Intermec CK71 User manual

TITLE
Model
DOCUMENT NO.
PAGE
CK71 Service Work Instructions
CK71A
SWICK71-000
Page 1of 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

TITLE
Model
DOCUMENT NO.
PAGE
CK71 Service Work Instructions
CK71A
SWICK71-000
Page 2of 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

TITLE
Model
DOCUMENT NO.
PAGE
CK71 Service Work Instructions
CK71A
SWICK71-000
Page 3of 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
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

TITLE
Model
DOCUMENT NO.
PAGE
CK71 Service Work Instructions
CK71A
SWICK71-000
Page 4of 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

TITLE
Model
DOCUMENT NO.
PAGE
CK71 Service Work Instructions
CK71A
SWICK71-000
Page 5of 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

TITLE
Model
DOCUMENT NO.
PAGE
CK71 Service Work Instructions
CK71A
SWICK71-000
Page 6of 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.

TITLE
Model
DOCUMENT NO.
PAGE
CK71 Service Work Instructions
CK71A
SWICK71-000
Page 7of 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
1
715-578S-007
HOUSING,BOTTOM,ASSY C2, EV12 SPARE
1
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

TITLE
Model
DOCUMENT NO.
PAGE
CK71 Service Work Instructions
CK71A
SWICK71-000
Page 8of 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

TITLE
Model
DOCUMENT NO.
PAGE
CK71 Service Work Instructions
CK71A
SWICK71-000
Page 9of 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

TITLE
Model
DOCUMENT NO.
PAGE
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

TITLE
Model
DOCUMENT NO.
PAGE
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

TITLE
Model
DOCUMENT NO.
PAGE
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

TITLE
Model
DOCUMENT NO.
PAGE
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

TITLE
Model
DOCUMENT NO.
PAGE
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

TITLE
Model
DOCUMENT NO.
PAGE
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.

TITLE
Model
DOCUMENT NO.
PAGE
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

TITLE
Model
DOCUMENT NO.
PAGE
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

TITLE
Model
DOCUMENT NO.
PAGE
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

TITLE
Model
DOCUMENT NO.
PAGE
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.

TITLE
Model
DOCUMENT NO.
PAGE
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