Working Instruction, Mechanical
Working Instruction, Mechanical
Applicable for W595
CONTENTS
1 Introduction .............................................................................. 3
1.1 Equipment ................................................................................. 5
1.2 General cautions ...................................................................... 6
1.3 Adhesives ................................................................................. 6
2 Disassembly ............................................................................. 7
2.1 Overview ................................................................................... 7
2.1.1 Battery Cover and Battery ..................................................... 8
2.1.2 Deco Plate ............................................................................. 9
2.1.3 Front Cover Assy ................................................................. 10
2.1.4 Main Keyboard .................................................................... 11
2.1.5 Rear Cover .......................................................................... 12
2.1.6 Top and Bottom Cap ........................................................... 14
2.1.7 Earspeaker, Display and PBA Navigation ........................... 15
2.1.8 Frame Assy ......................................................................... 19
2.1.9 Hinge ................................................................................... 20
3 Replacements ......................................................................... 21
3.1 Battery Cover and Battery ..................................................... 22
3.2 Deco Plate ............................................................................... 22
3.3 Front Cover Assy ................................................................... 22
3.4 Main Keyboard ........................................................................ 22
3.5 Rear Cover .............................................................................. 22
3.6 Top and Bottom Cap .............................................................. 22
3.7 Earspeaker, Display and PBA Navigation ............................ 22
3.8 Frame Assy ............................................................................. 23
3.9 Hinge ....................................................................................... 23
3.9.1 Camera Assy ....................................................................... 24
3.9.2 Co-Brand ............................................................................. 26
3.9.3 Dust Gasket Hinge .............................................................. 27
3.9.4 Gasket Camera ................................................................... 27
3.9.5 Gasket Hinge....................................................................... 28
3.9.6 Gasket Microphone ............................................................. 28
3.9.7 Gasket Speaker Bottom ...................................................... 29
3.9.8 Gasket Speaker Top ........................................................... 29
3.9.9 Half to Half FPC .................................................................. 30
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3.9.10 Keyboard Navigation ........................................................... 32
3.9.11 Light Guide Navi Keyboard ................................................. 33
3.9.12 Light Guide Main Keyboard ................................................. 34
3.9.13 Loudspeaker Bottom ........................................................... 35
3.9.14 Loudspeaker Top ................................................................ 36
3.9.15 Main Window ....................................................................... 37
3.9.16 PBA Main Keyboard FPC .................................................... 38
3.9.17 Tape Main Keyboard LED ................................................... 40
3.9.18 Tape Navigation LED .......................................................... 41
3.9.19 Tape Navigation LED middle ............................................... 41
3.9.20 Volume Key ......................................................................... 42
3.9.21 Walkman Key ...................................................................... 42
3.10 Liquid Indicator ...................................................................... 43
3.11 Core Unit Label ....................................................................... 44
4 Reassembly ............................................................................ 45
4.1 Overview ................................................................................. 46
4.1.1 Hinge ................................................................................... 47
4.1.2 Frame Assy ......................................................................... 48
4.1.3 Earspeaker, Display and PBA Navigation ........................... 49
4.1.4 Top and Bottom Cap ........................................................... 54
4.1.5 Rear Cover .......................................................................... 55
4.1.6 Main Keyboard .................................................................... 57
4.1.7 Front Cover Assy ................................................................. 58
4.1.8 Deco Plate ........................................................................... 59
4.1.9 Battery Cover and Battery ................................................... 60
5 Revision History ..................................................................... 61
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Working Instruction, Mechanical
1 Introduction
W595
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Working Instruction, Mechanical
W595s
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Working Instruction, Mechanical
1.1 Equipment
SPECIAL TOOLS
• NTZ 112 459 Torque screwdriver (or equivalent)
• 1222-3513 Bits (PH00)
• NTZ 112 302/2 Front opening tool
• NTZ 112 521 Flex film assembly tool
• NTZ 112 590 Guitar pick
STANDARD TOOLS
Standard tools have to be locally purchased
• Dentist hook
• ESD tweezers
OTHER EQUIPMENT
• ESD wristband
• ESD gloves
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
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Working Instruction, Mechanical
1.2 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:
WITCH OFF THE PHONE AND REMOVE ANY MEMORY STICK BEFORE THE START OF THE DISASSEMBLY!
