50V normal,-10%,10% 0402C
C118 Top V 5 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C119 Top W 6 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C120 Top W 6 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C121 Top W 7 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C122 Top Y 6 Chipcap 5% NP0 27p 50V normal,-5%,5% 0402C
C148 Top N 2 CHIPCAP X5R 1u0 6.3V normal,-10%,10% 0603C
C149 Top N 2 CHIPCAP X5R 1u0 6.3V normal,-10%,10% 0603C