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Working Instruction, Mechanical

Working Instruction, Mechanical
Applicable for K550i, K550c, K550im, W610i & W610c

CONTENTS

1 Introduction .............................................................................. 3
1.1 1.2 1.3 1.4 K550 .........................................................................3 W610 .........................................................................4 Equipment.................................................................................5 General cautions ......................................................................6

2 Disassembly ............................................................................. 7
2.1 Overview ...................................................................................8
2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 Battery Cover & Battery K550 Only ....................................... 9 Battery Cover & Battery W610 Only .................................... 11 Speaker Cover K550 ........................................................... 12 Speaker Cover W610 .......................................................... 13 Front Cover ......................................................................... 14 Keypad ................................................................................ 16 PCBA .................................................................................. 17

3 Replacements......................................................................... 18
3.1 Battery Cover..........................................................................19 3.2 Speaker Cover ........................................................................19 3.3 Front Cover .............................................................................19 3.4 Keypad ....................................................................................19 3.5 PCBA .......................................................................19 3.6 Back Cover..............................................................................19 3.7 Co-brand Label .......................................................................20 3.8 RF Cap.....................................................................................22 3.9 Vibrator....................................................................................23 3.10 Power Key ...............................................................................24 3.11 Volume Key.............................................................................25 3.12 Music Key................................................................................27 3.13 Camera Key.............................................................................29 3.14 Ear Speaker" Receiver" Tape................................................31 3.15 Ear Speaker "Receiver" .........................................................32 3.16 LCD .......................................................................33 3.17 Frame .......................................................................37 3.18 Dome Assy..............................................................................39 3.19 Loudspeaker ...........................................................................40 3.20 Flash LED / BT Antenna Frame.............................................42 3.21 Flash LED................................................................................44
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Working Instruction, Mechanical

3.22 BT Antenna .............................................................................45 3.23 Shield Lid Main BB.................................................................46 3.24 Camera ....................................................................................48 3.25 Antenna ...................................................................................51 3.26 SIM Tape..................................................................................53 3.27 Liquid Intrusion Indicator ......................................................54 3.28 KRH Label ...............................................................................55

4 Reassembly ............................................................................ 56
4.1 Overview .................................................................................57
4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 PCBA .................................................................................. 58 Keypad ................................................................................ 59 Front Cover ......................................................................... 60 Speaker Cover .................................................................... 61 Speaker Cover .................................................................... 62 Battery & Battery Cover K550 Only ..................................... 63 Battery & Battery Cover W610 Only .................................... 65

5 Revision history ..................................................................... 66

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Working Instruction, Mechanical

1 Introduction
1.1 K550

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Working Instruction, Mechanical

1.2 W610

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Working Instruction, Mechanical

1.3 Equipment
SPECIAL TOOLS
NTZ 112 459 NTZ 112 288 NTZ 112 1052 NTZ 111 077 NTZ 112 521 NTZ 112 302/2 Torque screwdriver (or equivalent) Torx bit no. 6 JCIS BIT Camera Tool Flex film assembly tool Front opening tool

STANDARD TOOLS
Standard tools have to be locally purchased Dentist hook ESD tweezers Guitar pick

LABEL EQUIPMENT
The following special equipment is required when replacing or installing a new label: Hot air flow solder station Zebra printer connected to computer

OTHER EQUIPMENT
ESD-wristband ESD-gloves Isopropyl alcohol Air blower

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Working Instruction, Mechanical