• S
EEP ALL CONTACT SURFACES CLEAN!
• K
E CAREFUL WHEN USING TOOLS LIKE THE DENTIST HOOK, TWEEZERS, OPENING TOOLS, GUITAR PICK
• B
ETC. TO AVOID SCRATCHES OR DAMAGES TO THE EXTERIOR AND INTERIOR PARTS OF THE PHONE!
• B
E CAREFUL NOT TO DAMAGE ANY CONTACT SPRINGS!
EMEMBER TO REMOVE THE PROTECTION FOILS ON NEW PARTS SUCH AS THE FRONT COVER AND LCD!
• R
EVER TOUCH THE DISPLAY GLASS!
• N
SE AIR BLOW EQUIPMENT TO KEEP THE FRONT WINDOW AND DISPLAY MODULE DUST FREE!
• U
1.3 Adhesives
Use a dentist hook and/or the tweezers to remove old adhesives.
Clean the surface with isopropyl alcohol before attaching new adhesives.
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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
2.1 Overview
REASSEMBLY
Done
The disassembly is done in the following order:
1. Battery Cover and Battery
2. Deco Plate
3. Front Cover Assy
4. Main Keyboard
5. Rear Cover
6. Top and Bottom Cap
7. Earspeaker
8. Display
9. PBA Navigation
10. Frame Assy
11. Main PBA
12. Hinge
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2.1.1 Battery Cover and Battery
Remove the Battery Cover.
Remove the Battery.
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2.1.2 Deco Plate
Release the Deco Plate with a guitar pick.
Remove the Deco Plate.
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2.1.3 Front Cover Assy
Remove the two screws (PH00).
Use a guitar pick and slide along the side to release the
snap hooks.
Slide along the other side.
Remove the Front Cover.
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2.1.4 Main Keyboard
Release the Main Keyboard with a guitar pick.
Be careful with the Light Guide underneath.
Remove the Main Keyboard.
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2.1.5 Rear Cover
Remove the two bottom screws (PH00).
Remove the two top screws (PH00).
Release the snap hooks along both sides with a front
opening tool.
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Rear Cover continue
Release the hook with a guitar pick.
Release the Rear Cover from the core unit.
Be careful with the hook.
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2.1.6 Top and Bottom Cap
Remove the Bottom Cap.
Unsnap the hooks on the Top cap.
Remove the Top Cap.
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2.1.7 Earspeaker, Display and PBA Navigation
Remove the screw (PH00).
Release the Earspeaker with a guitar pick.
Slide along the Earspeaker fllex.
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Earspeaker, Display and PBA Navigation continue
Release the PBA Navigation.
Turn over the PBA Navigation to reach the connectors.
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Earspeaker, Display and PBA Navigation continue
Open the connector carefully.
Remove the flex.
Remove the Earspeaker, Display and PBA Navigation.
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Earspeaker, Display and PBA Navigation continue
Open the Earspeaker connector carefully.
Remove the Earspeaker flex.
Open the Display connector carefully.
Remove the Display flex.
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2.1.8 Frame Assy
Slide carefully along the side button flex with a guitar pick to
release it from the hooks.
Remove the two screws (PH00).
Remove the Frame Assy.
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2.1.9 Hinge
Remove the two screws (PH00).
Lift up the Main PBA.
Open the connector carefully.
Remove the Main PBA Keyboard FPC and the Main PBA.
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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 and Battery
Follow the 2.1.1 Disassembly instructions
Prepare the new Battery Cover.
