Intermec CK71a Service Work Instructions

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 1 of 42

Revision History

Rev

ECN Number

Description

Updated

Pages

Released by

A

328735

First release

Dave Cook

B

334205

Extensive numerous updates to reflect part number

corrections, changes, and additions since original

release

Dave Cook

C

335284

Added part numbers and repair information for

changes driven by Pasion/refresh program. New

keypads/keyboards, LCD, touch panel, and MLB.

Added operation sections for recommended

repair/test flow, scan window, and battery pogo pin

seal.

Dave Cook

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 2 of 42

Table of Contents

Repair & Test Flow ........................................................................................................................................................................... 3

Stylus ................................................................................................................................................................................................ 4

Handstrap .......................................................................................................................................................................................... 5

Keypad Overlay ................................................................................................................................................................................ 6

Bottom Housing ................................................................................................................................................................................ 7

Scan Windows ................................................................................................................................................................................ 10

Camera Window ............................................................................................................................................................................. 11

Side Scan Buttons ........................................................................................................................................................................... 12

Vibrator Motor ................................................................................................................................................................................ 13

Super Capacitor ............................................................................................................................................................................... 14

Core Assembly ................................................................................................................................................................................ 15

Scan Bracket Assembly .................................................................................................................................................................. 16

Side Scan PCB’s ............................................................................................................................................................................. 18

Keyboard PCB ................................................................................................................................................................................ 19

Top Housing.................................................................................................................................................................................... 21

LCD Display & Touch Panel .......................................................................................................................................................... 23

EX25 Scan Engine .......................................................................................................................................................................... 28

EV12 Scan Engine .......................................................................................................................................................................... 30

Camera ............................................................................................................................................................................................ 32

EA30 Scan Engine .......................................................................................................................................................................... 33

N5603 Scan Engine ......................................................................................................................................................................... 35

Main Logic Board ........................................................................................................................................................................... 37

Battery Connector Seal ................................................................................................................................................................... 39

Labeling .......................................................................................................................................................................................... 40

Screws & Torque Settings ............................................................................................................................................................... 41

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 3 of 42

OPERATION:

Repair & Test Flow

The following repair and test flow process must be followed to ensure that a unit being repaired is properly tested and

configured.

CK71 high Level repair process

Step

Process

Reference

Document

Location

Comments

1

Repair Unit

SWICK71-000

WorkManager

2

Review Service

Repair Bulletins

Service Repair

Bulletins

CK70 SRI

page links

3

USB PreFlash

OTPCN70-006

WorkManager

Erase FFS, load Default CStore, load Non-

LP OS

4

70-Series BIT Test

Procedure

OTPCN70-009

WorkManager

Run built in test procedure (installs and

runs on the unit being tested)

5

CN70 OS Flash

Update Procedure

OTPCN70-005

WorkManager

Alternate process used in manufacturing to

load the core operating system. Not

typically used in service.

5

Load OS per unit’s

configuration

SAP BOM

SAP

OS installed using an SD card. This step is

key on LP (Language Provision) OS

configurations.

6

Load SU per unit’s

configuration

SAP BOM

SAP

Load SU (Software Update). An SU of

zero zero doesn’t need to be reloaded.

7

Government

Configurations

Load Information

Assurance Software

943-418-002

WorkManager

Link to software download can be found

on the CN7X/CK7X SRI page

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 4 of 42

OPERATION:

Stylus

The stylus is attached to the bottom housing. Un-loop it’s tether from the retaining slot in the bottom cover to remove

and/or replace it. Installation is reverse order of removal.

Parts Required

Item

Part Number

Description

Qty

714-732S-001

Stylus

1

Unloop tether from slot

in bottom housing

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 5 of 42

OPERATION:

Handstrap

The handstrap is attached to the bottom housing. It can be removed and installed without opening the unit.

