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SERVICE MANUAL
Level 1&2

RM-38

Transceiver characteristics:

Band: Tri-band phone for GSM/EDGE 900/1800/1900MHz

Camera: Integrated camera 2 Megapixel
Display: TFT Active matrix color display with 262.144 colors,
high resolution 176 x 208 pixel
Bluetooth
FM radio, MP3/eAAC+
Vibra Alert
Connector: Pop Port™ connector
Memory expandable up to 1GB (Micro SD card)
Twist- On design
USB 2.0

Transceiver with BP-6M 1100mAh Li-Ion battery pack

Talk time Standby Note

Depends on network
up to 3 h up to 10 days
parameters

Environmental characteristics:

• Lead-free soldered

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TABLE OF CONTENTS Page

1. INTRODUCTION 3
2. GENERAL REPAIR INFORMATION 4
3. PATHFINDER FOR WORKSHOP STAFF 5
4. EXPLODED VIEW AND COMPONENT DISPOSAL 6
5. SPARE PARTS OVERVIEW 7
6. SPARE PARTS LIST 8
7. SERVICE TOOLS 9
8. SW-UPDATE 11
9. DISASSEMBLY INSTRUCTION UPPER BLOCK 12
10. ASSEMBLY INSTRUCTION UPPER BLOCK 17
11. DISASSEMBLY INSTRUCTION LOWER BLOCK 23
12. ASSEMBLY INSTRUCTIONS LOWER BLOCK 26
13. LEGEND OF QUICK TROUBLE SHOOTER 31
14. QUICK TROUBLE SHOOTER PART 1 32
15. QUICK TROUBLE SHOOTER PART 2 33
16. QUICK TROUBLE SHOOTER PART 3 34
17. QUICK TROUBLE SHOOTER PART 4 35
18. CAMERA GONOGO TEST 36
19. BLUETOOTH GONOGO TEST  37
20. GONOGO TEST 38

CHANGE HISTORY
Status Version No. Date Comments
Draft 0.1 16.1.2006 Initial draft
Approved 1.0 13.3.2006
Approved 2.0 16.3.2006 Service Tools modified

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1. INTRODUCTION

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:cc-ts-rc.documentation@nokia.com

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:
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
2. 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.
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.

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.

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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2. GENERAL REPAIR INFORMATION

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.

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3. PATHFINDER FOR WORKSHOP STAFF

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

• Online Troubleshooting
Former NOKIA CarePoint can be found on
• Product Information
content, such as NOKIA Online
• Videos – Disassembly/Assembly
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 Disassembly & Assembly Troubleshooting
Basic information about the phone, Instructions on disassembling and as- Step-by-step instructions on locating
features, and technologies sembling the phone 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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4. EXPLODED VIEW AND COMPONENT DISPOSAL

Recommendation for the ecologically friendly disposal of components. Colorized components show the various categories.
See the corresponding ITEM/CIRCUIT REF in the Spare Parts Service Bulletins on NOL.

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5. SPARE PARTS OVERVIEW

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6. SPARE PARTS LIST

Please repleace 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 a daily basis.

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7. SERVICE TOOLS

FLS-4S incl. ACF-8, Driver and User Guide

Dongle and flash device combined, developed specifically for POS use.

ACF-8
Universal Power Supply for FLS-4S.

Travel Charger AC-4

Small and lightweight charger for fast charging of your phone battery.

Internal Battery BP-6M

Inserted under the back cover, this Li-Ion 1100 mAh battery provides
power in a lightweight package.

Headset HS-3
Provides convenient handsfree use and the pleasure of listening to
music in stereo from your compatible Nokia phone. Available in black
and white.

SS-45
Camera Removal Tool.

CA-53
Service Cable to connect the PC with the Pop-Port™ connector.

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SS-93
Opening Tool

RJ-113
Soldering Jig

Lead-free Soldering 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 fiber 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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8. SW-UPDATE

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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9. DISASSEMBLY INSTRUCTION UPPER BLOCK

1. You will need the following tools: The SRT-6, metal tweezers, 2. Unlock and remove the BATTERY COVER.
a Torx plus size 6 driver, the SIM Tool, a torque driver with a torx
plus size 6 bit, and a DC Plug.

3. Gently pry open the A-COVER ASSEMBLY with the SRT-6 and 4. Push down both metal latches to unlock the snaps of the CAP-
discard it. Do not use it again. COVER.

5. Release both screws in the order shown. 6. Do not mismatch these screws with the other ones.

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7. Remove the KEYMAT ASSEMBLY SYMBIAN. 8. Carefully bend open the 2 metal snaps of the DISPLAY SHIELD
ASSEMBLY on the left side.