Follow the 4.1.9 Reassembly instructions
3.2 Deco Plate
Follow the 2.1.1 – 2.1.2 Disassembly instructions
Prepare the new Deco Plate.
Follow the 4.1.8 – 4.1.9 Reassembly instructions
3.3 Front Cover Assy
Follow the 2.1.1 – 2.1.3 Disassembly instructions
Prepare the new Front Cover Assy.
Follow the 4.1.7 – 4.1.9 Reassembly instructions
3.4 Main Keyboard
Follow the 2.1.1 – 2.1.4 Disassembly instructions
Prepare the new Main Keyboard.
Follow the 4.1.6 – 4.1.9 Reassembly instructions
3.5 Rear Cover
Follow the 2.1.1 – 2.1.5 Disassembly instructions
Prepare the new Rear Cover.
Follow the 4.1.5 – 4.1.9 Reassembly instructions
3.6 Top and Bottom Cap
Follow the 2.1.1 – 2.1.6 Disassembly instructions
Prepare the new Top or/and Bottom Cap.
Follow the 4.1.4 – 4.1.9 Reassembly instructions
3.7 Earspeaker, Display and PBA Navigation
Follow the 2.1.1 – 2.1.3 and 2.1.7 Disassembly instructions
Prepare the new Earspeaker, Display or/and PBA Navigation.
Follow the 4.1.3 and 4.1.7 – 4.1.9 Reassembly instructions
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3.8 Frame Assy
Follow the 2.1.1 – 2.1.8 Disassembly instructions
Prepare the new Frame Assy.
Follow the 4.1.2 – 4.1.9 Reassembly instructions
3.9 Hinge
Follow the 2.1.1 – 2.1.9 Disassembly instructions
Prepare the new Hinge.
Follow the 4.1.1 – 4.1.9 Reassembly instructions
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3.9.1 Camera Assy
REMOVAL
Follow the 2.1.1 – 2.1.9 Disassembly instructions.
Lift the Shield Camera Can Lid with a dentist hook.
Remove the Shield Camera Can Lid.
Open the connector carefully.
Remove the Camera.
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Camera Assy continue
INSTALLATION
Replace the new Camera flex.
Close the connector gently.
Mount the Shield Camera Can Lid.
Press to attach.
Follow the 4.1.1 – 4.1.9 Reassembly instructions.
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3.9.2 Co-Brand
REMOVAL
Follow the 2.1.1 Disassembly instructions.
Remove the Co-Brand with a dentist hook.
INSTALLATION
Mount a new Co-Brand.
Press to attach.
Follow the 4.1.9 Reassembly instructions.
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Working Instruction, Mechanical
3.9.3 Dust Gasket Hinge
REMOVAL
Follow the 2.1.1 – 2.1.9 Disassembly instructions.
Remove the Dust Gasket Hinge.
Clean the Rear Cover with isopropyl alcohol.
INSTALLATION
Mount a new Dust Gasket Hinge. Press to attach.
Follow the 4.1.1 – 4.1.9 Reassembly instructions.
3.9.4 Gasket Camera
REMOVAL
Follow the 2.1.1 – 2.1.5 Disassembly instructions.
Remove the Gasket Camera.
Clean the Rear Cover with isopropyl alcohol.
INSTALLATION
Mount a new Gasket Camera. Press to attach.
Follow the 4.1.5 – 4.1.9 Reassembly instructions.
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3.9.5 Gasket Hinge
REMOVAL
Follow the 2.1.1 – 2.1.9 Disassembly instructions.
Remove the Gasket Hinge.
Clean the Rear Cover with isopropyl alcohol.
INSTALLATION
Mount a new Gasket Hinge. Press to attach.
Follow the 4.1.1 – 4.1.9 Reassembly instructions.
3.9.6 Gasket Microphone
REMOVAL
Follow the 2.1.1 – 2.1.9 Disassembly instructions.