Tools Required

Description

Part Number

Straight blade screwdriver

Parts Required

Item

Part Number

Description

Qty

1

825-209-001

Handstrap Assembly, CK70/CK71

1

2

800-565-001

SCREW,8-32X5/16,100DEG FH,SS,BLK O,ROHS

1

Removal

1. Unclip the handstrap where it attaches near the bottom of the unit.

2. Remove the screw that attaches the other end of the handstrap to the back of the unit.

Installation

Installation is reverse order of removal. Tighten screw to 5.0 +/- 0.2 in-lb of torque when installing.

unclip

2

1

Remove screw

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 6 of 42

OPERATION:

Keypad Overlay

Tools Required

Description

Part Number

Small straight blade screwdriver or Xacto knife

Isopropyl alcohol solution

Parts Required

Item

Part Number

Description

Qty

option

355-469-001

OVERLAY,GRAPHIC,NUMERIC,FKEY,CK71

1

355-471-001

OVERLAY,GRAPHIC,ALPHANUMERIC,CK71

1

Numeric FKEY Overlay Alpha Numeric Overlay

Removal

Using the tip of a small straight bladed screwdriver or other thin edge tool peel back an edge of the overlay from the

top housing. Then grasp that edge with your fingers and remove the overlay the rest of the way.

Installation

1. Select the appropriate replacement overlay.

2. Prior to installing the new overlay ensure that the contact surface area of the top housing is clean and free of any

adhesive residue left over from the overlay that was removed.

3. Remove the adhesive release liner from the new overlay and install the new overlay pressing thoroughly across the

entire area to ensure adequate adhesion.

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 7 of 42

OPERATION:

Bottom Housing

The bottom housing will need to be removed to access internal assemblies or if it needs to be replaced. The bottom

housing is secured with 10 screws. There is a different spare bottom housing for each scan engine option due to

differences in the factory installed shock mounts and scan windows.

Tools Required

Description

Part Number

T10 Torx driver

T7 Torx driver

Parts Required

Item

Part Number

Description

Qty

1

715-578S-006

HOUSING,BOTTOM,ASSY C2, EX25 SPARE

1

715-578S-007

HOUSING,BOTTOM,ASSY C2, EV12 SPARE

1

715-578S-008

HOUSING,BOTTOM,ASSY C2, EA30 SPARE (and N5603)

1

2

800-570-002

SCREW 4-40X1/2 PH TORX W/NYL CRES ROHS

8

3

800-574-002

SCREW 2-56 X 7/16 PH TORX W/NYL CRES ROH

2

4

906-016-002

Kapton Tape (1.39 inches)

1

5

655-529-001

Adhesive, vibrator wiring

1

NOTE: A new bottom housing will not have any labeling on it

Removal

1. Remove the stylus from its storage slot in the back cover.

2. Remove the uSD/SIM card slot access cover.

3. Remove 10 screws. Discard the screws. The screws have a one time use seal. New screws must be used when

reinstalling the bottom housing.

1

3

2

4

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CK71A

SWICK71-000

Page 8 of 42

4. Gently pull the bottom housing away from the unit. Moderate resistance will be encountered due to the tight fit of

the rubber shock mounts located in the bottom housing against the sides of the scan engine. Once the cover is loose

slide it forward slightly before removing so the scan window area does not hang up on the face of the scan engine.

5. Disconnect the vibrator motor and supercap cables.

6. Rotate the bottom housing away from the rest of the unit exposing the I/O flex cable as shown.

7. Remove the kapton tape over the flex connector latch.

8. Open the flex connector latch and slide the I/O flex cable out of the connector.

Installation

Installation of the bottom housing is reverse order of removal.

1. Prior to installing a bottom housing inspect the overmolded seal in the top housing for any signs of damage.

2. Insert the I/O flex cable into the connector and close the latch.

3. Install a piece of Kapton tape over the latch.

4. Position the bottom housing over the top housing and reconnect the vibrator and supercap cables. Position the

cables so they will not get pinched during reassembly. Stick the vibrator cable down on the adhesive patch. Early

production units do not have this patch. It can be added or replaced as needed.

Kapton tape

Vibrator cable

Supercap cable

Adhesive patch

5

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 9 of 42

5. Place the bottom housing onto the top housing and push it down seating it into the overmolded seal around the

edge of the top housing. Be sure the vibrator and supercap cables are not pinched under the housing.

6. Install new screws. Torque them per the following pattern. Torque the eight 4-40 screws to 6.0+/-0.2 in-lb. Torque

the two 2-56 screws at each side of the battery compartment to 3.5+/-0.2 in-lb.

6. Reinstall the uSD/SIM card slot access cover.

7. If this is a new bottom housing the appropriate camera window will need to be installed. Refer to the Camera

Window operation.