9. Gently open the flex connector with the SRT-6. 10. When the clips are released properly, the shield can be lifted
up easily.

11. Separate the LCD MODULE by releasing the 4 snaps 12. Carefully slot through the flex connector. Always use a new
with the SRT-6. DISPLAY SHIELD ASSEMBLY when reassembling.

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13. Cover the display with a protective film. 14. Release the next both screws in the order shown.

15. Remove the screws. Do not mismatch these screws with the 16. Carefully open the UPPER BLOCK CONNECTOR.
other ones.

17. Also open the BOARD TO BOARD CONNECTOR with the SRT-6 18. Lift up both connectors and shift out the ENGINE MODULE
ASSEMBLY.

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19. Carefully release the clips of the ANTENNA FRAME ASSEMBLY. 20. Prevent scratching the PWB surface while unlocking the clips
These clips are very delicate and can easily be damaged. of the EARPIECE ASSEMBLY.

21. Peel up the CABLE SUPPORT TAPE. 22. Unscrew the 4 screws in the order shown.

23. These 4 screws are different . Do not mismatch these screws 24. Carefully separate the lower block, but remember the UPPER
with the other ones. BLOCK CONNECTOR.

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25. Release the adhered DOMESHEET with the SRT-6. 26. Push down the MAIN FLEX ASSEMBLY with your thumb to
release the adhesive tape from the UPPER FRAME ALUMINIUM.

27. Shift out the MAIN FLEX ASSEMBLY and discard it. Do not use it 28. The POP PORT DOOR can be pulled out easily.
again when assemble. Always use a new MAIN FLEX ASSEMBLY when reassembling.

29. The disassembling procedure is now complete.

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10. ASSEMBLY INSTRUCTION UPPER BLOCK

1. Remove the cover tape from the MAIN FLEX ASSEMBLY… 2. Shift the MAIN FLEX ASSEMBLY into the UPPER FRAME ALUMINIUM.

3. Peel up the cover tape from the DOMESHEET. 4. Align the DOMESHEET with the SIM Tool, mind the surrounding
components.

5. Now fix the MAIN FLEX ASSEMBLY to the UPPER FRAME 6. Carefully bend down both SWIVEL SENSOR flex foils.
ALUMINIUM using finder pressure.

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7. Bring the Lower Block into position above the UPPER FRAME 8. Insert the screws with tweezers, note the different screw types.
ALUMINIUM and align the 2 SWIVEL SENSORS into their guides.

9. Tighten the 4 screws slightly. 10. Check the correct positioning of the SWIVEL SENSORS.

11. Now, tighten the screws with the correct torque in the order 12. Fix the cables with a new Cable Support Tape.
shown, using a torque of 18 Ncm .

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13. Align the EARPIECE ASSEMBLY and click it into its place. 14. Mind the guiding pins while fixing the ENGINE MODULE to the
ANTENNA FRAME ASSEMBLY. Ensure that all snaps are engaged.

15. Push down the Cables while shifting the assembly into the 16. Close the BOARD TO BOARD CONNECTOR.
UPPER FRAME ALUMINIUM.

17. Close the UPPER BLOCK CONNECTOR by using finger pressure. 18. Place the screws, note the different used screw types.

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19. Tighten the screws in the order shown, using a torque of 20. Slot through the flex foil of the LCD MODULE.
18Ncm.

21. Fix all metal latches of the DISPLAY SHIELD ASSY. 22. Close the flex connector.

23. Flip over the DISPLAY SHIELD ASSEMBLY and push it into its 24. Fix it using finger pressure.
place.

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25. Ensure that all snaps on both sides are well locked. The left 26. Insert the screws with tweezers, note the different screw
side is shown here. types.

27. Tighten the screws in the order shown, using a torque of 18 28. Place the CAP COVER and fix both latches.
Ncm.

29. Insert the KEYMAT ASSEMBLY SYMBIAN. 30. Remove the cover tape and place the new A-COVER ASSEMBLY,
beginning from the top.

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31. Fix all the plastic clips. 32. Complete the assembly by placing the BATTERY COVER.

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11. DISASSEMBLY INSTRUCTION LOWER BLOCK

1. You will need the following tools: The SRT-6, metal tweezers, 2. Always cover the windows with protective film. Remove the
the SS-45 Camera removal tool, a dental tool, a torque driver with battery if still inserted.
a Torx Plus ® size 6 bit, and a Torx Plus ® driver size 6.