Remove the Gasket Microphone.
INSTALLATION
Mount a new Gasket Microphone.
Follow the 4.1.1 – 4.1.9 Reassembly instructions.
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3.9.7 Gasket Speaker Bottom
REMOVAL
Follow the 2.1.1 – 2.1.6 and 2.1.8 Disassembly instructions.
Remove the Gasket Speaker Bottom.
Clean the Frame Assy with isopropyl alcohol.
INSTALLATION
Mount a new Gasket Speaker Bottom with a par of
tweezers. Press with your finger to attach.
Follow the 4.1.2 and 4.1.4 – 4.1.9 Reassembly instructions.
3.9.8 Gasket Speaker Top
REMOVAL
Follow the 2.1.1 – 2.1.5 Disassembly instructions.
Remove the Gasket Speaker Top.
Clean the Rear Cover with isopropyl alcohol.
INSTALLATION
Mount a new Gasket Speaker Top.
Follow the 4.1.5 – 4.1.9 Reassembly instructions.
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3.9.9 Half to Half FPC
REMOVAL
Follow the 2.1.1 – 2.1.9 Disassembly instructions.
Lift up the Half to Half FPC from the Shield Can Lid with a
par of tweezers.
Open the connector carefully.
Remove the Half to Half FPC.
Remove the HtH Adhesive with a dentist hook.
Clean the Shield Can Lid with isopropyl alcohol.
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Half to Half FPC continue
INSTALLATION
Replace a new HtH Adhesive.
Install the Half to Half FPC in the connector.
Close the connector gently.
Mount the Half to Half FPC to the HtH Adhesive.
Press to attach.
Follow the 4.1.1 – 4.1.9 Reassembly instructions.
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3.9.10 Keyboard Navigation
REMOVAL
Follow the 2.1.1 – 2.1.3 Disassembly instructions.
Remove the Keyboard Navigation.
INSTALLATION
Mount a new Keyboard Navigation.
Follow the 4.1.7 – 4.1.9 Reassembly instructions.
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Working Instruction, Mechanical
3.9.11 Light Guide Navi Keyboard
REMOVAL
Follow the 2.1.1 – 2.1.3 Disassembly instructions and
the 3.9.17 Replacements instructions.
Remove the Light Guide Navi Keyboard with a guitar pick.
INSTALLATION
Mount a new Light Guide Navi Keyboard.
Press to attach.
Follow the 3.9.17 Replacements instructions and
the 4.1.7 - 4.1.9 Reassembly instructions.
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Working Instruction, Mechanical
3.9.12 Light Guide Main Keyboard
REMOVAL
Follow the 2.1.1 – 2.1.4 Disassembly instructions and
the 3.9.18 Replacements instructions.
Remove the Light Guide Main Keyboard with a par of
tweezers.
INSTALLATION
Mount a new Light Guide Main Keyboard.
Press to attach.
Follow the 3.9.18 Replacements instructions and
the 4.1.6 - 4.1.9 Reassembly instructions.
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3.9.13 Loudspeaker Bottom
REMOVAL
Follow the 2.1.1 – 2.1.8 Disassembly instructions.
Remove the Loudspeaker Bottom with a dentist hook.
Remove the Adhesive Speaker Bottom with a dentist hook.
Clean the pit in the Frame Assy with isopropyl alcohol.
INSTALLATION
Mount a new Adhesive Speaker Bottom.
Mount a new Loudspeaker Bottom.
Notice that the pin on the Loudspeaker should be in the
right direction. Press to attach.
Follow the 4.1.2 – 4.1.9 Reassembly instructions.
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3.9.14 Loudspeaker Top
REMOVAL
Follow the 2.1.1 – 2.1.8 Disassembly instructions.
Remove the Loudspeaker Top with a dentist hook.
INSTALLATION
Mount a new Loudspeaker Top.
Notice that the pin on the Loudspeaker should be in the
right direction
Press to attach.
