Sony Ericsson Walkman W600I User manual

Working Instruction, Mechanical
3/00021-1/FEA 209 544/594 B
©Sony Ericsson Mobile Communications AB
Working Instruction, Mechanical
Applicable for W600i, W600c, W550i, and W550c
Contents
1General..................................................................................................................4
1.1 Phone Portions - Base and Flip...................................................................4
1.2 Using Hand and ESD Protection.................................................................4
1.3 Protection of LCDs, Lenses, and Windows.................................................4
1.4 Acceptable Pry Tools ..................................................................................4
1.5 When an “ * ” appears beside a Tool in “Tools Needed:”............................4
2Base ......................................................................................................................5
2.1 Base Disassembly.......................................................................................5
2.1.1 Battery Cover Removal..................................................................5
2.1.2 Battery Removal.............................................................................6
2.1.3 Outer Base Cover Removal...........................................................7
2.1.4 Circuit Board Removal.................................................................11
2.2 Base Reassembly .....................................................................................13
2.2.1 Circuit Board Installation..............................................................13
2.2.2 Outer Base Cover Installation......................................................17
2.2.3 Battery Installation........................................................................22
2.2.4 Battery Cover Installation.............................................................23
3Flip.......................................................................................................................24
3.1 Flip Disassembly.......................................................................................24
3.1.1 Inner Base Cover Removal..........................................................24
3.1.2 Style-Up Cover Removal..............................................................25
3.1.3 Display Cover Removal................................................................28
3.1.4 Display Carrier Assembly’s Disassembly from Inner Flip Cover..29
3.2 Flip Reassembly........................................................................................33
3.2.1 Display Carrier Assembly’s Reassembly to Inner Flip Cover.......33
3.2.2 Display Cover Installation.............................................................37
3.2.3 Style-Up Flip Cover Installation....................................................40
3.2.4 Inner Base Cover Installation.......................................................42
4Part Replacements..............................................................................................44
4.1 Battery Cover ............................................................................................44
4.2 Battery.......................................................................................................44
4.3 Outer Base Cover......................................................................................44
4.4 Camera Panel ...........................................................................................47
4.5 Mirror.........................................................................................................48
4.6 Antenna Assembly ....................................................................................48
4.6.1 Antenna Assembly Removal........................................................48
4.6.2 Antenna Assembly Installation.....................................................49
4.7 RF Port Plug..............................................................................................51
4.7.1 RF Port Plug Removal .................................................................51
4.7.2 RF Port Plug Installation ..............................................................52

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 2(128)
4.8 Vibrator......................................................................................................53
4.8.1 Vibrator Removal .........................................................................53
4.8.2 Vibrator Installation ......................................................................53
4.9 Rear Speaker Module ...............................................................................54
4.9.1 Rear Speaker Module Removal...................................................54
4.9.2 Rear Speaker Module Installation................................................54
4.10 Rear Speaker Cloth...................................................................................55
4.11 Side Speaker.............................................................................................57
4.11.1 Side Speaker Removal ................................................................57
4.11.2 Side Speaker Installation .............................................................57
4.12 Keypad Switch Assembly – Main Keypad.................................................58
4.12.1 Keypad Switch Assembly Removal..............................................58
4.12.2 Keypad Switch Assembly Installation...........................................59
4.13 Dome Foil – Main Keypad.........................................................................60
4.13.1 Keypad Dome Foil Removal ........................................................60
4.13.2 Keypad Dome Foil Installation .....................................................61
4.14 Camera Module.........................................................................................62
4.14.1 Camera Module Removal ............................................................62
4.14.2 Camera Module Installation .........................................................64
4.15 System Connector.....................................................................................66
4.15.1 System Connector Removal ........................................................66
4.15.2 System Connector Installation .....................................................66
4.16 System Connector Cover..........................................................................67
4.17 Label..........................................................................................................69
4.17.1 Label Removal.............................................................................69
4.17.2 Label Installation..........................................................................70
4.18 Inner Base Cover ......................................................................................71
4.19 Bluetooth Antenna.....................................................................................71
4.19.1 Bluetooth Antenna Removal ........................................................71
4.19.2 Bluetooth Antenna Installation .....................................................73
4.20 Magnet ......................................................................................................74
4.20.1 Magnet Removal..........................................................................74
4.20.2 Magnet Installation.......................................................................75
4.21 Liquid Intrusion Indicator...........................................................................76
4.21.1 Liquid Intrusion Indicator Removal...............................................76
4.21.2 Liquid Intrusion Indicator Installation............................................76
4.22 Keypad......................................................................................................79
4.23 Cable Assemblies......................................................................................79
4.23.1 Removal of Cable Assemblies.....................................................79
4.23.2 Installation of Cable Assemblies..................................................81
4.24 Hinge and Hinge Sleeve............................................................................83
4.25 Keypad Lock Key ......................................................................................84
4.25.1 Keypad Lock Key Removal..........................................................84
4.25.2 Keypad Lock Key Installation.......................................................85
4.26 Screw Cover Panel – Base .......................................................................87
4.26.1 Base Screw Cover Panel Removal..............................................87
4.26.2 Base Screw Cover Panel Installation...........................................88
4.27 Screw Cover Panel - Flip...........................................................................89
4.27.1 Flip Screw Cover Panel Removal ................................................89
4.27.2 Flip Screw Cover Panel Installation .............................................90

