Service Manual
Trakker Antares®
241X Hand-Held
Terminal
Intermec Technologies Corporation
Corporate Headquarters
6001 36th Ave. W.
Everett, WA 98203
U.S.A.
www.intermec.com
The information contained herein is proprietary and is provided solely for the purpose of allowing customers
to operate and service Intermec-manufactured equipment and is not to be released, reproduced, or used for any
other purpose without written permission of Intermec.
Information and specifications contained in this document are subject to change without prior notice and do
not represent a commitment on the part of Intermec Technologies Corporation.
 2003 by Intermec Technologies Corporation. All rights reserved.
The word Intermec, the Intermec logo, Norand, ArciTech, CrossBar, Data Collection Browser, dcBrowser,
Duratherm, EasyCoder, EasyLAN, Enterprise Wireless LAN, EZBuilder, Fingerprint, i-gistics, INCA (under
license), InterDriver, Intermec Printer Network Manager, IRL, JANUS, LabelShop, Mobile Framework,
MobileLAN, Nor*Ware, Pen*Key, Precision Print, PrintSet, RoutePower, TE 2000, Trakker Antares, UAP,
Universal Access Point, and Virtual Wedge are either trademarks or registered trademarks of Intermec
Technologies Corporation.
Throughout this manual, trademarked names may be used. Rather than put a trademark ( or ) symbol in
every occurrence of a trademarked name, we state that we are using the names only in an editorial fashion, and
to the benefit of the trademark owner, with no intention of infringement.
There are U.S. and foreign patents pending.
nuggetf
d 39 Contents
Contents
Before You Begin v
Safety Summary v
Safety Icons vi
Global Services and Support vi
Warranty Information vi
Web Support vii
Who Should Read This Document? vii
1
2
Troubleshooting
Troubleshooting the 241X 1-3
Replacing Parts
Cautions 2-3
Replacing Parts 2-4
Opening the Terminal 2-4
Replacing the Radio (2415 Only) 2-5
Replacing the Memory Card (2410 Only) 2-8
Replacing the Main PCB 2-8
Replacing the Beeper 2-11
Replacing the LCD 2-13
Replacing the Display Lens 2-15
Replacing the Keypad Assembly (Top Cover) 2-15
Replacing the Antenna (2415 Only) 2-17
Replacing the Scan Engine 2-20
Replacing the PDF 417 Scan Engine 2-22
Replacing the E1022 Linear Imager 2-24
Replacing the PDF 417 PCB Assembly 2-26
Replacing the Scanner Lens or E1022 Scan Window 2-27
Replacing the Backup Capacitor 2-30
Replacing the Bottom Cover 2-33
Closing the Terminal 2-36
iii
Trakker Antares 241X Hand-Held Terminal Service Manual nuggetf
3
Exploded Views and Spare Parts Lists
Exploded View 3-3
Spare Parts List 3-4
PDF 417 Scan Engine Exploded View 3-6
PDF 417 Scan Engine Spare Parts List 3-7
E1022 Linear Imager Exploded View 3-8
E1022 Linear Imager Spare Parts List 3-9
4
Theory of Operation
Main PCB 4-3
Liquid Crystal Display (LCD) Interface 4-3
Keyboard Interface 4-3
Scanner Interface 4-4
Lithium-Ion Battery Charger 4-4
Lithium-Ion Main Battery 4-4
Backup Power Source 4-4
Light Emitting Diodes (LEDs) 4-4
Microprocessor 4-4
Memory Map 4-5
Oscillators 4-5
Flash Memory 4-5
Static RAM 4-5
PC Card Interface 4-6
Beeper Driver 4-6
ASIC 4-6
Power Supplies 4-7
Interface Devices 4-7
External Devices 4-7
Display 4-8
Keyboard 4-8
PC Card/Radio 4-8
iv
d 39
C d 39 nuggetf
d 39 Before You Begin
Before You Begin
This section provides you with safety information, technical support information, and
sources for additional product information.
Safety Summary
Your safety is extremely important. Read and follow all warnings and cautions in this
document before handling and operating Intermec equipment. You can be seriously
injured, and equipment and data can be damaged if you do not follow the safety
warnings and cautions.
Do not repair or adjust alone
Do not repair or adjust energized equipment alone under any circumstances. Someone
capable of providing first aid must always be present for your safety.
First aid
Always obtain first aid or medical attention immediately after an injury. Never neglect
an injury, no matter how slight it seems.
Resuscitation
Begin resuscitation immediately if someone is injured and stops breathing. Any delay
could result in death. To work on or near high voltage, you should be familiar with
approved industrial first aid methods.
Energized equipment
Never work on energized equipment unless authorized by a responsible authority.
Energized electrical equipment is dangerous. Electrical shock from energized
equipment can cause death. If you must perform authorized emergency work on
energized equipment, be sure that you comply strictly with approved safety regulations.
v
Trakker Antares 241X Hand-Held Terminal Service Manual nuggetf
d 39
Safety Icons
This section explains how to identify and understand warnings, cautions, and notes that
are in this document. You may also see icons that tell you when to follow ESD
procedures and when to take special precautions for handling optical parts.
Warning
A warning alerts you of an operating procedure, practice, condition, or statement
that must be strictly observed to avoid death or serious injury to the persons working
on the equipment.
Caution
A caution alerts you to an operating procedure, practice, condition, or statement that
must be strictly observed to prevent equipment damage or destruction, or corruption
or loss of data.
This icon appears at the beginning of any procedure in this manual that could cause
you to touch components (such as printed circuit boards) that are susceptible to
damage from electrostatic discharge (ESD). When you see this icon, you must follow
standard ESD guidelines to avoid damaging the equipment you are servicing.
Because finger oils can impede the performance of scanner parts and dissolve the
reflective coating of the plastic mirrors, always wear finger cots or non-powdered
latex gloves when handling optical parts.
Note: Notes either provide extra information about a topic or contain special
instructions for handling a particular condition or set of circumstances.
Page 2-3 lists cautions you must follow before repairing the 241X.
Global Services and Support
Warranty Information
To understand the warranty for your Intermec product, visit the Intermec web site at
http://www.intermec.com, click Support, and then click Warranty.
Disclaimer of warranties: The sample code included in this document is presented for
reference only. The code does not necessarily represent complete, tested programs. The
code is provided “as is with all faults.” All warranties are expressly disclaimed,
including the implied warranties of merchantability and fitness for a particular purpose.
vi
C d 39 nuggetf
d 39 Before You Begin
Web Support
Visit the Intermec web site at http://www.intermec.com to download many of our
current manuals in PDF format. To order printed versions of the Intermec manuals,
contact your local Intermec representative or distributor.
Visit the Intermec technical knowledge base (Knowledge Central) at
http://intermec.custhelp.com to review technical information or to request technical
support for your Intermec product.
Telephone Support
These services are available from Intermec Technologies Corporation.
Call 1-800-755-5505
and choose this option
Service
Description
Factory Repair and
On-site Repair
Request a return authorization
number for authorized service
center repair, or request an onsite repair technician.
1
Technical Support
Get technical support on your
Intermec product.
2
Service Contract
Status
Inquire about an existing
contract, renew a contract, or
ask invoicing questions.
3
Schedule Site
Surveys or
Installations
Schedule a site survey, or
request a product or system
installation.
4
Ordering Products
Talk to sales administration,
place an order, or check the
status of your order.
5
Who Should Read This Document?
This manual contains all of the information necessary to repair the Trakker Antares®
2410 and 2415 hand-held terminals. It provides an exploded view of the terminals, the
spare parts lists, procedures that describe how to replace parts, and information about
how to test the terminal.
This manual is written for service technicians.
vii
blank page
1
Troubleshooting
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nugget
Troubleshooting
1
This chapter describes how to troubleshoot problems with the terminal.
Troubleshooting the 241X
This table lists symptoms of common problems and their possible solutions.
Symptom
Possible Solution
When you press q to turn on
the terminal, the screen is
blank and nothing happens.
