Nokia N91 User manual

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Service Manual N91 RM-43 / RM-158 Copyright © 2006 NOKIA Corporation. All rights reserved.
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RM-43 /RM-158
Transceiver characteristics:
Band:
- RM-43: GSM/GPRS/EDGE 900/1800/1900MHz +2100 WCDMA
- RM-158: GSM/GPRS/EDGE 900/1800/1900MHz
Camera: 2 Megapixel, 20x stepless digital zoom
Display: Active matrix color display with 262.144 colors,
resolution 176 x 208 pixel
Bluetooth
WLAN (only RM-43)
USB
Visual Radio + Media Player
Memory Capacity: about 16 MB internal memory + 4 GB Hard Drive
Enhanced music features: 8-band Equalizer, Stereo Widening
Loudness, Balance
SERVICE MANUAL
Level 1&2
Environmental characteristics:
• Lead-free soldered
Talk time Standby Note
up to 4h (GSM) up to 190h (GSM) Depends on network
parameters
Transceiver with BL-5C 970 mAh Li-Ion battery pack

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CHANGE HISTORY
Status Version No. Date Comments
Draft 0.1 03.Mrz.2006 Initial draft
Approved 1.0 28.Mrz.2006 Approval
Approved 2.0 24.Apr.2006 RM-158 added
Approved 3.0 27.Apr.2006 Operating Band corrected and Battery capacity in the Tools chapter changed
Page
TABLE OF CONTENTS
INTRODUCTION 3
GENERAL REPAIR INFORMATION 4
PATHFINDER FOR WORKSHOP STAFF 5
EXPLODED VIEW AND COMPONENT DISPOSAL 6
SPARE PARTS OVERVIEW 7
SPARE PARTS LIST 8
SERVICE TOOLS 9
SW-UPDATE 11
DISASSEMBLY INSTRUCTION 12
ASSEMBLY INSTRUCTION 19
LEGEND FOR QUICK TROUBLE SHOOTER 26
QUICK TROUBLE SHOOTER PART 1 27
QUICK TROUBLE SHOOTER PART 2 28
QUICK TROUBLE SHOOTER PART 3 29
QUICK TROUBLE SHOOTER PART 4 30
QUICK TROUBLE SHOOTER PART 5 31
CAMERA GONOGO TEST 32
BLUETOOTH GONOGO TEST 33
GONOGO TEST 34
BATTERY TEST 34
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Service Manual N91 RM-43 / RM-158 Copyright © 2006 NOKIA Corporation. All rights reserved.
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The purpose of this document is to help NOKIA service levels 1 and 2 workshop technicians to service NOKIA products. This
Service Manual must be used only by authorized NOKIA service suppliers. The content of it is confidential. Please note that
NOKIA also provides other guidance documents (e.g. Service Bulletins) for service suppliers. Follow these regularly and
comply with the given instructions.
While every effort has been made to ensure the accuracy of this document, some errors may exist.
If you find any errors or if you have further suggestions, please notify NOKIA using the address below:
mailto:c[email protected]
Please keep in mind also that this documentation is continuously being updated and modified, so always watch out for
the newest version.
Warnings and Cautions
Please refer to the phone’s user’s guide for instructions relating to operation, care, and maintenance, which include impor-
tant safety information. Note also the following:
Warnings:
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. THE CELLULAR TELEPHONE MUST NOT BE OPERATED IN
AREAS LIKELY TO CONTAIN POTENTIALLY EXPLOSIVE ATMOSPHERES, EG PETROL STATIONS (SERVICE STATIONS), BLASTING
AREAS ETC.
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.
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. Use only approved components as specified in the parts list.
4. Ensure all components, modules, screws, and insulators are correctly re–fitted after servicing and alignment.
5. Ensure all cables and wires are repositioned correctly.
1.
2.
3.
INTRODUCTION1.
Electrostatic discharge can easily damage the sensitive components of electronic products.
Therefore, every Service Supplier must observe the precautions, mentioned in the appropriate
“Service Partner Requirements”, available on NOKIA Online. Also see ESD Protection Require-
ments in this Service Manual.