8. If this is a new bottom housing new product labeling will also need to be applied. Refer to the Labeling operation.

1

2

6

10

0

7

3

5

9

8

4

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 10 of 42

OPERATION:

Scan Windows

CK71 scan windows can be replaced as needed. Be sure to select the correct window and mask for the given scan

engine installed in the unit.

Tools Required

Description

Part Number

Parts Required

Item

Part Number

Description

Qty

option

714-733-001

Window, scan, assembly (for EX25,EA30,N5603)

1

option

714-763-001

WINDOW ASSEMBLY, EV12+, CK71 (for EV12 only)

1

option

655-329-001

MASK,WINDOW,EX25 (for EX25 only)

1

option

655-215-001

Mask,window,EA30/EV12 (for EA30, EV12, N5603)

1

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 11 of 42

OPERATION:

Camera Window

The camera windows in the bottom housing can be replaced as needed. These will also need to be installed anytime a

bottom housing assembly is replaced. There are two identical windows covered by a single trim overlay. The

windows can be replaced individually or both at the same time. Anytime a window is replaced a new trim overlay

will need to be installed. The windows and overlay used on a unit with a camera installed are different than the

windows and overlay used on a unit with no camera.

Tools Required

Description

Part Number

Isopropyl alcohol solution

Non conductive pry tool

3M SP3010

Small straight blade screwdriver or Xacto knife

Parts Required

Item

Part Number

Description

Qty

1

715-590-001

LENS, CAMERA FLASH ASSEMBLY

1

819-347-001

OVERLAY,CAMERA,BLANK

1

NOTE: Parts shown are for a CK71 with a camera

Removal

1. Remove the bottom housing assembly (refer to Bottom Housing operation).

2. Using a blunt tip tool push out the camera window.

Installation

1. Select the appropriate camera window (actual window or blank overlay for units without a camera).

2. Ensure that the contact surface area of the bottom housing is clean and free of any adhesive residue left over from

the window that was removed.

3. Remove the adhesive release liner from the new window and place into the window opening in the bottom

housing. Note the correct orientation of the square and round masked areas in the window as shown in the photo

above. Once in place press thoroughly around the edge to ensure adequate adhesion.

4. Re-install bottom housing assembly.

1

Location of camera

window

Round opening

over flash

square opening

over camera

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 12 of 42

OPERATION:

Side Scan Buttons

The side scan button assemblies in the bottom housing are individually replaceable as needed.

Tools Required

Description

Part Number

Isopropyl alcohol solution

Tweezers

Parts Required

Item

Part Number

Description

Qty

1

714-764-001

ASSY, SIDE KEYCAP

2

Removal

1. Remove the bottom housing assembly (refer to Bottom Housing operation).

2. Using a pair of tweezer grasp a corner of the button assembly needing replacement and pull it away from the

bottom housing. Remove it completely.

Installation

1. Ensure that the contact surface area of the bottom housing is clean and free of any adhesive residue left over from

the button assembly that was removed.

2. Remove the adhesive release liner from the new button assembly and place it in the bottom housing. Once in place

press thoroughly around the edge to ensure adequate adhesion.

3. Repeat steps 1 & 2 for the other button assembly as needed.

4. Re-install bottom housing assembly.

1

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 13 of 42

OPERATION:

Vibrator Motor

The vibrator motor is friction fit into the bottom housing assembly. It’s attached cable plugs into the keyboard PCB

assembly.

Tools Required

Description

Part Number

Tweezers

Parts Required

Item

Part Number

Description

Qty

1

324-025-002

Vibrator motor

1

2

906-016-007

Tape, Kapton-5/8W, RoHS

10mm

Removal

1. Remove the bottom housing assembly (refer to Bottom Housing operation).

2. Pull the vibrator motor out of its slot in the bottom housing.

Installation

1. Press the vibrator motor into its slot in the bottom housing.

2. Route the cable around away from the uSD/SIM door opening and install a piece of kapton tape as shown in the

picture below.

3. Re-install the bottom housing assembly. Refer to Bottom Housing operation.

1

2

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 14 of 42

OPERATION:

Super Capacitor

The backup power super capacitor is secured inside the bottom housing with a bracket and two screws.