Follow the 4.1.2 – 4.1.9 Reassembly instructions.
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3.9.15 Main Window
REMOVAL
Follow the 2.1.1 – 2.1.3 Disassembly instructions.
Remove the Main Window from the Front Cover.
INSTALLATION
Mount a new Main Window.
Press to attach.
Remove the Protection Tape.
Follow the 4.1.7 – 4.1.9 Reassembly instructions.
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3.9.16 PBA Main Keyboard FPC
REMOVAL
Follow the 2.1.1 – 2.1.9 Disassembly instructions.
Release the tongue from the backside of the Hinge.
Push it through the Hinge.
Remove the PBA Main Keyboard FPC.
Remove the old Conductive adhesive.
There will be a new Conductive adhesive on the new
PBA Main Keyboard FPC.
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PBA Main Keyboard FPC continue
Remove the Adhesive Main Keyboard with a par of
tweezers. Clean with isopropyl alcohol.
INSTALLATION
Mount a new Adhesive Main Keyboard with a par of
tweezers.
Push the right tongue through the Hinge.
Push the left tongue through the Hinge.
Mount the new PBA Main Keyboard FPC on the Hinge.
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PBA Main Keyboard FPC continue
Mount the tongue.
Press to attach.
Follow the 3.9.12 Replacements instructions and
the 4.1.1 - 4.1.9 Reassembly instructions.
3.9.17 Tape Main Keyboard LED
REMOVAL
Follow the 2.1.1 – 2.1.4 Disassembly instructions.
Remove the Tape.
INSTALLATION
Mount a new Tape and press with your finger to attach.
Follow the 4.1.5 – 4.1.9 Reassembly instructions.
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3.9.18 Tape Navigation LED
REMOVAL
Follow the 2.1.1 – 2.1.3 Disassembly instructions.
Remove the Tape.
INSTALLATION
Mount a new Tape and press with your finger to attach.
Follow the 4.1.7 – 4.1.9 Reassembly instructions.
3.9.19 Tape Navigation LED middle
REMOVAL
Follow the 2.1.1 – 2.1.3 Disassembly instructions.
Remove the Tape.
INSTALLATION
Mount a new Tape and press with your finger to attach.
Follow the 4.1.7 – 4.1.9 Reassembly instructions.
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3.9.20 Volume Key
REMOVAL
Follow the 2.1.1 – 2.1.5 Disassembly instructions.
Remove the Volume Key.
INSTALLATION
Mount a new Volume Key.
Follow the 4.1.5 – 4.1.9 Reassembly instructions.
3.9.21 Walkman Key
REMOVAL
Follow the 2.1.1 – 2.1.5 Disassembly instructions.
Remove the Walkman Key.
INSTALLATION
Mount a new Walkman Key.
Follow the 4.1.5 – 4.1.9 Reassembly instructions.
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3.10 Liquid Indicator
INSPECTION
There is a Liquid Indicator located at the arrow.
REMOVAL
Follow the 2.1.1 – 2.1.8 Disassembly instructions.
Remove the old Liquid Indicator with a dentist hook.
INSTALLATION
Use a pair of tweezers to mount a new Liquid Indicator
on the Frame Assy.
Follow the 4.1.2 - 4.1.9 Reassembly instructions.
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3.11 Core Unit 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.
NE LABEL ONLY IS ALLOWED!
O
Follow the 4.1.9 Reassembly instructions.
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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 disassembly is done in the following order:
1. Hinge
2. Main PBA
3. Frame Assy
4. PBA Navigation
5. Display
6. Earspeaker
7. Top and Bottom Cap
8. Rear Cover
9. Main Keyboard
10. Front Cover Assy
11. Deco Plate
12. Battery Cover and Battery
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4.1.1 Hinge
Install the Main PBA Keyboard FPC in the connector.
Close the connector gently.
Install the Half to Half FPC through the Hinge.