Try these possible solutions in order:
OR
When you press q to turn the
terminal off, it does not enter
Suspend mode and returns to
the Boot menu.
Keypad does not work.
Some keys on the keypad
work, while others do not.
•
The main battery may not be charged or may be faulty.
Charge or replace the main battery.
•
There may be a connection problem between battery
contacts and main PCB. Clean the battery contacts.
•
The q key on keypad may not be working properly.
Follow the “Replacing the Keypad Assembly (Top
Cover)” procedure in Chapter 2.
•
There may be a power supply failure in the main PCB.
Follow the “Replacing the Main PCB” procedure in
Chapter 2.
Try these possible solutions in order:
•
The keypad may be disconnected. Make sure that the
keypad flex cable is connected to the main PCB. If it is,
follow the “Replacing the Keypad Assembly (Top
Cover)” procedure in Chapter 2.
•
The main PCB assembly keypad interface may have
failed. Follow the “Replacing the Main PCB” procedure
in Chapter 2.
Try these possible solutions in order:
•
The keypad interface may have a failed row/column
connection. Or, the keypad flex cable or keypad may be
damaged. Follow the “Replacing the Keypad Assembly
(Top Cover)” procedure in Chapter 2.
•
The main PCB assembly keypad interface may have
failed. Follow the “Replacing the Main PCB” procedure
in Chapter 2.
1-3
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
Troubleshooting the 241X (continued)
Symptom
Possible Solution
Nothing is displayed on the
screen.
Try these possible solutions in order:
Screen displays missing or
“stuck” pixels and lines.
Backlight does not work.
Beeper does not work or the
frequency or volume is not
adequate.
1-4
•
The contrast may be set too light or too dark. Press (
+ to adjust the contrast.
•
The display/beeper flex cable may be disconnected.
Make sure that the display/beeper flex cable is
connected to the LCD and the main PCB.
•
The LCD may be damaged. Follow the “Replacing the
LCD” procedure in Chapter 2.
•
The main PCB assembly display interface may have
failed. Follow the “Replacing the Main PCB” procedure
in Chapter 2.
Try these possible solutions in order:
•
The LCD may be damaged. Follow the “Replacing the
LCD” procedure in Chapter 2.
•
The main PCB assembly display interface may have
failed. Follow the “Replacing the Main PCB” procedure
in Chapter 2.
Try these possible solutions in order:
•
The LCD may be damaged. Follow the “Replacing the
LCD” procedure in Chapter 2.
•
The backlight key on keypad may not be working
properly. Try these possible solutions in order:
•
Follow the “Replacing the Keypad Assembly (Top
Cover)” procedure in Chapter 2.
•
Follow the “Replacing the Main PCB” procedure
in Chapter 2.
Try these possible solutions in order:
•
The sound porthole may be blocked. Clean the sound
porthole.
•
The beeper may be damaged. Follow the “Replacing
the Beeper” procedure in Chapter 2.
•
The beeper driver on the main PCB may be damaged.
Follow the “Replacing the Main PCB” procedure in
Chapter 2.
nugget
Troubleshooting
1
Troubleshooting the 241X (continued)
Symptom
Possible Solution
Real time clock does not
maintain correct time.
Try these possible solutions in order:
Scanner does not emit a beam,
or scanner emits a beam but
does not scan the bar code.
Tethered scanner does not
emit a beam.
Terminal will not
communicate in a serial
network.
•
The main battery may not be able to hold a charge.
Make sure that the backup capacitor is fully charged.
•
The backup capacitor may not be able to hold a charge.
Follow the “Replacing the Backup Capacitor”
procedure in Chapter 2.
•
The 32.768 KHz crystal for the real time clock on the
main PCB may be damaged. Follow the “Replacing the
Main PCB” procedure in Chapter 2.
Try these possible solutions in order:
•
The scan engine or linear imager may have failed.
Follow one of these procedures in Chapter 2:
“Replacing the Scan Engine,” “Replacing the PDF 417
Scan Engine,” or “Replacing the E1022 Linear
Imager.”
•
The main PCB assembly scan engine interface may
have failed. Follow the “Replacing the Main PCB”
procedure in Chapter 2.
Try these possible solutions in order:
•
There may be a problem with the tethered scanner or
the scanner configuration. Make sure that the tethered
scanner works and that the terminal is properly
configured for the scanner.
•
The main PCB assembly scan engine interface may
have failed. Follow the “Replacing the Main PCB”
procedure in Chapter 2.
Try these possible solutions in order:
•
The terminal may not be properly configured for
serial communications. Make sure that the serial
communication parameters are properly configured.
•
The serial cable may have failed. Replace the serial
cable.
•
The main PCB assembly serial interface may have
failed. Follow the “Replacing the Main PCB” procedure
in Chapter 2.
1-5
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
Troubleshooting the 241X (continued)
1-6
Symptom
Possible Solution
Terminal will not
communicate in an RF
network.
Try these possible solutions in order:
•
Make sure that the radio is configured properly for the
network. If the radio is properly configured, there may
be a problem with the access point.
•
The antenna may not be properly connected. Make sure
that the antenna cables are or correctly connected to the
radio. If the antenna cables are correctly connected, the
antenna may be damaged. Follow the “Replacing the
Antenna (2415 Only)” procedure in Chapter 2.
•
The radio card may be damaged. Follow the “Replacing
the Radio (2415 Only)” procedure in Chapter 2.
2
Replacing Parts
Blank page
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Replacing Parts
2
This chapter explains how to open, replace parts in, and close the 241X hand-held
terminal. It also provides preliminary cautions to follow when servicing the 241X.
Cautions
Note: Opening this product can result in voiding the warranty. The internal workings of
this product can only be accessed by Intermec service personnel.
Caution
Integrated circuits on the printed circuit board (PCB) in the terminal are very
sensitive to damage by electrostatic discharge (ESD). Prevent ESD by always wearing
skin contact ground straps firmly attached to the equipment metal base assembly
when working inside of the terminal. Never open the package without safeguarding
the entire work area with ESD protection. Failure to comply may result in damage to
PCB components.
Because finger oils can dissolve the reflective coating of the plastic mirrors, always
wear finger cots or non-powdered latex gloves when handling optical parts.
Follow ESD Procedures
This icon appears at the beginning of any procedure in this manual that could cause
you to touch components (such as printed circuit boards) that are susceptible to
damage from electrostatic discharge (ESD). When you see this icon, you must follow
standard ESD guidelines to avoid damaging the equipment you are servicing.
2-3
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
Replacing Parts
This section describes how to open, replace parts in, and close the 241X hand-held
terminal. Each procedure also lists the tools and parts that you will need.
Opening the Terminal
To perform repairs on the 241X, you need to open the terminal. To open the terminal,
you need the following tool:
•
#1 Phillips screwdriver
To open the terminal
1. Press _ to turn off the terminal.
2. While holding the terminal in one hand, grasp the battery pack on both sides.
3. Pull down on the battery release latch to release and remove the battery pack.
4. Remove the six Phillips screws holding the top and bottom covers together.
5. Slowly open but do not entirely separate the top and bottom covers. Be careful not
to rip any connections from the main printed circuit board (PCB).
Scanner
flex
cable
Radio/
memory
card
Antenna
cable
Retaining
block
Main PCB
Backup capacitor
assembly cable
241XM015.eps
6. Disconnect the backup capacitor assembly cable from the main PCB.
7. Disconnect the scanner flex cable from the main PCB.
The previous illustration shows the scanner flex cable attached to the connector
toward the top of the main PCB. However, if you are repairing a 241X with a
PDF 417 scan engine or E1022 linear imager, the scanner flex cable will be attached
to the connector toward the bottom of the main PCB.