1.4 General cautions
The following cautions are considered to be generic for all phone models and will not be repeated in the Disassembly, Replacements and Reassembly sections: TURN OFF THE PHONE AND REMOVE THE SIM CARD AND THE M2 MEMORY CARD BEFORE STARTING THE DISASSEMBLY! KEEP ALL CONTACT SURFACES CLEAN! BE CAREFUL WHEN USING TOOLS LIKE THE DENTIST HOOK, TWEEZERS, OPENING TOOLS, GUITAR PICK ETC. TO AVOID SCRATCHES OR DAMAGES TO THE EXTERIOR AND INTERIOR PARTS OF THE PHONE! BE CAREFUL NOT TO DAMAGE ANY CONTACT SPRINGS! REMEMBER TO REMOVE THE PROTECTION FOILS ON NEW PARTS SUCH AS THE LCD! NEVER TOUCH THE DISPLAY GLASS! USE AIR BLOW EQUIPMENT TO KEEP THE FRONT WINDOW AND DISPLAY MODULE DUST FREE!

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Working Instruction, Mechanical

2 Disassembly
When you are going to replace a part being listed in Replacements, the instruction of that section usually begins by directing you to this Disassembly section with a specification of the instructions you have to carry out in order to disassemble the phone as far as needed before returning to Replacements for the actual replacement.

REPLACEMENTS Start Contents page

DISASSEMBLY

REASSEMBLY Done

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Working Instruction, Mechanical

2.1 Overview
The disassembly is done in the following order: 1. Battery Cover (a) & Battery (b) 2. Speaker Cover 3. Front Cover 4. Keypad 5. PCBA

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Working Instruction, Mechanical

2.1.1 Battery Cover & Battery K550 Only

Unlock the battery cover by opening the side locks in the direction showing in the picture.

Grip the battery cover at the bottom with fingers, and then start lifting upwards from the phone.

Remove battery cover.

Raise the battery and remove from phone using Nylon pointer.

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Working Instruction, Mechanical

Battery Cover & Battery continued

Raise and remove battery

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Working Instruction, Mechanical

2.1.2 Battery Cover & Battery W610 Only

Press down on battery cover as shown then push away from the phone as shown in picture,

Slide off battery cover,

Remove battery same way as shown in K550 instruction.

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Working Instruction, Mechanical

2.1.3 Speaker Cover K550

Insert guitar pick as shown in the picture.

Using guitar pick push speaker cover outwards from the phone.

Using finger lift speaker cover upwards as shown in picture.

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Working Instruction, Mechanical

2.1.4 Speaker Cover W610

Overview picture.

Insert guitar pick as shown in the picture.

Using guitar pick push speaker cover outwards from the phone, the lift off the speaker cover.

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Working Instruction, Mechanical

2.1.5 Front Cover

Use torx bit no. 6 to remove these four screws.

Insert the guitar pick as shown in picture

1. Insert the guitar pick as shown in picture. 2. For W610 models pay extra attention at camera key area, do not use force as it will crack the rear cover when loosening front cover!

Slide the guitar pick along the bottom of the phone to unlatch snap hooks

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Working Instruction, Mechanical

Front Cover continued

Slide guitar pick along the side of the phone then follow round to the other side of phone unlatching all snap hooks as shown in picture.

Grip at the bottom then lift front cover upwards from the top end of phone.

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Working Instruction, Mechanical

2.1.6 Keypad

Overview of inner part of phone.

Remove keypad by using tweezers.

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Working Instruction, Mechanical

2.1.7 PCBA

Use JCIS bit no to remove the screw.

Use the Nylon pointer and insert at the bottom and raise the PCBA upwards as shown in picture.

Grip at the side and lift the PCBA away from the phone.

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Working Instruction, Mechanical

3 Replacements
Search for the part to be replaced on the Contents page and go to that instruction to be found in this Replacements section. The instruction usually begins by directing you to the Disassembly section with a specification of the instructions you have to carry out in order to disassemble the phone as far as needed before the actual replacement. Go back to this Replacements section and carry out the instruction. The instruction usually ends by directing you to the Reassembly section with a specification of the instructions you have to carry out in order to reassemble the phone.