Install two new Screws Ph 1.6 x 3.0 with a torque
screwdriver at 12 Ncm (PH00 bit).
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4.1.2 Frame Assy
Mount the Frame Assy.
Press to attach.
Install two new Screws Ph 1.2 x 3.4 with a torque
screwdriver at 12 Ncm (PH00 bit).
If the PBA Main Keyboard FPC is reused - Clean the
Sidekey flex with isopropyl alcohol to remove the old
adhesive.
Mount a new Adhesive Sidekey FPC.
Mount the Sidekey flex with a par of tweezers.
Notice the hooks.
Press to attach.
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4.1.3 Earspeaker, Display and PBA Navigation
If the Earspeaker is reused - Clean the Earspeaker flex
with isopropyl alcohol to remove the old adhesive.
Mount a new Adhesive Earsp FPC Top and a new Adhesive
Earsp FPC Bottom.
If the Earspeaker is reused - remove the Adhesive
Earspeaker.
If the Earspeaker is reused - mount a new Adhesive
Earspeaker.
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Earspeaker, Display and PBA Navigation continue
Install the Display flex in the connector.
Close the connector gently.
Install the Earspeaker flex in the connector.
Close the connector gently.
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Earspeaker, Display and PBA Navigation continue
Remove the old Adhesive Navigation PBA and clean with
isopropyl alcohol.
Mount a new Adhesive Navigation PBA.
Slide the Display under the hooks.
Turn over the PBA Navigation and install the Half to Half
FPC in the connector.
Close the connector.
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Earspeaker, Display and PBA Navigation continue
Slide the PBA Navigation under the hook.
Press the PBA Navigation to attach.
Press the Earspeaker flex to attach.
Press the Earspeaker to attach.
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Earspeaker, Display and PBA Navigation continue
Install a new Screw Ph 1.4 x 1.6 with a torque screwdriver
at 12 Ncm (PH00 bit).
Replace the Light Guide Navi Keyboard if it is damaged
or loose.
Follow the 3.9.11 Replacements instructions.
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4.1.4 Top and Bottom Cap
Mount the Top Cap. Notice the two hooks.
Mount the Bottom Cap.
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4.1.5 Rear Cover
Start by this hook when the Rear Cover is mounted.
Bend to mount the Rear Cover by the System connector.
Notice the hook.
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Rear Cover continue
Install two new Screws Ph 1.6 x 6.5 with a torque
screwdriver at 15 Ncm (PH00 bit) in the top.
Install two new Screws Ph 1.6 x 6.5 with a torque
screwdriver at 15 Ncm (PH00 bit) in the bottom.
Replace the Light Guide Main Keyboard if it is damaged
or loose.
Follow the 3.9.12 Replacements instructions.
Press along both sides to attach the snap hooks.
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4.1.6 Main Keyboard
Mount a new Main Keyboard. Start by the Microphone.
Align the Main Keyboard along the Bottom Cap.
Press to attach.
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4.1.7 Front Cover Assy
The Main Window Gasket is brittle. Replace the Main
Window if Main Window Gasket is damaged.
Follow the 3.9.15 Replacements instructions.
Align the Front Cover. Start with the hooks in the lower part.
Press the Front Cover with your fingers.
Install two new Screws Ph 1.4 x 2.1 with a torque
screwdriver at 15 Ncm (PH00 bit).
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4.1.8 Deco Plate
Mount a new Deco Plate. Be careful with the two hooks on
the Deco Plate.
Press to attach.
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4.1.9 Battery Cover and Battery
Mount the Battery.
Mount the Battery Cover.
Press to attach.
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5 Revision History
Rev. Date Changes / Comments
1 2008-09-26 First release
2 2008-10-09 Added instr for 1210-0722
3 2008-10-28 Added picture for reassembling of the Battery cover.
4 2008-11-13 Changed part number NTZ112459
5 2009-01-29 Added tool 1222-3513
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