2-4
nugget
Replacing Parts
2
Replacing the Radio (2415 Only)
To replace the radio, you need the following tools:
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need one of the following parts depending on the 2415’s configuration:
•
802.11 2126 ETSI (P/N 070512S-002)
•
802.11 2126 Japan (P/N 070514S-002)
•
802.11 2126 Mexico (P/N 070517S-002)
•
802.11 2126 U.S./Canada (P/N 070513S-002)
•
802.11 PC24-11-FC/R ROTW (P/N 073348S-001)
•
802.11 PC24-11-FC/R US/Canada (P/N 073347S-001)
•
OpenAir RM181 Australia (P/N 069516S-001)
•
OpenAir RM181 Euro1 (P/N 069512S-001)
•
OpenAir RM181 France/Mexico (P/N 069517S-001)
•
OpenAir RM181 Japan (P/N 591086-001)
•
OpenAir RM181 U.S./Canada (P/N 069513S-001)
•
OpenAir RM182 Australia (P/N 071825S-001)
•
OpenAir RM182 Euro (P/N 071824S-001)
•
OpenAir RM182 Israel/Spain (P/N 071826S-001)
•
OpenAir RM182 U.S./Canada (P/N 071823S-001)
To replace the radio
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. Remove the radio card from the
main PCB.
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Radio
card
Screw
Retaining
block
b. Slide the radio card out of the
connector on the main PCB.
Note: The antenna cables are not
shown for clarity.
241XM016.eps
2-5
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
3. Remove the antenna cable or
cables from the radio card.
Mount
strap
Cut
here
a. If necessary, carefully cut the
mount strap in half.
b. Disconnect the antenna cable
or cables from the radio card.
4. Install the new radio card.
a. Compare the connector tabs
on the new radio card to the
connector on the main PCB to
determine which side of the
new radio card is the back
(faces the main PCB).
Main
PCB
241XM014.eps
b. Attach the mount strap to the back of the radio card by removing the backing
from the adhesive area shown and applying the mount strap to the radio card.
Mount
strap
Mount
strap
Radio
card
Remove
backing
241XM017.eps
c. Turn the radio card over and slide it into the connector. Firmly press the radio
card into the connector until it stops.
5. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
2-6
nugget
Replacing Parts
2
6. Press the antenna cable or cables into the connectors on the radio.
•
If you are replacing an
802.11b radio, connect the
antenna cables to ports | and
|| as shown.
Antenna
cable
(2 places)
Port I
Port II
241XM018.eps
•
If you are replacing an
OpenAir radio, connect
the antenna cable to the
connector on the radio.
Antenna
cable
241XM019.eps
7. Remove the remaining backing from the mount strap, pull the mount strap over the
antenna cable connectors, and secure the mount strap to the top of the radio card.
8. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
2-7
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
Replacing the Memory Card (2410 Only)
To replace the memory card, you need the following tools:
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need one of the following parts:
•
2MB memory card (P/N 590092-001)
•
4MB memory card (P/N 590092-002)
To replace the memory card
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. Remove the memory card from
the main PCB.
Memory
card
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Screw
Retaining
block
b. Slide the memory card out of
the connector on the main
PCB.
3. Install the new memory card.
241XM005.eps
a. Compare the connector tabs
on the new memory card to
the connector on the main
PCB to determine which way to insert the memory card.
b. Slide the memory card into the connector. Firmly press the memory card into
the connector until it stops.
4. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
5. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
Replacing the Main PCB
To replace the main PCB, you need the following tools:
2-8
•
#1 Phillips screwdriver
•
Torque screwdriver
•
Trakker Antares Download and Configuration Tool (P/N T43434)
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Replacing Parts
2
You also need one of the following parts:
•
2MB main PCB (P/N 071589S-002)
•
4MB main PCB (P/N 071588S-002)
To replace the main PCB
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
Make sure you note the configuration on the serial number label on the bottom
cover.
2. Remove the radio or memory card
from the main PCB.
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Radio or
memory card
Screw
Retaining
block
b. Slide the radio or memory
card out of the connector on
the main PCB.
Note: The antenna cables (2415
only) are not shown for clarity.
241XM036.eps
3. Remove the keypad flex cable from the main PCB.
Keypad
flex cable
Main PCB
241XM013.eps
4. Gently lift the main PCB out of the top cover. Be careful not to rip the connection
between the main PCB and the display/beeper flex cable.
2-9
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
5. Turn the main PCB over and remove the display/beeper flex cable from the main
PCB.
Main PCB
Display/beeper
flex cable
Top
cover
241XM035.eps
6. Connect the display/beeper flex cable to the new main PCB.
7. Install the new main PCB.
8. Connect the keypad flex cable to the main PCB.
9. Install the radio or memory card.
a. Compare the connector tabs on the radio or memory card to the connector on
the main PCB to determine which way to insert the card.
b. Slide the radio or memory card into the connector. Firmly press the card into
the connector until it stops.
10. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
11. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
12. Use the configuration you noted in Step 1 and standard practices for the Trakker
Antares Download and Configuration Tool to load the correct configuration,
firmware, and application software.
2-10
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Replacing Parts
2
Replacing the Beeper
To replace the beeper, you need the following tools:
•
#1 Phillips screwdriver
•
Flathead screwdriver
•
Torque screwdriver
You also need the following part:
•
Display/beeper flex cable assembly (P/N 069705-002)
To replace the beeper
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. Remove the main PCB. Follow Steps 2 through 5 for “Replacing the Main PCB”
on page 2-9.
3. Remove the display/beeper flex cable from the LCD.
Display/beeper
flex cable
LCD
Screw
(four places)
Top cover
Beeper
241XM022.eps
4. Use the flathead screwdriver to gently pry the beeper off of the top cover.
2-11
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
5. Remove the adhesive backing from the new beeper, and attach it to the top cover.
Make sure that the beeper is aligned with the alignment edge on the top cover.
LCD
Display/beeper
flex cable
Screw
(four places)
Beeper
Alignment
edge
Top cover
241XM020.eps
6. Connect the display/beeper flex cable to the LCD.
7. Connect the display/beeper flex cable to the main PCB.
8. Install the main PCB.
9. Connect the keypad flex cable to the main PCB.
10. Install the radio or memory card.
a. Compare the connector tabs on the radio or memory card to the connector on
the main PCB to determine which way to insert the card.
b. Slide the radio or memory card into the connector. Firmly press the card into
the connector until it stops.
11. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
12. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
2-12
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Replacing Parts
2
Replacing the LCD
To replace the LCD, you need the following tools:
•
#0 Phillips screwdriver or T5 Torx screwdriver
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need the following part:
•
LCD (P/N 071363S-001)
To replace the LCD
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. Remove the radio or memory card
from the main PCB.
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Radio or
memory card
Screw
Retaining
block
b. Slide the radio or memory
card out of the connector on
the main PCB.
Note: The antenna cables (2415
only) are not shown for clarity.
241XM036.eps
3. Remove the keypad flex cable from the main PCB.
Keypad
flex cable
Main PCB
241XM013.eps
2-13
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
4. Gently lift the main PCB out of the top cover. Be careful not to rip the connection
between the main PCB and the display/beeper flex cable.
5. Remove the display/beeper flex cable from the LCD.
Display/beeper
flex cable
LCD
Screw
(four places)
Top cover
Beeper
241XM022.eps
6. Remove the four screws holding the LCD in place and remove the LCD.
7. Install the new LCD and tighten the screws to 0.226 Nm (2 in-lb).
8. Connect the display/beeper flex cable to the new LCD.
9. Install the main PCB.
10. Connect the keypad flex cable to the main PCB.
11. Install the radio or memory card.
a. Compare the connector tabs on the radio or memory card to the connector on
the main PCB to determine which way to insert the card.
b. Slide the radio or memory card into the connector. Firmly press the card into
the connector until it stops.
12. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
13. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
2-14
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Replacing Parts
2
Replacing the Display Lens
To replace the display lens, you need the following tools:
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need the following parts:
•
One of these display lenses
•
2410 (P/N 069423-003)
•
2415 (P/N 069427-003)
•
Clear Orbit Label (if necessary) (P/N 071228-001)
•
Oracle Ready Label (if necessary) (P/N 072558-001)
To replace the display lens
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. Remove the LCD. Follow Steps 2 through 6 for “Replacing the LCD” on page
2-13.