REPLACEMENTS Start Contents page

DISASSEMBLY

REASSEMBLY Done

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Working Instruction, Mechanical

3.1 Battery Cover
Follow the 2.1.1 Disassembly instructions! Prepare the new battery cover. Follow the 4.1.5 Reassembly instructions!

3.2 Speaker Cover
Follow the 2.1.2 Disassembly instructions! Prepare the new speaker cover. Follow the 4.1.4 Reassembly instructions!

3.3 Front Cover
Follow the 2.1.1 2.1.3 Disassembly instructions! Prepare the new front cover. Follow the 4.1.3 4.1.5 Reassembly instructions!

3.4 Keypad
Follow the 2.1.1 2.1.4 Disassembly instructions! Prepare the new keypad. Follow the 4.1.2 4.1.5 Reassembly instructions!

3.5 PCBA
Follow the 2.1.1 2.1.5 Disassembly instructions! Prepare the new PCBA. Follow the 4.1.1 4.1.5 Reassembly instructions!

3.6 Back Cover
Follow the 2.1.1 2.1.5 Disassembly instructions! Prepare the new back cover. Install the vibrator, music, camera, volume & power keys. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.7 Co-brand Label

REMOVAL
Use dentist hook to loosen the co-brand label.

Lift co-brand off with tweezers.

Remove any glue found in co-brand area of the phone.

INSTALLATION
1. Position co-brand into place using the corner as placement guide. 2. Using tweezers place the co-brand label onto the phone.

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Working Instruction, Mechanical

Co-brand Label continued

Use fingers to secure the co-brand label.

It should look like this.

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Working Instruction, Mechanical

3.8 RF Cap

REMOVAL
Follow the 2.1.1 Disassembly instructions! Use dentist hook to remove RF Cap.

INSTALLATION
Use nylon pointer to position the RF Cap back into place.

Check alignment of the RF Cap. Follow the 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.9 Vibrator

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Remove with tweezers gripping the side avoiding metal contacts.

INSTALLATION
Place the vibrator in the cavity,

Use nylon pointer to position into place Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.10 Power Key

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Remove using tweezers.

INSTALLATION
Position into place with tweezers.

Check placement with Nylon pointer. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.11 Volume Key

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Overview picture.

Remove using tweezers

INSTALLATION
Overview picture.

1. Place into position first. 2. Position other side second.

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Working Instruction, Mechanical

Volume Key continued

1. Check placement and secure using nylon pointer. 2. Repeat same action for other side

Should look like this. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.12 Music Key

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Overview picture.

Remove using tweezers

INSTALLATION
Use Nylon pointer to position Music key.

1. Check placement and secure using nylon pointer. 2. Repeat same action for other side

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Working Instruction, Mechanical

Music Key continued

Should look like this.

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Working Instruction, Mechanical

3.13 Camera Key

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Overview picture.

Remove with tweezers.

INSTALLATION
Overview picture.

1. Place into position first. 2. Position other side second.

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Working Instruction, Mechanical

Camera Key continued

Should look like this. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.14 Ear Speaker" Receiver" Tape

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Remove with tweezers.

Overview picture

INSTALLATION
1. Place into position first. 2. Position other side second.

Should look like this. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.15 Ear Speaker "Receiver"
REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Follow the 3.15 Removal instructions! Use tweezers and remove outwards from PCBA as shown in picture.

Lift away from the PCBA.

INSTALLATION
1. Place into position first. 2. Position other side second.

Use nylon pointer to place into position. Follow the 3.15 Installation instruction! Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.16 LCD

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Insert front opening tool as shown in picture.

1. Slide tool down then lift upwards at the bottom of dome assy. 2. Lift upwards with side opening tool.

Lift dome assy upwards

Lift over until dome assy is fully open as shown in position. Be-careful not to twist dome assy flex!

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Working Instruction, Mechanical

LCD continued

Lift connector & release using side opening tool.

Lift LCD from frame using side opening tool as shown in picture.