Tools Required

Description

Part Number

#0 Phillips Screwdriver

Parts Required

Item

Part Number

Description

Qty

1

236-225-001

SUPERCAP, ASSEMBLY

1

2

653-674-001

Retaining Bracket

1

3

800-451-002

Thd Forming Screw, M1.7x4mm Blk PH, RoHS

2

Removal

1. Remove the bottom housing assembly (refer to Bottom Housing operation).

2. Note orientation of existing super cap.

3. Remove two screws that secure the supercap bracket to the bottom housing.

4. Remove the supercap assembly.

5. Remove the supercap from the retaining bracket as needed.

Installation

1. If you are installing a new supercap peel the adhesive release liner from the adhesive patch installed on the new

supercap.

2. Place the supercap in the bottom housing with the connecting cable oriented as shown above.

3. Place the retaining bracket over the supercap assembly carefully aligning it with the supercap and the mounting

holes prior to contacting the adhesive patch.

4. Install two screws with 1.2 +/- 0.2 in-lb of torque

5. Re-install the bottom housing assembly.

1

2

3

Supercap

assembly

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 15 of 42

OPERATION:

Core Assembly

The core assembly will need to be removed from the top housing in order to access and/or replace assemblies

attached to the magnesium frame or to replace the top housing assembly itself.

Tools Required

Description

Part Number

T10 Torx driver

T7 Torx driver

Non conductive pry tool

3M SP3010

Removal

1. Remove the bottom housing assembly (refer to Bottom Housing operation).

2. Using a non-conductive pry tool release the magnesium frame tabs from one side of the top housing and rotate the

core assembly out of the top housing.

Installation

1. Insert the magnesium frame tabs along one edge with their mating slots in the top housing. Do this at a high

enough angle to prevent the touch panel gasket from dragging against the top housing and thus deforming it.

2. Using firm pressure push down along the opposite edge of the magnesium frame snapping its tabs into their mating

slots in the top housing. Be careful not to damage any internal assemblies with excessive force during this procedure.

3. Inspect the perimeter of the touch panel and make sure the gasket is uniformly pressed against the top housing with

no visible protrusions into the active touch panel area.

4. Re-install the bottom housing assembly.

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 16 of 42

OPERATION:

Scan Bracket Assembly

The scan bracket assembly hosts the main unit speakers and scan handle sensor. It also provides the platform to

which the scan engine, camera, and side scan PCB’s are attached. Servicing this assembly will generally require that

it be removed from the CK71A. It will also need to be removed and then re-installed when servicing other assemblies

such as the main logic board.

Any failure of the bracket itself, the speakers, the speaker gaskets, the scan handle sensor, or the harness that

connects the speakers and sensor to the main logic board will require that the base scan bracket assembly be replaced.

The base scan bracket assembly contains these items already factory installed. For the CK71A there are different

scan bracket assemblies, one for each different scan engine option. The scan engine, camera, and side scan PCB’s

can be individually replaced. Refer to other operations in this guide related specifically to those items.

Tools Required

Description

Part Number

T10 Torx driver

T7 Torx driver

Parts Required

Item

Part Number

Description

Qty

option

715-598S-001

EA30 SCAN BRACKET CK71, SPARE

1

option

715-583S-001

EX25 SCAN BRACKET CK71, SPARE

1

option

715-585S-002

EV12 SCAN BRACKET CK71, SPARE

1

option

715-718S-001

N5603 SCAN BRACKET CK71, SPARE

1

2

800-573-001

SCREW 2-56X0.1875 PH TORX W/NYL CRES ROHS

4

Removal

1. Remove the bottom housing assembly (refer to Bottom Housing operation).

2. Disconnect the scan switch/speaker harness from the main logic board.

3. Using a T7 torx driver remove 4 screws that secure the scan bracket to the core assembly.

4. Gently lift the scan bracket away from the core assembly.

5. Disconnect the scan engine and camera flex cables from the main logic board.

Scan switch/speaker

harness connector

2

1

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 17 of 42

The scan bracket assembly can now be serviced itself or set aside to be re-installed later. If the base scan bracket

assembly is being replaced you will remove the scan engine, camera, and side scan PCB’s and transfer them to the

replacement base scan bracket assembly. See the EA30 Scan Engine, EX25 Scan Engine, EV12 Scan Engine,

Camera, and Side Scan PCB operations elsewhere in this guide for tool, parts, & procedures related specifically to

those items.

Installation

1. Position the scan bracket assembly over the main logic board and attach the scanner flex and camera flex cables..

2. Using a T7 torx driver install 4 screws and secure the scan bracket assembly to the core assembly with 2.5+/-0.2

in-lbs of torque.