3. From the inside of the terminal, push the display lens out of the display window
area of the top cover. You may need to clean the top cover to remove any adhesive
residue left by the display lens.
4. Make sure the new display lens is free from fingerprints and scratches. Remove the
adhesive backing from the new display lens and carefully apply it to the top cover.
Firmly press the adhesive area of the new display lens onto the top cover.
Use an ionized air gun to blow any dust out of the interior of the terminal.
5. Install the LCD. Follow Steps 7 through 11 for “Replacing the LCD” on page 2-14.
6. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
7. If necessary, attach the Clear Orbit or Oracle Ready label to the display lens.
Replacing the Keypad Assembly (Top Cover)
To replace the keypad assembly, you need the following tool:
•
#1 Phillips screwdriver
•
Torque screwdriver
2-15
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
You also need the following parts depending on the terminal’s configuration:
•
One of these display lenses
•
2410 (P/N 069423-003)
•
2415 (P/N 069427-003)
•
Clear Orbit Label (if necessary) (P/N 071228-001)
•
Oracle Ready Label (if necessary) (P/N 072558-001)
•
One of these keypad assemblies
•
•
37-key function numeric (P/N 069842S-004)
•
37-key large numeric (P/N 069472S-004)
•
55-key alphanumeric (P/N 069471S-004)
One of these keypad overlays
•
37-key basic (P/N 069421-001)
•
37-key international (P/N 069422-001)
•
37-key 5250 TE (P/N 070279-001)
•
37-key 3270 TE (P/N 070377-001)
•
37-key VT/ANSI TE (P/N 069420-001)
•
37-key function numeric (P/N 069836-001)
•
37-key international function numeric (P/N 069840-001)
•
37-key VT/ANSI TE function numeric (P/N 069841-001)
•
55-key basic (P/N 069417-001)
•
55-key international (P/N 069419-001)
•
55-key 5250 TE (P/N 069418-001)
•
55-key 3270 TE (P/N 070376-001)
•
55-key VT/ANSI TE (P/N 069416-003)
To replace the keypad assembly
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. Remove the LCD. Follow Steps 2 through 6 for “Replacing the LCD” on page
2-13.
3. Remove the adhesive backing from the keypad overlay and apply it to the new
keypad assembly.
2-16
nugget
Replacing Parts
2
4. Make sure the display lens is free from fingerprints and scratches. Remove the
adhesive backing from the display lens and carefully apply it to the new keypad
assembly. Firmly press the adhesive area of the new display lens onto the keypad
assembly.
5. Use an ionized air gun to blow any dust out of the interior of the terminal.
6. Install the LCD in the new keypad assembly. Follow Steps 7 through 12 for
“Replacing the LCD” on page 2-14.
7. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
8. If necessary, attach the Clear Orbit label or the Oracle Ready label to the display
lens.
Replacing the Antenna (2415 Only)
To replace the antenna, you need the following tool:
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need one of the following parts:
•
Dual micropatch (802.11b) antenna (P/N 590993-001)
•
Single micropatch (OpenAir) antenna (P/N 590995-001)
•
Dipole (European OpenAir) antenna (P/N 069769-001)
To replace the antenna
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. Remove the radio card from the
main PCB.
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Radio
card
Screw
Retaining
block
b. Slide the radio card out of the
connector on the main PCB.
Note: The antenna cables are not
shown for clarity.
241XM016.eps
2-17
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
3. Remove the scan engine or E1022
linear imager assembly.
•
•
For a standard scan engine or
PDF 417 scan engine, remove
the two screws holding the
scan engine assembly in place.
Screw
(2 or 4 places)
Scan engine or
E1022 linear imager
assembly
Antenna
For an E1022 linear imager,
remove the four screws
holding the E1022 linear
imager assembly in place.
4. Remove the scan engine or linear
imager assembly from the bottom
cover.
5. Turn the assembly over and
remove the antenna.
241XM028.eps
6. Install the new antenna.
•
If you are installing an 802.11b antenna,
orient the antenna so that the antenna
cables face the bracket on the scan
engine or linear imager assembly. Make
sure that the cables align with the
channels on the bracket, and gently
press the antenna onto the bracket.
Antenna cable
(2 places)
Antenna
Foam
Channel
(2 places)
241XM029.eps
Scan engine/
linear imager
assembly
•
If you are installing an OpenAir
antenna, orient the antenna so that the
antenna cable faces the bracket on the
scan engine or linear imager assembly.
Make sure that the cable aligns with the
channel on the bracket, and gently press
the antenna onto the bracket.
Antenna
Antenna cable
Foam
Channel
(2 places)
241XM023.eps
Scan engine/
linear imager
assembly
2-18
nugget
•
If you are installing a European
OpenAir antenna, orient the antenna
so that the antenna cable and the foam
padding faces opposite of the bracket
on the scan engine or linear imager
assembly. Make sure that the antenna
cable is positioned toward the top of the
bracket.
Replacing Parts
Antenna
2
Antenna cable
Foam
padding
241XM024.eps
Scan engine/
linear imager
assembly
7. If you removed a standard scan engine or PDF 417 scan engine in Step 3, install the
scan engine assembly.
a. Place the assembly in the bottom
cover. Make sure the assembly is
firmly seated in the cover.
Retainers
b. Slide the assembly toward the top
of the cover so that the front of
the assembly slides under the
retainers.
c. Install the two screws that hold
the scan engine assembly in place
and tighten them to 0.565 Nm
(5 in-lb).
241XM025.eps
8. If you removed an E1022 linear imager in Step 3, place the E1022 linear imager
assembly in the bottom cover and install the four screws that hold the assembly in
place. Tighten the screws to 0.565 Nm (5 in-lb).
9. Install the radio card.
a. Compare the connector tabs on the radio card to the connector on the main PCB
to determine which way to insert the card.
b. Slide the radio card into the connector. Firmly press the card into the connector
until it stops.
c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
10. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
2-19
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
Replacing the Scan Engine
Because finger oils can dissolve the reflective coating of the plastic mirrors, always
wear finger cots or non-powdered latex gloves when handling optical parts.
To replace the scan engine, you need the following tools:
•
#0 Phillips screwdriver or T5 Torx screwdriver
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need one of the following scan engines:
•
Standard range (P/N 590014S-003)
•
High density (P/N 590039S-002)
•
High visibility (P/N 590040S-002)
•
Long range (P/N 590038S-002)
•
Advanced long range (P/N 591098S-001)
To replace the scan engine
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. (2415 only) Remove the radio
card from the main PCB.
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Radio
card
Screw
Retaining
block
b. Slide the radio card out of the
connector on the main PCB.
Note: The antenna cables are not
shown for clarity.
2-20
241XM016.eps
nugget
Replacing Parts
2
3. Remove the two screws holding the scan engine assembly in place.
Screw
(2 places)
Scan engine
assembly
Antenna
241XM038.eps
4. Remove the scan engine assembly.
5. (2415 only) Turn the assembly over and remove the antenna.
6. Remove the three screws that hold the scan engine in place and remove the scan
engine.
7. Install the new scan engine in the scan engine bracket and secure it with the three
screws tightened to 0.226 Nm (2 in-lb).
8. (2415 only) Install the antenna. For help, see Step 6 for “Replacing the Antenna” on
page 2-18.
9. Install the scan engine assembly.
a. Place the assembly in the bottom
cover. Make sure the assembly is
firmly seated in the cover.
Retainers
b. Slide the assembly toward the top
of the cover so that the front of the
assembly slides under the retainers.
c. Install the two screws that hold the
scan engine assembly in place and
tighten them to 0.565 Nm (5 in-lb).