Working Instruction, Mechanical
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4.28 Co-Brand Label.........................................................................................91
4.28.1 Co-Brand Label Removal.............................................................91
4.28.2 Co-Brand Label Installation..........................................................92
4.29 Dome Foil Assembly – Navigation Keypad...............................................94
4.29.1 Navigation Keypad Dome Foil Assembly Removal......................94
4.29.2 Navigation Keypad Dome Foil Assembly Installation...................94
4.30 Display Flex Film Assembly and Display Carrier.......................................95
4.30.1 Display Flex Film and Display Carrier Disassembly.....................95
4.30.2 Display Flex Film and Display Carrier Reassembly.....................98
4.31 Display Carrier.........................................................................................103
4.32 LCD Assembly.........................................................................................104
4.32.1 LCD Assembly Removal............................................................104
4.32.2 LCD Assembly Installation.........................................................106
4.33 Microphone..............................................................................................108
4.34 Microphone Grommet..............................................................................109
4.35 Display Cover..........................................................................................110
4.36 Gaming Keys...........................................................................................110
4.36.1 Gaming Key Removal................................................................110
4.36.2 Gaming Key Installation.............................................................111
4.37 Navigation Keypad..................................................................................112
4.38 Receiver..................................................................................................112
4.38.1 Receiver Removal......................................................................112
4.38.2 Receiver Installation...................................................................113
4.39 Receiver Dust Cloth on Inner Flip Cover.................................................114
4.40 Style-Up Cover........................................................................................116
4.41 Inner Flip Cover.......................................................................................116
4.42 Camera Key ............................................................................................116
4.42.1 Camera Key Removal................................................................116
4.42.2 Camera Key Installation.............................................................117
4.43 Volume Key.............................................................................................119
4.43.1 Volume Key Removal.................................................................119
4.43.2 Volume Key Installation..............................................................120
4.44 Music Player Key.....................................................................................122
4.44.1 Music Player Key Removal........................................................122
4.44.2 Music Player Key Installation.....................................................123
4.45 Power Key...............................................................................................125
4.45.1 Power Key Removal...................................................................125
4.45.2 Power Key Installation................................................................126
4.46 Rubber Plug ............................................................................................127
5Revision History.................................................................................................128