3. Connect the scan switch/speaker cable to the main logic board. Make sure the cable is routed through the retention

feature in the bracket as shown below.

5. Re-install the bottom housing assembly.

Harness routed through

retention in bracket

Camera flex

cable

connection

Scanner

flex cable

connection

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 18 of 42

OPERATION:

Side Scan PCB’s

The side scan PCB’s are located on the scan bracket assembly one on each side. They can be removed and installed

without removing the scan bracket assembly.

Tools Required

Description

Part Number

T10 Torx driver

T7 Torx driver

Phillips screwdriver with #0 tip

Parts Required

Item

Part Number

Description

Qty

1

224-873S-0100

Side Button Board

1

2

800-450-003

Thd Form Screw,M1.7 x 3mm Flat Hd RoHS

2

Removal

1. Remove the bottom housing assembly (refer to Bottom Housing operation).

2. Using a #0 Phillips screwdriver remove 2 screws that secure the side scan PCB to the scan bracket assembly.

Installation

1. Position the side scan PCB at its location on the scan bracket assembly.

2. Using a #0 Phillips screwdriver install 2 screws and secure the side scan PCB to the scan bracket assembly with

1.2+/-0.2 in-lbs of torque.

3. Re-install the bottom housing assembly.

1

2

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 19 of 42

OPERATION:

Keyboard PCB

There are two styles of keyboard/keypad assemblies that have been produced. Original production used a conductive

trace and puck keyboard/keypad combination (shown at left in picture below). Current production uses a snap dome

switch and plunger keyboard/keypad combination (shown at right in picture below).

Do not mix assemblies. A conductive trace keyboard PCBA should always be used with a conductive puck

keypad. A snap dome keyboard PCBA should always be used with a plunger style keypad. Units should be repaired

with the style of keyboard/keypad they were originally built with.

Conductive trace style snap dome switch style

Tools Required

Description

Part Number

T10 Torx driver

T7 Torx driver

Non conductive pry tool

3M SP3010

Parts Required

Item

Part Number

Description

Qty

Option

224-871S-0603

PCB assy, kp, CK71-C, alph-num (conductive traces)

1

Option

234-271S-0200

PCB,Keypad TE Dome Assy (snap domes)

1

Option

224-872S-0503

PCB assy, kp, CK71-C, num (conductive traces)

1

Option

234-273S-0200

Keypad,Alpha C1-C2 Lg Key Dome Assy (snap domes)

1

Option

234-093S-0603

PCB ASSY, KP, COZ-C, ALPH-NUM, CHINA (conductive traces)

1

Option

234-272S-0200

PCB,Keypad TE Dome Assy China (snap domes)

1

Option

234-094S-0503

PCB ASSY, KP, COZ-C, NUM, CHINA (conductive traces)

1

Option

234-274S-0200

Keypad,Alpha C1-C2 Lg KeyDome China Assy

1

2

800-569-001

SCREW 2-56X3/16 FH TORX W/NYL CRES ROHS

4

3

655-306-001

Mic Cover

1

Removal

1. Remove the bottom housing assembly (refer to Bottom Housing operation).

2. Remove the core assembly from the top housing (refer to Core Assembly operation).

3. Using a T7 torx driver remove 4 screws that attach the keyboard PCB assembly to the core assembly.

4. Pull the keyboard PCB away from the core assembly unplugging it from its connection to the main logic board.

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CK71 Service Work Instructions

CK71A

SWICK71-000

Page 20 of 42

Installation

1. Position the keyboard PCB assembly over the magnesium frame lining its connector up with mating connector on

the main logic board.

2. Press down over the connector to secure the keyboard PCB assembly into position on the magnesium frame.

3. Using a T7 torx driver install 4 screws and secure the keyboard PCB to the magnesium frame with 2.5+/-0.2 in-lbs

of torque.

4. If this is a replacement keyboard PCB install a new microphone cover over the new keyboard PCB’s microphone.

If you are re-installing the existing keyboard PCB assembly inspect the microphone cover and replace as needed.

Make sure the microphone cover hole is lined up with the hole in the microphone as shown in the picture below.

5. Re-install the core assembly

6. Re-install the bottom housing assembly.

Microphone cover correctly

installed with holes lined up

2

3

Connection to

main logic board

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