241XM025.eps
2-21
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
10. (2415 only) Install the radio card.
a. Compare the connector tabs on the radio card to the connector on the main PCB
to determine which way to insert the card.
b. Slide the radio card into the connector. Firmly press the card into the connector
until it stops.
c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
11. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
Replacing the PDF 417 Scan Engine
Because finger oils can dissolve the reflective coating of the plastic mirrors, always
wear finger cots or non-powdered latex gloves when handling optical parts.
To replace the PDF 417 scan engine, you need the following tools:
•
#0 Phillips screwdriver or T5 Torx screwdriver
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need the following scan engine:
•
PDF 417 (P/N 591081S-001)
To replace the PDF 417 scan engine
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. (2415 only) Remove the radio
card from the main PCB.
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Radio
card
Screw
Retaining
block
b. Slide the radio card out of the
connector on the main PCB.
Note: The antenna cables are not
shown for clarity.
2-22
241XM016.eps
nugget
Replacing Parts
2
3. Remove the two screws holding the scan engine assembly in place.
Screw
(2 places)
Scan engine
assembly
Antenna
241XM038.eps
4. Remove the scan engine assembly.
5. (2415 only) Turn the assembly over and remove the antenna.
6. Remove the scan engine flex cable from the PDF 417 PCB assembly.
PDF 417
scan engine
Scan
engine
adapter
Scan engine
flex cable
Screw
(2 places)
Scan engine
bracket
PDF 417
PCB assembly
241XM056 .eps
Screw
(3 places)
7. Remove the three screws that hold the scan engine adapter in place and remove the
scan engine and scan engine adapter.
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Trakker Antares 241X Hand-Held Terminal Service Manual nugget
8. Remove the two screws that hold the scan engine in the scan engine adapter and
remove the scan engine.
9. Install the new scan engine in the scan engine adapter and secure it with the two
screws tightened to 0.226 Nm (2 in-lb).
10. Install the scan engine adapter in the scan engine bracket and secure it with the three
screws tightened to 0.226 Nm (2 in-lb).
11. (2415 only) Install the antenna. For help, see Step 6 for “Replacing the Antenna” on
page 2-18.
12. Install the scan engine assembly.
a. Place the assembly in the bottom
cover. Make sure that the assembly
is firmly seated in the cover.
Retainers
b. Slide the assembly toward the top
of the cover so that the front of the
assembly slides under the retainers.
c. Install the two screws that hold the
scan engine assembly in place and
tighten them to 0.565 Nm (5 in-lb).
241XM025.eps
13. (2415 only) Install the radio card.
a. Compare the connector tabs on the radio card to the connector on the main PCB
to determine which way to insert the card.
b. Slide the radio card into the connector. Firmly press the card into the connector
until it stops.
c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
14. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
Replacing the E1022 Linear Imager
Because finger oils can dissolve the reflective coating of the plastic mirrors, always
wear finger cots or non-powdered latex gloves when handling optical parts.
To replace the E1022 linear imager, you need the following tools:
•
#0 Phillips screwdriver
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need the following part:
2-24
nugget
•
Replacing Parts
2
E1022 linear imager assembly (P/N 072612S-001)
To replace the E1022 linear imager
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. (2415 only) Remove the radio
card from the main PCB.
Radio
card
Screw
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Retaining
block
b. Slide the radio card out of the
connector on the main PCB.
Note: The antenna cables are not
shown for clarity.
241XM016.eps
3. Remove the four screws holding the E1022 linear imager assembly in place.
Screw
(4 places)
E1022
linear
imager
Antenna
Scan
window
241XM053 .eps
4. Remove the E1022 linear imager assembly from the bottom cover.
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Trakker Antares 241X Hand-Held Terminal Service Manual nugget
5. (2415 only) Turn the assembly over and remove the antenna.
6. (2415 only) Install the antenna in the new E1022 linear imager assembly. For help,
see Step 6 for “Replacing the Antenna” on page 2-18.
7. Place the E1022 linear imager assembly in the bottom cover and install the four
screws that hold the assembly in place. Tighten the screws to 0.565 Nm (5 in-lb).
8. (2415 only) Install the radio card.
a. Compare the connector tabs on the radio card to the connector on the main PCB
to determine which way to insert the card.
b. Slide the radio card into the connector. Firmly press the card into the connector
until it stops.
c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
9. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
Replacing the PDF 417 PCB Assembly
To replace the PDF 417 PCB assembly, you need the following tools:
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need the following part:
•
PDF 417 PCB assembly (P/N 071200S-003)
To replace the PDF 417 PCB assembly
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. (2415 only) Remove the radio
card from the main PCB.
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Radio
card
Screw
Retaining
block
b. Slide the radio card out of the
connector on the main PCB.
Note: The antenna cables are not
shown for clarity.
2-26
241XM016.eps
nugget
Replacing Parts
2
3. Remove the scanner flex cable from the PDF 417 PCB assembly.
Scanner
flex cable
PDF 417
PCB assembly
Bottom
cover
241XM055 .eps
4. Remove the PDF 417 PCB assembly.
5. Connect the scanner flex cable to the new PDF 417 PCB assembly.
6. (2415 only) Install the radio card.
a. Compare the connector tabs on the radio card to the connector on the main PCB
to determine which way to insert the card.
b. Slide the radio card into the connector. Firmly press the card into the connector
until it stops.
c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
7. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
Replacing the Scanner Lens or E1022 Scan Window
Because finger oils can dissolve the reflective coating of the plastic mirrors, always
wear finger cots or non-powdered latex gloves when handling optical parts.
To replace the scanner lens or E1022 scan window, you need the following tools:
•
#1 Phillips screwdriver
•
Torque screwdriver
2-27
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
You also need one of the following parts:
•
Scanner lens (P/N 069461-001)
•
E1022 scan window (P/N 072340-001)
To replace the scanner lens or E1022 scan window
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. (2415 only) Remove the radio
card from the main PCB.
Radio
card
Screw
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Retaining
block
b. Slide the radio card out of the
connector on the main PCB.
Note: The antenna cables are not
shown for clarity.
241XM016.eps
3. Remove the scan engine or linear imager assembly.
•
If you are repairing a terminal with a standard scan engine or PDF 417 scan
engine, remove the two screws holding the scan engine assembly in place and
remove the scan engine assembly.
•
If you are repairing a terminal with an E1022 linear imager, remove the four
screws holding the E1022 linear imager assembly in place and remove the
linear imager assembly.
4. Remove the scanner lens or E1022 scan window.
•
If you are replacing a scanner
lens, push the scanner lens
out of the scan engine
bracket.
Scanner
lens
Scan
engine
bracket
241XM026.eps
2-28
nugget
•
Replacing Parts
If you are replacing an E1022
scan window, push the scan
window out of the bottom
cover.
2
E1022 scan
window
Bottom
cover
241XM039.eps
5. Make sure the new scanner lens or scan window is free from fingerprints and
scratches. Install the new scanner lens or scan window.
•
If you are replacing a scanner lens, peel the backing off of the new scanner lens
and place it on the scan engine bracket.
•
If you are replacing an E1022 scan window, peel the backing off of the new
scan window and place it on the bottom cover.
6. If you removed a scan engine assembly in Step 3, install the scan engine assembly.
a. Place the assembly in the bottom
cover. Make sure that the
assembly is firmly seated in the
cover.
Retainers
b. Slide the assembly toward the
top of the cover so that the front
of the assembly slides under the
retainers.
c. Install the two screws that hold
the scan engine assembly in place
and tighten them to 0.565 Nm
(5 in-lb).
241XM025.eps
7. If you removed an E1022 linear imager assembly in Step 3, place the E1022 linear
imager assembly in the bottom cover. Install the four screws that hold the assembly
in place and tighten them to 0.565 Nm (5 in-lb).
2-29
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
8. (2415 only) Install the radio card.
a. Compare the connector tabs on the radio card to the connector on the main PCB
to determine which way to insert the card.
b. Slide the radio card into the connector. Firmly press the card into the connector
until it stops.
c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
9. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
Replacing the Backup Capacitor
To replace the backup capacitor, you need the following tools:
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need the following part:
•
Backup capacitor assembly (P/N 069617-003)
To replace the backup capacitor
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
2. (2415 only) Remove the radio
card from the main PCB.
a. Remove the screw holding the
retaining block in place, and
remove the retaining block.