Working Instruction, Mechanical
3/00021-1/FEA 209 544/594 B
©Sony Ericsson Mobile Communications AB 4(128)
1General
1.1 Phone Portions - Base and Flip
This document uses the hinge of the phone to divide the phone into two identifiable portions.
The portion of the phone that contains the keypad will be referred to throughout this document as
the base portion of the phone. The other portion of the phone is the part that contains the display.
This will be referred to as the flip portion of the phone. The basic disassembly and reassembly
procedures will be structured based on these two distinct portions.
1.2 Using Hand and ESD Protection
When handling this product, keep all surfaces clean of dirt, dust, debris, and hand oil. Use
appropriate ESD precautions when working on this product. The use of finger cots or gloves, an
ESD mat, and an ESD wrist strap are required at minimum.
1.3 Protection of LCDs, Lenses, and Windows
Any time the screen portion of a display assembly, the windows of a display cover, or a camera
lens is unprotected and will be exposed for an extended period of time, add a protective film over
the exposed part to reduce the amount of dust, finger prints, debris, and/or damage that the part
may obtain.
1.4 Acceptable Pry Tools
Whenever the phrase “pry tool” is used, a nylon pointer, an orangewood stick, or a front opening
tool may be used, depending on the user’s preference.
1.5 When an “ * ” appears beside a Tool in “Tools Needed:”
A “ * ” beside a tool in a procedure’s list of tools indicates that the tool is not specifically called
out in those instructions, but an operator may find it helpful to use that tool when performing
some steps of that procedure.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 5(128)
2Base
2.1 Base Disassembly
The disassembly of the base portion of this product is broken down into sections by the
components that need to be removed to perform the disassembly. The sections that make up the
“Base Disassembly” procedure are arranged in the order that they must be performed to properly
disassemble the base portion of this product. If your task is to replace one of the components
that is removed during the base disassembly, just perform the sections of the base disassembly
through to the point that the part you are trying to replace is removed.
2.1.1 Battery Cover Removal
Tools needed: None
Step-by-Step Instructions
1. Using your thumbs, slide the battery cover towards
the system connector until a 5 to 6 MM gap forms
between the battery cover and the edge of the battery
opening adjacent the camera.
NOTE! The battery cover will not slide more than
5 or 6 MM.
2. Once battery cover has been slide 5 to 6 MM
towards the system connector, lift the battery cover
away from the phone.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 6(128)
2.1.2 Battery Removal
All of the sections of the Base Disassembly preceding this section must be performed in
sequential order before the disassembly steps listed below can be performed.
Tools needed:
•Pry Tool
Step-by-Step Instructions
1. At the end of the battery closest to the system
connector, catch the flat end of a pry tool on the
accessible portion of the battery that is adjacent to
the system connector.
2. Using the pry tool, push the battery towards the
camera while simultaneously lifting the end of the
battery. The end being lifted should come free from
the battery cavity.
3. Once one end of the battery is free from the battery
cavity, lift the battery away from the phone.
NOTE! Do not tap the phone against a hard surface
in an attempt to get the battery out. Damage
to the phone may result!

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 7(128)
2.1.3 Outer Base Cover Removal
All of the sections of the Base Disassembly preceding this section must be performed in
sequential order before the disassembly steps listed below can be performed.
Tools needed:
•Pry Tool •Style 2A ESD tweezers (Blunt tip)
•Torque screwdriver •Torx Plus size 5 bit
•Front opening tool
Step-by-Step Instructions
NOTE! Be careful not to scratch the inner base
cover when removing the base’s screw
cover panel.
1. Open the phone so that the main keypad is accessible
and locate the screw cover panel on the inner base
cover.
2. Begin lifting the screw cover panel away from the
inner base cover by using the tip of one side of a pair
of style 2A tweezers or a front opening tool at one of
the two locations indicated.
3. Once a portion of the screw cover panel is slightly
lifted, grip the lifted portion of the panel and peel it
off of the base.
NOTE! The screw cover panel cannot be reused.
4. Carefully clean off any remaining adhesive residue
from the area on the inner base cover where the
screw cover panel mounts using the style 2A
tweezers, alcohol, and a lint free wipe.
5. Remove the two screws that were concealed by the
base’s screw cover panel using a torque driver and a
Torx Plus size 5 bit.

Working Instruction, Mechanical
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Step-by-Step Instructions
6. Remove the four screws indicated from the battery
cavity side of the base using a torque driver and a
Torx Plus size 5 bit.
7. Lift the system connector end of the base assembly
away from the flip portion of the phone as high as it
will easily move.
8. With a pry tool, gently pry at the two locations
indicated to release catches that hold the outer base
cover assembly to the inner base cover. When
prying, make sure to rotate the pry tool towards the
keypad.
9. With the latch along each side of the outer base
cover assembly released, gently wiggle the outer
base cover assembly side to side so that the antenna
loop portion of the outer base cover releases from the
inner base cover.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 9(128)
Step-by-Step Instructions
10. Once the two halves of the base are free from each
other, rotate the outer base cover so that it is
perpendicular to the rest of the phone.
NOTE! Use one hand to hold the phone in this
current orientation.
11. Remove the keypad from the inner base cover and
set the keypad aside.
12. Rotate the outer base cover assembly so that it is still
perpendicular to the rest of the phone, but the battery
cavity is adjacent to the keypad area on the inner
base cover.
NOTE! Continue to use one hand to hold the phone
in this current orientation.