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GENERAL REPAIR INFORMATION2.
This section provides useful repair information how to carry out repairs:
Make sure your testing equipment is functioning properly before beginning repair work.
To familiarize yourself with the NOKIA product read the tutorials or user’s guide on www.nokia.com -->Support-->
Phones, by selecting the Phone Model.
Before starting repairs you must observe ESD precautions such as being in your ESD Protected Area and connecting
your wristband.
Use gloves to avoid corrosion and fingerprints.
Cover windows and displays with a protective film to avoid dust and scratches.
Use a lint-free cloth (e.g. Micro-Fibre cloth) to clean the LCD.
When cleaning the pads use a soft cloth/ESD brush and Isopropanol. Do not use a glass fiber pencil: this scratches the
surface and will corrosion.
Non-faulty mechanical parts (except shielding lids and bent parts or soldered components), may be reused if they are
not soldered.
When removing the shielding lids make sure to replace them with new ones, otherwise the high-frequency leakage
can affect the device.
Always use original NOKIA spare parts.
Check the soldering joints of the parts concerned with regard to the fault symptom (e.g. soldered connectors or
switches) and resolder them if necessary (Level 2 only).
Remove excess soldering flux after repair.
Observe the torque requirements when assembling the unit.
Preferably use your own equipment for testing. E.g. if the customer complains about charger function, please test the
phone with your own charger to determine if the malfunction is being caused by phone or charger causes the mal-
function.
A SIM card is needed for all GoNoGo tests.
When doing the fault log entries, always note the Item code of the part that caused the malfunction. Also, fill in the
appropriate part code from the assembly if needed.
Please be aware that some malfunctions may be software related and solved by an update.
There are several documents available on NOL which must be followed:
First, pay attention to the latest content pages of Service Bulletins, which are always available for each folder on NOKIA
Online. Make sure your documentation is up to date.
The service level indicator at the bottom of each document displays the appropriate target group.
Downloads > Support Library >
1. Instructions
2. General Service Bulletins
3. Product related documents
4. Spare Part Service Bulletins
5. Service Tools Service Bulletins
6. Common Software Service Bulletins
etc…
Use General SB-217 as a reference or overview.
Please also check NOKIA Online (NOL) for latest news and files on a regular basis.
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PATHFINDER FOR WORKSHOP STAFF3.
In addition to the information in this Service Manual, there are other instructions and data, which must be followed. Main
documentation database is NOKIA Online with the purpose of serving different multimedia content, like video clips or
interactive tutorials.
It is mandatory to watch for newest technical and organizational information on a daily basis to be updated as required
(see “Latest files in Support Library”). New information must be processed and implemented as soon as possible.
When logged into NOL you can also find needed information in different folders like:
Support Library
Phones
Service Manuals
Service Bulletins
Software
Repair Information
Level 1&2 e-learning (former NOKIA CarePoint) on NOKIA Online
Former NOKIA CarePoint
content, such as
Online Troubleshooting
Product Information
Videos – Disassembly/Assembly
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can be found on
NOKIA Online
NOKIA Online
Care Services
Training
Phone Models
Level 1&2 e-learning courses offer a quick overview of the NOKIA phone and support on repair and testing.
Overview & Guides
Basic information about the phone,
features, and technologies
Disassembly & Assembly
Instructions on disassembling and as-
sembling the phone
Troubleshooting
Step-by-step instructions on locating
and repairing the most common prob-
lems with the phone
To reduce the server traffic we recommend downloading the newest version of large files like videos, Phoenix packages, or
Service Manuals only once to distribute it internally for further use.

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Recommendation for the ecologically friendly disposal of components. Colorized components show the different catego-
ries. See corresponding ITEM/CIRCUIT REF in the Spare Parts Service Bulletins on NOL.
EXPLODED VIEW AND COMPONENT DISPOSAL4.

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SPARE PARTS OVERVIEW5.

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SPARE PARTS LIST6.
Please replace this page (placeholder) with the latest corresponding Service Bulle-
tins (spare parts, SWAP units and service tools) from NOL!
This will ensure that you are using up-to-date order codes only.
Therefore, Service Bulletins on NOL have to be checked on daily basis.

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FLS-4S incl. ACF-8, Driver and User Guide
Dongle and flash device incorporated into one package, developed
specifically for POS use.
ACF-8
Universal Power Supply is used to power FLS-4S.
Travel Charger AC-4
Small and lightweight charger for fast charging of your phone battery.
Internal Battery BL-5c
Inserted under the back cover, this Li-Ion 970 mAh battery provides
power in a lightweight package.
Headset HS-28
Comfortable earphones combined with excellent audio quality provide
a pleasurable listening experience. Control your music and calls re-
motely, and use it together with compatible headphones of your own
choice. Available in Nokia N91 sales package.
SS-15X
Camera removal tool. One side is for disassembly, the other side for
assembly.
DKE-2
USB Cable
SERVICE TOOLS7.

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Service Manual N91 RM-43 / RM-158 Copyright © 2006 NOKIA Corporation. All rights reserved.
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SS-93
Opening Tool
RJ-85
Soldering Jig
Lead-free Solder Wire
Mandatory for lead-free products (Level 2 only).
0772040 NMP Standard Toolkit
NOKIA opening tool SRT-6 NOKIA No. 0770431
Tonichi torque driver NOKIA No. 6901525
Hoya micro Fibre cloth MX304
Dastex gloves S, M, XL
Artilux goggles AH166
Wera bit T5 867/4TX 5x50
Wera 867/4 6IP; 50mm (Torx 6 PLUS®)
Wera bit T6 867/4TX 6x50
Wera 867/1 5IP; 25mm (Torx 5 PLUS®)
Wera bit T6 PLUS® 867/4TX 6IP
Facom side cutter 416E
Facom T5 driver SP.14032
Facom T6 driver SP.14033
Facom slot screwdriver AEF. 2x35.E
Wetec tweezers 7abb SA-ESD
Wetec tweezers 22 SA-ESD
Wetec tweezers 13 SA-SMD ESD
Wetec tweezers PSF SA-ESD
Wetec ESD brush E1211
Kaiser Fototechnik airbrush 6315
Wetec dental tool DEM83266/0
RS Components Scissors 323-5732
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SW-UPDATE8.
Flash Concept – (Point of Sales)
To use the FLS-4S Flash Dongle you should follow the user’s guide inside the sales package. Always check for the latest ver-
sion of flash software, which is available on NOKIA Online.