Radio
card
Screw
Retaining
block
b. Slide the radio card out of the
connector on the main PCB.
Note: The antenna cables are not
shown for clarity.
2-30
241XM016.eps
nugget
Replacing Parts
2
3. If you are repairing a 241X with a PDF 417 scan engine, remove the PDF 417 PCB
assembly from the bottom cover.
Scanner
flex cable
PDF 417
PCB assembly
Bottom
cover
241XM055 .eps
4. Remove the screw holding the radio/memory card support bar in place and remove
the radio/memory card support bar.
Screw
(2 places)
Radio/memory card
support bar
Radio/memory card
support bracket
Backup
capacitor
Bottom
cover
241XM008.eps
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Trakker Antares 241X Hand-Held Terminal Service Manual nugget
5. Remove the screw holding the radio/memory card support bracket in place and
remove the radio/memory card support bracket.
6. Remove the backup capacitor.
7. Install the new backup capacitor. Make sure that the scanner reed switch is properly
seated in the bottom cover.
Scanner
reed switch
Wires
241XM033.eps
8. Install the radio/memory card support bracket and the radio/memory card support
bar, and tighten the screws to 0.565 Nm (5 in-lb). Make sure that the wires are
positioned in the channels under the radio/memory support bar.
9. If you removed the PDF 417 PCB assembly from the bottom cover in Step 3, install
the PDF 417 PCB assembly in the bottom cover.
10. (2415 only) Install the radio card.
a. Compare the connector tabs on the radio card to the connector on the main PCB
to determine which way to insert the card.
b. Slide the radio card into the connector. Firmly press the card into the connector
until it stops.
c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
11. Close the terminal. For help, see “Closing the Terminal” on page 2-36.
2-32
nugget
Replacing Parts
2
Replacing the Bottom Cover
To replace the bottom cover, you need the following tools:
•
#1 Phillips screwdriver
•
Torque screwdriver
You also need the following parts:
•
•
Bottom cover:
•
Standard bottom cover (scan engine or PDF 417 scan engine) (P/N 069456-001)
•
Multi-scanner bottom cover (scan engine, PDF 417 scan engine, or E1022
linear imager):
•
Multi-scanner bottom cover (P/N 072232-001)
•
E1022 scan window (P/N 072340-001)
Scanner safety label:
•
Non-laser safety (P/N 069940-001)
•
Laser safety (P/N 069405-001)
•
Configuration/Serial Number label
•
RF certification label or print on demand set:
•
RM 181 Australia (2415 only) (P/N 069409-002)
•
RM 181 Euro1 (2415 only) (P/N 069412-002)
•
RM 181 France/Mexico (2415 only) (P/N 069414-001)
•
RM 181 Japan (2415 only) (P/N 070057-001)
•
RM 181 US/Canada (2415 only) (P/N 069408-001)
•
RM182 OpenAir, 2126 802.11b, PC24-11-FC/R 802.11b, or 2410 terminal
•
Print On Demand Set (P/N 072691-001)
•
White Ribbon (P/N 591371-001)
To replace the bottom cover
1. Open the terminal. For help, see “Opening the Terminal” on page 2-4.
Make sure you note the configuration on the serial number label on the bottom
cover.
2. Remove the backup capacitor assembly. See Steps 2 through 6 for “Replacing the
Backup Capacitor” on page 2-30.
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Trakker Antares 241X Hand-Held Terminal Service Manual nugget
3. Remove the scan engine or E1022
linear imager assembly.
•
•
For a standard scan engine or
PDF 417 scan engine, remove
the two screws holding the
scan engine assembly in place.
Screw
(2 or 4 places)
Scan engine or
E1022 linear imager
assembly
Antenna
For an E1022 linear imager,
remove the four screws
holding the E1022 linear
imager assembly in place.
241XM028.eps
4. Install the backup capacitor assembly in the new bottom cover. Make sure that the
scanner reed switch is properly seated in the bottom cover.
Scanner
reed switch
Wires
241XM033.eps
5. Replace the radio/memory card support bracket and the radio/memory card support
bar, and tighten the screws to 0.565 Nm (5 in-lb). Make sure that the wires are
positioned in the channels under the radio/memory support bar.
6. If you removed the PDF 417 PCB assembly from the bottom cover, install the PDF
417 PCB assembly in the bottom cover.
2-34
nugget
Replacing Parts
2
7. If you removed a standard scan engine or PDF 417 scan engine in Step 3, install the
scan engine assembly.
a. Place the assembly in the bottom
cover. Make sure the assembly is
firmly seated in the cover.
Retainers
b. Slide the assembly toward the top
of the cover so that the front of
the assembly slides under the
retainers.
c. Install the two screws that hold
the scan engine assembly in place
and tighten them to 0.565 Nm
(5 in-lb).
241XM025.eps
8. If you removed an E1022 linear imager in Step 3, place the E1022 linear imager
assembly in the bottom cover and install the four screws that hold the assembly in
place. Tighten the screws to 0.565 Nm (5 in-lb).
9. (2415 only) Install the radio card.
a. Compare the connector tabs on the radio card to the connector on the main PCB
to determine which way to insert the card.
b. Slide the radio card into the connector. Firmly press the card into the connector
until it stops.
c. Install the retaining block on the main PCB and tighten the screw to 0.226 Nm
(2 in-lb).
10. Attach the appropriate scanner safety label and RF certification label. For 2410
terminals and RM182 OpenAir, 2126 802.11b, and PC24-11-FC/R 802.11b radios,
use standard print on demand practices to print the RF certification label.
Scanner
safety
label
Serial
number
label
RF certification
label
241XM037.eps
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Trakker Antares 241X Hand-Held Terminal Service Manual nugget
11. Use standard print on demand practices to print a serial number label that contains
the information you noted in Step 1, and attach the label to the terminal.
12. Close the terminal. For help, see the next procedure, “Closing the Terminal.”
Closing the Terminal
To close the terminal, you need the following tool:
•
#1 Phillips screwdriver
•
Torque screwdriver
To close the terminal
1. Connect the backup capacitor
assembly cable to the main
PCB.
Scanner
flex cable
Retaining
block
2. Connect the scanner flex cable
to the connector located toward
the top of the main PCB.
The illustration shows the
scanner flex cable attached to
the connector toward the top of
the main PCB. However, if you
have a PDF 417 scan engine or
an E1022 linear imager, connect
the scanner flex cable to the
connector located toward the
bottom of the main PCB.
Battery
contact
opening
Backup capacitor
assembly cable
Main
PCB
241XM027.eps
3. Carefully close the top and bottom covers. Make sure that the cables are not pinched
between the two covers or trapped in the battery contact opening.
4. Install the six Phillips screws in the bottom cover, and make sure you use the two
longest screws to secure the top of the terminal. Tighten the screws to 0.904 Nm
(8 in-lb).
5. Replace the battery pack.
2-36
3
Exploded Views and Spare Parts Lists
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3
39 Exploded Views and Spare Parts Lists
This chapter provides the exploded views and spare parts list for the 2410 and 2415
terminals.
Exploded View
To identify a part, find the part in the exploded view and locate its callout number in the
following spare parts list.
If you are repairing a 241X with a PDF 417 scan engine, see “PDF 417 Scan Engine
Exploded View” on page 3-6. If you are repairing a 241X with an E1022 linear imager,
see “E1022 Linear Imager Exploded View” on page 3-8.
9
7
8
6
Screw
(2 places)
10
5
Screw
(2 places)
Screw
(3 places)
4
Screw
(4 places)
11
12
3
3
14
1
241XM003.eps
3-3
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
39
Spare Parts List
To identify a part, find the callout number in this list and locate the part in the previous
exploded view.