Working Instruction, Mechanical
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Step-by-Step Instructions
13. Select one of the cable assemblies and lift it out of its
holder on the circuit board.
NOTE! Do not attempt to unplug the cable
assemblies by pulling on the mass of cables.
14. At the board connection of the cable being
disconnected, use the tip of a pair of style 2A
tweezers to unplug the cable connection from the
board. There are two locations that the connector
must be alternately pulled at to disconnect the cable
from the connector on the circuit board. The two
pulling locations are labelled location 1 and location
2.
15. Repeat the previous two steps to disconnect the other
cable/board connection.
16. Once the cable assemblies are disconnected, the
outer base cover assembly is free from the rest of the
phone.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 11(128)
2.1.4 Circuit Board Removal
Tools needed:
•Pry Tool
Step-by-Step Instructions
1. Unplug the system connector cover from the system
connector and set the system connector cover aside.
2. Unplug the keypad switch assembly’s flex film from
its connection on the circuit board using a pry tool
and set the keypad switch assembly aside.
3. Using a pry tool, gently pry in the two locations
indicated to release the catches that hold the circuit
board in the outer base cover.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 12(128)
Step-by-Step Instructions
4. Once the catches holding the circuit board have been
released, lift the end of the circuit board that is
adjacent to the antenna just far enough away from
the outer base cover that the side speaker’s connector
is clear of the outer base cover’s side wall.
5. While holding the circuit board in this lifted position,
unplug the side speaker from the circuit board.
6. Once the side speaker is disconnected, continue to
rotate the circuit board away from the end of the
outer base cover containing the antenna. Once the
angle between the circuit board and the outer base
cover has exceeded 45 degrees, the circuit board can
be easily lifted from the outer base cover.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 13(128)
2.2 Base Reassembly
The reassembly of the base portion of this product is broken down into sections by the
components that need to be installed to perform the reassembly of the base portion. The sections
that make up the “Base Reassembly” procedure are arranged in the order that they must be
performed to properly reassemble the base portion of this product. If only a partial disassembly
of the base has been performed, perform the only necessary reassembly sections.
2.2.1 Circuit Board Installation
Tools needed:
•Pry Tool •Style 2A ESD tweezers (Blunt tip)
Step-by-Step Instructions
1. Obtain the outer base cover and orient it so that its
inner surface is towards you.
2. Verify that the antenna assembly, the rear speaker
assembly, and the vibrator are in their correct
positions.
3. Verify that the antenna contact is correctly mounted
on top of the rib that protrudes up from the inner
surface of the outer base cover.
NOTE! There are two alignment pegs that position
the contact portion of the antenna. Make
sure that the two alignment pegs protrude
through their corresponding holes in the
contact portion of the antenna.
4. Remove the side speaker from its cavity that is along
the inner wall of the outer base cover by prying the
end of the speaker nearest the system connector
opening up out of the outer base cover. Then lift the
speaker from its cavity using your fingers.

Working Instruction, Mechanical
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Step-by-Step Instructions
5. Orient the circuit board relative to the outer base
cover so that the camera is towards the inner surface
of the outer base cover and the end of the circuit
board with the system connector corresponds to the
outer base cover’s system connector opening.
6. Rotate the circuit board so that it is at a 45 degree
angle to the outer base cover
7. Insert the end of circuit board, in which the system
connector is attached, into the outer base cover so
that the system connector inserts into its opening in
the outer base cover.
8. Hold the circuit board and the outer base cover in
this configuration using one hand and reconnect the
side speaker to the circuit board using the other
hand.
NOTE! When the side speaker’s board connector is
correctly connected, the wires coming off
of the side speaker’s connector extend
towards the center of the circuit board.
9. Rotate the circuit board down into the outer base
cover.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 15(128)
Step-by-Step Instructions
10. To lock the circuit board in the outer base cover,
press the circuit board down into the outer base
cover in the two locations indicated.
NOTE! Make sure the two wires of the side speaker
are twisted together before inserting the
speaker in its cavity, but be careful not to
over twist the wires.
11. With the side of the speaker containing the dust cloth
oriented towards the speaker port, insert the side
speaker into its cavity in the outer base cover.
12. Work the wires of the side speaker down into the gap
between the large shield can and the standoffs
protruding up from the outer base cover.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 16(128)
Step-by-Step Instructions
13. Insert the large tab portion of the system connector
cover into the opening between the system connector
the outer base cover.
14. Plug the system connector cover into the system
connector.
NOTE! If the system connector cover has been
installed correctly, the large tab portion of
the system connector cover can be seen
lying on top of the system connector.
15. With the keypad switch assembly held directly over
the circuit board and the dome foil side of the
assembly away from the circuit board, plug the
keypad switch assembly’s flex film into its
connection on the circuit board.
16. Then position the keypad switch assembly over the
exposed shield cans so that the lipped edges of the
keypad switch assembly’s metal plate catch on the
corresponding edges of the large shield can.