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DISASSEMBLY INSTRUCTION9.
1. You need the tools shown. 2. Protect the window with a plastic film.
3. Also protect the CAMERA WINDOW with a plastic film. 4. Unlock and remove the B-COVER ASSY.
5. Slightly release the clips of the ANTENNA COVER ASSEMBLY on
both sides.
6. Now lift off the ANTENNA COVER ASSEMBLY.
7. Remove the screws in the order shown. 8. Carefully unlock the clips on both sides of the assembly.

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9. Open the assembly before continuing. 10. Push down the KEYMAT while lifting of the SLIDE ASSEMBLY.
11. Protect the inner side window with a plastic film. 12. Protect the LCD with a plastic film, too.
13. Pull out the VOLUME KEY HARDTOP... 14. ...and the MENU KEY HARDTOP.
15. Unlock the RAIL SPRING L. 16. Pull it out carefully with tweezers.

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17. Now, the SLIDE ASSEMBLY isn’t fixed anymore and can be
removed easily.
18. Push out both SLIDE CONNECTOR POGOs .
19. Carefully release the adhered SLIDE BEZEL as shown. 20. Remove the SLIDE BEZEL carefully.
21. Remove the adhesive residue. 22. Remove the BEZEL COVER.
23. Open the LCD flex connector. 24. Lift up the LCD.

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25. Remove the DISPLAY FRAME ASSEMBLY.
28. Use the tweezers when lifting off the BUTTON JOYSTICK.
29. Take care of the T9 KEYMAT ASSEMBLY. 30. Lift up the T9 KEYMAT ASSEMBLY.
26. Note the grounding clips of the DISPLAY FRAME ASSEMBLY
when removing the EARPIECE.
27. Lift up and remove the EARPIECE with tweezers carefully.
31. Remove the ENGINE MODULE. 32. Use an A-COVER as support when removing the
CAMERA MODULE.

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33. Position the SS-15 Camera removal tool and grip it. 34. Pull out the CAMERA MODULE after the clips are released.
35. Remove the VIBRA ASSY. 36. Pull out the VIBRA SHIELD. Mind the grounding clips.
37. Unlock and remove the HOLD SWITCH HANDLE with the SRT-6. 38. Lift the 3,5 AUDIO JACK and remove it.
39. Use the slotted screwdriver to release the IHF SPEAKER. 40. Note not to damage the speaker adhesive.

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41. Carefully remove the IHF SPEAKER. Do not touch the
menbrane.
42. Unlock the SPACER FOR DC JACK carefully, prevent bending the
spring contacts.
43. Use the DC Plug to lever out the DC JACK first. 44. Then pull it out with the tweezers.
45. Unlock the BB UNISHIELD. 46. Turn the assembly and lift up the shield.
47. Now, move the shield in direction shown. 48. Unlock the HDD ASSEMBLY by using a slotted screwdriver.

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49. Note not to destroy the fixing joint. 50. Lever out the HDD ASSEMBLY.
51. Lift out the HDD ASSEMBLY. Never remove it by pulling at the
flex foil.

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1. You need the tools shown. 2. Remove the protection tape from the adhesive. Insert the HDD
ASSEMBLY and fix it. Do not push down the conductive tape .
3. Flip the connector plate of the HDD ASSEMBLY. Do not touch the
pads. Fix the connector plate.
4. Position the BB UNISHIELD.
5. Note that both snaps are fixed properly. 6. Place the DC JACK.
7. Complete the DC Jack with the SPACER FOR DC JACK. 8. Push it into its place slightly.
ASSEMBLY INSTRUCTION10.

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9. Check the SPACER FOR DC JACK for correct positioning as shown. 10. Check the IHF ADHESIVE. Replace it if destroyed or missing.
11. Place the IHF SPEAKER. Always use a new IHF SPEAKER GASKET
when replacing the speaker.
12. Push the IHF SPEAKER slightly into its place. Note the spring
contacts.
13. Insert the 3,5 AUDIO JACK into its compartment. 14. Note not to damage the spring contacts when pushing it into
its place.
15. Mind the correct position when placing the
HOLD SWITCH HANDLE.
16. Insert the VIBRA SHIELD.