Callout Number
Description
Part Number
1
Display lens
2410 display
2415 display
069423-003
069427-003
Keypad overlay
37-key basic
37-key international
37-key 5250 TE
37-key 3270 TE
37-key VT/ANSI TE
37-key function numeric
37-key international function numeric
37-key VT/ANSI TE function numeric
55-key basic
55-key international
55-key 5250 TE
55-key 3270 TE
55-key VT/ANSI TE
069421-001
069422-001
070279-001
070377-001
069420-001
069836-001
069840-001
069841-001
069417-001
069419-001
069418-001
070376-001
069416-003
Keypad assembly (top cover)
37-key function numeric
37-key large numeric
55-key alphanumeric
069842S-004
069472S-004
069471S-004
4
LCD
071363S-001
5
Display/Beeper flex cable assembly
069705-002
6
Main PCB assembly
2MB
4MB
071589S-002
071588S-002
Radio (2415 only)
802.11 2126 ETSI
802.11 2126 Japan
802.11 2126 Mexico
802.11 2126 U.S./Canada
802.11 PC24-11-FC/R ROTW
802.11 PC24-11-FC/R US/Canada
OpenAir RM181 Australia
OpenAir RM181 Euro1
OpenAir RM181 France/Mexico
OpenAir RM181 Japan
070512S-002
070514S-002
070517S-002
070513S-002
073348S-001
073347S-001
069516S-001
069512S-001
069517S-001
591086-001
2
3
7
3-4
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39 Exploded Views and Spare Parts Lists
3
Spare Parts List (continued)
Callout Number
Description
Part Number
7
Radio (2415 only) (continued)
OpenAir RM181 U.S./Canada
OpenAir RM182 Euro
OpenAir RM182 Israel/Spain
OpenAir RM182 U.S./Canada
069513S-001
071824S-001
071826S-001
071823S-001
Memory card (2410 only)
2MB
4MB
590092-001
590092-002
Scan engine
Standard range
High density
High visibility
Long range
Advanced long range (ALR)
590014S-003
590039S-002
590040S-002
590038S-002
591098S-001
9
Scanner flex cable
069652-001
10
Scanner lens
069461-001
11
Antenna (2415 only)
Micropatch, dual
Micropatch, single
Dipole
590993-001
590995-001
069769-001
12
Backup capacitor assembly
069617-003
13
Bottom cover
Standard bottom cover
Multi-scanner bottom cover
069456-001
072232-001
Main battery
Single cell (1350 mAh)
Dual cell (2700 mAh)
069428-001
069429-001
Clear Orbit label
071228-001
Oracle Ready label
072558-001
Scanner safety labels
Non-laser safety
Laser safety
069940-001
069405-001
RF certification labels
RM 181 Australia (2415 only)
RM 181 Euro1 (2415 only)
RM 181 France/Mexico (2415 only)
RM 181 Japan (2415 only)
RM 181 US/Canada (2415 only)
069409-002
069412-002
069414-001
070057-001
069408-001
7
8
14
3-5
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
39
Spare Parts List (continued)
Callout Number
Description
Part Number
RF certification labels (continued)
2410 terminal, RM182 OpenAir, 2126
802.11b, and PC24-11-FC/R 802.11b
Print On Demand Set
White Ribbon
072691-001
591371-001
PDF 417 Scan Engine Exploded View
This illustration shows the PDF 417 scan engine assembly in relation to the bottom
cover. To identify a part, find the part in the exploded view and locate its callout
number in the following PDF 417 Scan Engine Spare Parts List.
3
Screw
(2 places)
2
4
1
Screw
(3 places)
5
241XM031.eps
3-6
nugget
39 Exploded Views and Spare Parts Lists
3
PDF 417 Scan Engine Spare Parts List
To identify a part, find the callout number in this list and locate the part in the previous
PDF 417 Scan Engine Exploded View.
Callout Number
Description
Part Number
1
PDF 417 PCB assembly
071200S-003
2
Scan engine flex cable
071196-001
3
PDF 417 scan engine
591081S-001
4
Scan window
069461-001
5
Antenna (2415 only)
Micropatch, dual
Micropatch, single
Dipole
590993-001
590995-001
069769-001
3-7
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
39
E1022 Linear Imager Exploded View
This illustration shows the E1022 linear imager assembly. To identify a part, find the
part in the exploded view and locate its callout number in the following E1022 Linear
Imager Spare Parts List.
Screw
(4 places)
1
2
3
4
241XM0004.eps
3-8
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39 Exploded Views and Spare Parts Lists
3
E1022 Linear Imager Spare Parts List
To identify a part, find the callout number in this list and locate the part in the previous
E1022 Linear Imager Exploded View.
Callout Number
Description
1
E1022 linear imager assembly
072612S-001
2
E1022 decode flex cable
072507-001
3
Antenna (2415 only)
Micropatch, dual
Micropatch, single
Dipole
590993-001
590995-001
069769-001
Scan window
072340-001
4
Part Number
3-9
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4
Theory of Operation
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Theory of Operation
4
This appendix contains the theory of operation for the 241X.
Main PCB
The main PCB contains the primary circuitry for the Trakker Antares® terminals. It also
contains the Vadem VG-230, which is a PC/XT compatible processor. The functions of
the main PCB are:
•
Processing keyboard input
•
Processing output data to the liquid crystal display (LCD)
•
Processing decoded bar code data from the scanner interface
•
Processing decoded bar code data from the linear imager interface
•
Providing radio communication interface (2415 only)
•
Providing serial communication or input to devices such as wand scanners using
the COM1 external interface port
The main PCB also provides interfaces to the main battery and backup battery. The DC
power supply provides all necessary voltages to operate the terminal.
Liquid Crystal Display (LCD) Interface
The VG-230 supports the FRAME, LOCLK, M, LCDU(0-3), and SHCLK signals for
the LCD interface. The low battery LED is controlled independently from the ASIC
while the remaining ICON interfaces are controlled from the ASIC using ICON-CLK,
ICON-DATA, and ICON-CS. Discrete signals to the LCD include LCDEN, VPBIAS,
LCD-CTRL, and LCD-ADJ. Backlight Signals are BACKLT-ON and BACKLT-HIGH.
The LCD is powered from VCCBL, which is generated from VBAT, and VCCLCD,
which is switched from VCC230A with the VPLCD signal.
Keyboard Interface
The Vadem VG-230 provides a scanned keyboard interface to the keypad. The keypad
has a SUSPEND/RESUME button that is routed to the VG-230. An EXT interrupt is
created and toggles the processor into a low power mode.
The keypad provides a TRIGGER* interface for the scan button at the top of the
keyboard. The TRIGGER* is processed to enable bar code scanning.
To generate a hard reset and reboot of the terminal
•
Press and hold the _ key until the Good Read LED lights up for longer than 8
seconds.
4-3
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
Scanner Interface
The 241X has two scanner interface options:
•
Standard non-decoded scanner port. The ASIC (U501), in conjunction with PAL
(U101), handles non-decoded scanner communication. Signals include SOS, Video,
ScanEn, LasEn, and Gen-Cntl/AIM.
•
Serial communications port for decoded scanners. The Vadem VG-230 UART
COM1 port interface controls serial communication to and from decoded scanners.
Signals include TX, RX, CTS, and RTS.
The tethered scanner (TETH-SCAN) signal differentiates between internal and external
scanners, and 5 volt VCC power is supplied to either type of scanner.
Lithium-Ion Battery Charger
The external charger in the communications dock provides the charger electronics for
the internal lithium-ion main battery. Electronics are provided to monitor the charge
status and notify the user of battery status. The battery is charged to 3.6 volts.
Lithium-Ion Main Battery
The terminal uses a lithium-ion battery pack. The maximum voltage on the battery pack
is between 3.8 volts and 4.2 volts. The standard usage terminal model, with the
backlight off at 21°C (70°F), will run for more than 7 hours from the 1350 mAh
Intermec battery pack (P/N 069429) and more than 14 hours from the 2700 mAh
Intermec battery pack (P/N 069428).