Working Instruction, Mechanical
3/00021-1/FEA 209 544/594 B
©Sony Ericsson Mobile Communications AB 17(128)
2.2.2 Outer Base Cover Installation
If this part is being replaced, refer to the “Outer Base Cover” subsection under the “Parts
Replacement” portion of this document for detailed instructions on how to replace this part.
Tools needed:
•Torque screwdriver •Torx Plus size 5 bit
•Style 2A ESD tweezers (Blunt tip)
Step-by-Step Instructions
1. Rotate the inner base cover relative to the flip
portion of the phone so that the phone is in the open
position as shown.
NOTE! Verify that the two cables are not twisted
together.
2. Orient the outer base cover so that it is perpendicular
to the flip assembly with the system connector end of
the outer base cover towards the inner base cover
and the battery cavity adjacent to the inner base
cover’s keypad area.
NOTE! Use one hand to hold the phone in this
orientation.
NOTE! The cable assembly with the color mark
matches to the board connection that has the
large gold dot below it.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 18(128)
Step-by-Step Instructions
3. Select the cable you are going to connect and orient
the connector end of the cable so that the side of the
connector with the two notches is oriented away
from the board.
NOTE! Be careful not to damage the cable
assemblies when reconnecting them to the
circuit board.
NOTE! Do NOT attempt to plug the cable
assemblies in by using the cable assembly
itself to push the cable connection into the
board connection. Damage to the cable
assembly most likely will result.
4. Place the end of the cable assembly into the opening
of its board connection.
5. Using the tip of a pair of style 2A tweezers, work the
end of the cable into its board connector. There are
two locations that the connection on the end of the
cable must be alternately pushed at to get the cable
connection completely seated into its board
connector. The pushing locations are labelled
location 1 and location 2.
6. Repeat the previous three steps to connect the other
cable/board connection.
7. Once the cables are connected to the circuit board,
insert each of the cables into their corresponding
cable holders on the circuit board.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 19(128)
Step-by-Step Instructions
8. Obtain a keypad and orient it so that the keys are
towards the inner base cover and the curved edges of
the keypad correspond to the curved edges of the
recess in the inner base cover.
9. Insert the keypad into its recessed area in the inner
base cover and press the keypad into place so that it
is seated down onto the 6 positioning pegs that
extend up from the inner base cover.
10. Verify that the magnet, the Bluetooth antenna, and
the liquid intrusion indicator are in place on the inner
base cover before installing the outer base cover
assembly.

Working Instruction, Mechanical
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©Sony Ericsson Mobile Communications AB 20(128)
Step-by-Step Instructions
11. Rotate the outer base cover assembly so that its side
speaker moves towards the keypad.
12. Continue to rotate the outer base cover assembly
until the inner surfaces of the two base covers are
towards each other.
NOTE! Make sure the cables are still mounted in
their cable holders and the keypad switch
assembly is still correctly positioned before
performing the next step.
13. Hold the two halves of the phone so that the side of
the base with the IR window is downward and the
upper edges of the two halves are slightly rotated
away from each other so that the keypad switch
assembly and the keypad do not fall out of place
during the assembly of the two halves of the base.
14. Mate the two halves of the base and gently snap the
two halves together.
15. Check that there is no gap along the seam where the
two portions of the base assemble.