Grip at both sides and remove LCD from frame. DO NOT TOUCH LCD GLASS WINDOW!

INSTALLATION
Insert LCD as shown in picture.

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Working Instruction, Mechanical

LCD continued

Press to secure its position. DO NOT TOUCH LCD GLASS WINDOW!

Connect the board-to-board connector.

Press on the top of board-to-board connector.

Like this.

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Working Instruction, Mechanical

LCD continued

1. Fold over the dome assy into position. 2. locate the alignment pin

Use fingers to secure the dome assy's position & alignment.

Check the alignment as shown in picture.

It should look like this. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.17 Frame

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Follow the 3.16 Removal instruction! Overview picture.

Unlatch bottom snap hook

Unlatch side snap hooks,

Then the other side.

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Working Instruction, Mechanical

Frame continued

Unlatch top snap hooks.

Lift off frame

INSTALLATION
1. Fix into bottom position first. 2. The lower top section second.

Use fingers to secure all snap hooks. Follow the 3.16 Installation instruction! Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.18 Dome Assy

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Follow the 3.16 3.17 Removal instructions! Use nylon pointer to unlatch board-to-board connector.

INSTALLATION
Connect the board-to-board connector,

Like this. Follow the 3.17 3.16 Installation instructions! Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.19 Loudspeaker

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Overview picture.

Use tweezers to unlock connector.

Lift up until connector is loose.

Use nylon pointer to unlatch loud speaker.

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Working Instruction, Mechanical

Loudspeaker continued

Use flat tweezers to remove loud speaker.

INSTALLATION
1. Position first. 2. Lower other end into position and secure.

Use tweezers to secure connector.

Press on top to secure connector. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.20 Flash LED / BT Antenna Frame

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Follow the 3.19 Removal instruction! Overview picture.

1. Unlatch snap hooks, 2. lift frame upwards,

Then lift over the frame.

Use dentist hook to unlatch connector.

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Working Instruction, Mechanical

Flash LED / BT Antenna Frame continued

Use flat tweezers to remove flex.

INSTALLATION
Use flat tweezers to insert flex-to-connector.

Use nylon pointer to secure connector.

1. Fix into position first. 2. lower other side and secure snap hooks. Follow the 3.19 Installation instruction! Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.21 Flash LED

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Follow the 3.19 Removal instruction! Remove Flash LED ROA with tweezers

Overview picture

INSTALLATION
Take new Flash LED ROA and place onto Flash LED /BT Frame.

Should look like this. Follow the 3.19 Installation instruction! Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.22 BT Antenna

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Follow the 3.19 Removal instruction! Remove BT Antenna with tweezers

Overview picture

INSTALLATION
Take new BT Antenna and place onto Flash LED /BT Frame.

Should look like this. Follow the 3.19 Installation instruction! Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.23 Shield Lid Main BB
REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Follow the 3.19 3.20Removal instructions! Use dentist hook to loosen shield lid BB at each arrow point as shown in picture,

Then lift upwards slightly,

Pull shield can lid BB to avoid battery connector pins.

INSTALLATION
Overview picture.

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Working Instruction, Mechanical

Shield Lid Main BB continued

Position shield can lid BB avoiding battery pins.

Secure shield can lid BB as shown in picture,

Look like this. Follow the 3.20 3.19 Installation instructions! Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.24 Camera

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Overview picture.

Use camera removal tool and lower into position,

Insert into camera socket as shown in picture,

Then press the lever.

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Working Instruction, Mechanical

Camera continued

Lift upwards holding the lever closed.

Camera overview picture

Grip at side of camera and remove from tool.

INSTALLATION
a. Camera alignment pin. b. Socket alignment slot.

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Working Instruction, Mechanical

Camera continued

Use flat tweezers to position camera

Use fingers to secure at both corners. DO NOT TOUCH THE LENS!

Repeat this action for other corners

Look like this. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.25 Antenna

REMOVAL
Follow the 2.1.1 2.1.5 Disassembly instructions! Overview picture.