Backup Power Source
The backup power source can only be replaced by Intermec service technicians. The
backup power source consists of two capacitors connected in parallel. These capacitors
are recharged from the main battery or external DC charger. Specifications on the
capacitors are: 2.5V nominal voltage, 4.7F nominal capacitance. The capacitors are
charged to 2.4V with a maximum charge rate of 10 mA. The capacitors reach full
charge in about 15 minutes.
Light Emitting Diodes (LEDs)
The 241X has five status LEDs located just below the display in a single row. The
Battery LED is amber, and the other LEDs are green.
Microprocessor
The Vadem VG-230 is based on the NEC V30HL 8086 CPU core, which provides
PC/XT compatible core logic. The VG-230 uses a single bus architecture requiring only
one address and one data bus.
4-4
nugget
Theory of Operation
4
Memory Map
Up to 1MB of directly addressable memory space is supported by the V30HL. The
VG-230 provides access to additional memory space through 26 mapping registers.
Each memory mapping register controls a 16K block of memory. The bottom 512K of
the RAM array are always mapped to the base 512K of the 1MB memory space of the
V30HL. The top 32K of the RAM array are always mapped to the CGA BUFFER area
of the 1MB memory space of the V30HL. Finally, the bottom 64K of the heavy access
ROM array are always mapped to the top 64K of the 1MB memory space of the V30HL
or ROM BIOS.
Oscillators
The Vadem VG-230 requires two crystal oscillators. The primary crystal frequency for
the CPU oscillates at 32.215905 MHz and uses a third overtone configuration. The
second crystal oscillates at 32.768 KHz and provides the real time clock frequency. The
32.768 KHz uses a fundamental design with a variable capacitor to achieve the accuracy
setting required.
Flash Memory
The main PCB was designed to support 2MB or 4MB of flash memory. These memory
configurations are supported on the main PCB:
•
2MB—one 16Mbit flash (28F016SA)
•
4MB—two 16Mbit flash (28F016SA)
•
4MB—one 32Mbit flash (DD28F032SA)
The flash memory selected for the main PCB provides very high read/write
performance. The flash memory also features advanced write state machines.
The main PCB supports these additional features:
•
ASIC controlled boot address (BOOT-ADDR) signal for boot block swapping,
allowing the boot block to be reprogrammed and the check sum validated before
the new boot block is used.
•
ASIC controlled write protect (WP*) signal for controlling unwanted writes to the
flash memory.
•
+12V programming voltage flash devices. However, with an alternate stuffing of
components, +5V programming voltage flash devices can be supported.
Static RAM
Two 512K Static RAM (SRAM) devices are used in the main PCB to provide 1MB of
RAM. The SRAM is powered by VCC230A.
241X terminals that were manufactured earlier used pseudo-static RAM in place of
SRAM. With these terminals, when the main PCB is in Suspend mode, the ASIC
generates self-refresh (SELF-REF*) to maintain memory.
4-5
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
PC Card Interface
The VG-230 supports a PC card interface compatible with the PCMCIA version 2.0
standard. Interfaces supported are:
•
I/O cards
•
Up to 64MB of memory
•
Flash memory
•
Execute in place (XIP)
The PC card is powered by VCCRF, which is filtered VCC supply. Reset is an open
collector signal generated from RESOUT* per the PCMCIA specification. The PC card
programming voltage (VPPA) is switched from PS+12V with signal VPPEMA. VPA is
also wire OR’d with VCCRF per the PCMCIA specification.
Beeper Driver
Control signals BEEP0 and BEEP1 are input into PAL (U101) that, in turn, control
BLOUD and BDRIVE. These signals produce a waveform across the beeper located on
the LCD flex cable. BEEP0 and BEEP1 are produced by the ASIC as a result of control
registers in the ASIC. Volumes produced are Off, Quiet, Normal, Loud, and Very Loud.
Sound frequency is controlled by the frequency at which BEEP0 and BEEP1 are
toggled.
ASIC
Terminal specific functionality is implemented in an ASIC. The general block diagram
of the ASIC is shown below. The ASIC implements all digital logic necessary to
implement terminal functionality. A second 8250-compatible UART is implemented to
interface to intelligent input devices and to provide a factory test and debug interface for
software development. The count gathering logic includes buffer counters, a terminal
count interrupt, a DMA transfer on overflow, and initiate count gathering on a
configurable white-to-black or black-to-white transition. The Beep control logic allows
beep duration to be set in hardware. An interrupt sharing multiplexer is provided that
routes multiple interrupts to a single input of the 8259 interrupt controller.
4-6
nugget
Theory of Operation
4
Power Supplies
Source
Description
VBATF
Fused power that is generated from the main battery voltage (VBATMAIN) and
goes out to the 16-pin interface connector.
VCC230A
A DC to DC Step-Up Converter that generates +5V, +5% from the main battery
voltage. It draws its operating current from VBAT and supplies up to 1.5 A. It
powers the Vadem VG-230, ASIC, PSRAM, PIC, switched VCCLCD, and 3finger reset function. The power supply switches between +5V when VPSYS is
active and +3.5V when VPSYS is inactive.
VCC
A +5V, +5% power supply that is switched OFF or ON by VCC230A with
VPSYS. It powers scanner interfaces, flash memory, and scanner LEDs. It also
provides voltage for the PC card interface connector, beeper drive circuit, and
fused VCCEXT.
VCCLCD
A +5V, +5% power supply that is switched OFF or ON from VCC230A by
VPLCD, which is controlled by VG-230. VCCLCD provides power to the LCD.
VCCEXT
This power source goes to the 16-pin interface connector. VCCEXT is connected
to VCC through a fuse. The VCCEXT fuse can be reset.
VCCRF
VCCRF is a +5V, +5% filtered VCC power source for the PC card/radio interface
connector. VCCRF switches ON or OFF with VPSYS.
VPP1, 2
PC card voltage. Supplied by VCC.
Interface Devices
These interface devices are available for the terminal.
External Devices
A 16-position connector (COM-PORT 1) enables the terminal to interface with many
externally connected devices.
This port offers full RS-232 serial communication (RXD, TXD, RTS, CTS) and is fully
controllable within the Serial Port Communications menu. Other input devices such as
wand-emulated based tethered scanners (TETH-VIDEO, TETH-SOS, TETH-LASEN,
TRIGGER, GOODRD) are also supported.
4-7
Trakker Antares 241X Hand-Held Terminal Service Manual nugget
Display
This is a custom display module. The display is a full graphics type, with a matrix of
160 pixels horizontally by 128 pixels vertically, allowing 16 lines of 20 characters per
line to be displayed with an 8 x 8 pixel font. Several font sizes are supported. An ICON
driver IC, DC/DC bias power supply, EL backlight, and EL DC/AC power supply are
provided on the LCD module.
Keyboard
The keyboard scanning electronics provide for an 8x12 matrix of up to 64 regular keys.
The number of keys implemented depends on the keyboard layout and configuration.
The elastomeric keypad provides the operator indication of key travel and tactical
feedback. Pushing a key activates the membrane keypad matrix. The membrane keypad
switch resistance must be less than 300 ohms for a valid key press and greater than 10 k
ohms for a valid open.
PC Card/Radio
The terminals use a PC card interface for additional user memory. User memory
extension is available with Intermec-supplied SRAM PCMCIA cards.
The 2415 can also use the PC card as a radio interface. The radio is connected to the
main circuit board through the PCMCIA connector. There are two types of radios:
4-8
•
Proxim RangeLAN2, 2.4 GHz frequency hopping, spread spectrum radio with a 1.6
Mbps data rate
•
IEEE 802.11b Direct Sequence, Spread Spectrum radio with an 11Mbps data rate,
which is Wi-Fi compliant.
Corporate Headquarters
6001 36th Avenue West
Everett, Washington 98203
U.S.A.
tel 425.348.2600
fax 425.355.9551
www.intermec.com
Trakker Antares 241X Hand-Held Terminal Service Manual
*071796-001*
*071796-001*