3. Carefully pry open the CAMERA LENS ASSEMBLY and remove it. 4. Unlock and remove the SMIA 2MPIX CAMERA with the SS-45.

5. Unlock the LOWER CAP COVER with the SRT-6. 6. Remove the LOWER FRONT COVER and the
KEYMAT ASSY NUMERIC.

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7. Turn the assembly and remove the LOWER BACK COVER. 8. Lift up the KEYMAT ASSY MUSIC.

9. Peel up the COAX CABLE SUPPORT TAPE

10. Carefully open the LOWER BLOCK CONNECTOR with the dental
tool. Do this evenly on both sides of the connector.

12. Release the screws in the order shown.

11. Turn the upper block in order to prevent mechanical stress to
the joystick while unscrewing the screws.

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13. Now turn around the upper block. 14. Continue with the next screws in the order shown.

15. Carefully separate the parts. 16. Pass out the LOWER SIDE RAIL RIGHT.

17. Remove the LOWER SIDE RAIL LEFT, too. 18. The disassembly procedure of the upper block is now
completed.

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12. ASSEMBLY INSTRUCTIONS LOWER BLOCK

1. Start with the LOWER AUDIOBOX ASSEMBLY. 2. Place the LOWER SIDE RAIL RIGHT.

3. Place the LOWER SIDE RAIL LEFT, too. 4. Bring the parts together, positioning as shown. Mind the correct
positioning of the LOWER BLOCK CONNECTOR.

5. Insert the screws. 6. Turn the unit to prevent mechanical stress to the joystick.

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7. To prevent damaging the plastic threads, turn the screws left 8. Apply the torqure of 18Ncm to the screws in the order shown.
first, then thighten them slightly.

9. Turn over the lower block. 10. Continue tightening the next screws with the torque of
18 Ncm in the order shown.

12. Carefully close the connector. Do this evenly side by side.

11. Turn back the lower block.

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13. Protect the connector with a new COAX CABLE SUPPORT TAPE. 14. Position the KEYMAT ASSY MUSIC.

15. Mind the guiding pins. 16. Insert the LOWER BACK COVER and fix the snaps.

17. Turn the lower block. 18. Insert the KEMAT ASSY NUMERIC and fix the snaps.

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19. Place the LOWER FRONT COVER. 20. Fix all the parts while placing the LOWER CAP COVER.

21. Mind the guide pin before positioning of the SMIA 2 MPIX 22. Grip the camera with the SS-45.
CAMERA.

23. Place the camera into its housing. 24. Push down the Camera evenly.

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25. Place the CAMERA LENS ASSEMBLY and fix it. 26. Check the window for correct positioning and cleanness.

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13. LEGEND OF QUICK TROUBLE SHOOTER

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14. QUICK TROUBLE SHOOTER PART 1

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15. QUICK TROUBLE SHOOTER PART 2

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16. QUICK TROUBLE SHOOTER PART 3

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17. QUICK TROUBLE SHOOTER PART 4

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18. CAMERA GONOGO TEST

Before starting the GoNoGo

test, check that camera
window is clean. If not,
clean the window with
cloth.

• Press the red receiver button to reach the Home Menu

• Twist the wrist
• Press Select
• Press Capture to take a photo
This Image will be saved to Gallery into the Photos folder automatically.
Test was successful, if the Image appears on your Display. The camera is ok.
• Select Options
• Select Delete
• Select Yes
If the test is failed see Quick Trouble Shooter.

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19. BLUETOOTH GONOGO TEST

Bluetooth test
You need another Bluetooth device (e.g. 6230) to do a GoNoGo test.
Make sure that Bluetooth is activated in the reference unit. The distance between the devices should not be more than 5m.

Reference unit, Bluetooth Test unit

Settings on the test unit:

• Press the red receiver button to reach the Home Menu

• Select Contacts
If phone and SIM memory is empty, create one new entry.
• Select an entry
• Select Options
• Select Send
• Select Via Bluetooth
Search window appears and shows all Bluetooth units in range.
Choose one unit and press Select
Press Accept on the Reference unit.
Test was successful, if you get the message “Business card received” on the Reference unit.
• Press red End key of the Test unit to reach the Home Menu
Note: If the Bluetooth is activated, switch it off!

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Multimedia Creation & Support CONFIDENTIAL 16.3.2006

20. GONOGO TEST

A battery tester lets you test the capacity of NOKIA batteries.

Please refer to the latest information on NOKIA Online.

http://www.astratec.co.uk/ http://www.cadex.com/

Service Manual 3250 RM-38 Copyright © 2006 NOKIA Corporation. All rights reserved.

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