Use nylon pointer to unlatch antenna snap hook

Grip at both sides and remove as shown in picture.

INSTALLATION
Overview picture.

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Working Instruction, Mechanical

Antenna continued

Insert as shown in picture.

Press on the bottom to secure. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.26 SIM Tape
PRE-ASSEMBLY CHECK
Follow the 2.1.1 2.1.5 Disassembly instructions! Instruction text Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.27 Liquid Intrusion Indicator
INSPECTION
There is one Liquid Intrusion Indicators located on the PCBA. To get access to and to inspect the indicators: Follow 2.1.1 2.1.5 Disassembly instructions!

REMOVAL
Remove the activated liquid intrusion indicator with the dentist hook and the tweezers.

INSTALLATION
Attach the new liquid intrusion indicator with the tweezers and the dentist hook. Follow the 4.1.1 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

3.28 KRH Label
Follow the 2.1.1 Disassembly instructions! Read the old label and/or write the information into the "Label make" program before removal Note the position of the label before removal Heat up the label by using hot air, if needed Carefully remove the label without causing scratches If there still are residues, clean the surface with isopropyl alcohol

Check that the proper label format is loaded in the Zebra printer Write a new label by using the program "Label make" and check that the printing is OK Take the new label and place it onto the frame as in the adjacent picture ONE LABEL ONLY IS ALLOWED! Follow the 4.1.5 Reassembly instructions!

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Working Instruction, Mechanical

4 Reassembly
After replacing a part being listed in Replacements, the instruction of that section usually ends by directing you to this Reassembly section with a specification of the instructions you have to carry out in order to reassemble the phone.

REPLACEMENTS Start Contents page

DISASSEMBLY

REASSEMBLY Done

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Working Instruction, Mechanical

4.1 Overview
The reassembly is done in the following order: 1. PCBA 2. Keypad 3. Front Cover 4. Speaker Cover 5. Battery (a) & Battery Cover (b)

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Working Instruction, Mechanical

4.1.1 PCBA

1. Place PCBA into bottom position first. 2. Lower top end of PCBA into back cover.

Secure PCBA like this. AVOID TOUCHING LCD GLASS!

Use 18 Ncm torque to tighten the screw with torx JCIS bit.

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Working Instruction, Mechanical

4.1.2 Keypad

Use tweezers to place keypad into position.

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Working Instruction, Mechanical

4.1.3 Front Cover

1. Fix into position at bottom first. 2. Lower top end of front cover second.

Press down on front cover to secure snap hooks as shown in picture.

Use 24 Ncm torque to tighten the four screws with torx bit no. 6.

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Working Instruction, Mechanical

4.1.4 Speaker Cover

1. Bring speaker cover into position first. 2. Lower downwards

Press on top of speaker cover to secure snap hooks

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Working Instruction, Mechanical

4.1.5 Speaker Cover

1. Bring speaker cover into position first, 2. Then position the other section of speaker cover.

Using fingers secure speaker cover, like this.

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Working Instruction, Mechanical

4.1.6 Battery & Battery Cover K550 Only

Place battery into position against battery contacts.

Lower and secure.

1. Position battery cover first like this. 2. Lower battery cover as shown.

Use fingers to close battery cover.

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Working Instruction, Mechanical

Battery & Battery Cover continued

Battery cover locks will be in open position as shown in picture.

Slide locks to bottom direction of the phone to secure.

Overview picture.

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Working Instruction, Mechanical

4.1.7 Battery & Battery Cover W610 Only

Place battery into position against battery contacts as shown in K550 instruction. Slide on battery cover as shown.

Secure battery cover, like this.

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Working Instruction, Mechanical

5 Revision history
Rev. A B C Date 2007-02-19 2007-02-23 2007-08-06 Changes / Comments 1st Release W610 Added W610 instruction page 14 update

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