Apple 540C manual

Service Source K Po werBook 500 Series PowerBook 520, PowerBook 520c, PowerBook 540, PowerBook 540c[...]

Service Source K Basics Po werBook 500 Series[...]

Basics General Information - 1 General Information The PowerBook 500 Series introduces a number of technology and design innovations to the PowerBook family of computers. The series features a built-in trackpad, intelligent batteries, two battery bays, an optional PCMCIA expansion module, and four displays: monochrome and color FSTN and active- mat[...]

Basics Repair Strategy - 2 Repair Strategy Service the PowerBook 500 Series computers through module exchange and parts replacement. Customers can request on-site service from an Apple Authorized Service Provider Plus (AASP+) Apple Assurance (US only), or request a courier through the Apple Canada Technical Answerline (Canada only). They can also c[...]

Basics Repair Strategy - 3 Large businesses, universities, and K-12 accounts must provide a purchase order on all transactions, including orders placed through the AppleOrder (US only) or ARIS (Canada only) system. USA Ordering US Service Providers not enrolled in AppleOrder may fax their orders to Service Provider Support (512-908- 8125) or mail t[...]

Basics Repair Strategy - 4 Canadian Ordering Canadian Service Providers not enrolled in ARIS may fax their orders to Service Provider Support in Canada (1-800-903-5284). For Canadian inquiries, please call Service Provider Support at 905-513-5782 and select option #3.[...]

Basics Warranty/AppleCare/ARIS - 5 Warranty/AppleCare/ARIS US Only The PowerBook 500 Series computers are covered under the Apple One-Year Limited Warranty. The AppleCare Service Plan is also available for these products. Service Providers are reimbursed for warranty and AppleCare repairs made to these computers. For pricing information, refer to ?[...]

Basics Rear Panel - 6 Rear Panel The illustration below shows the location of ports and connectors on the rear panel of the PowerBook 500 Series.[...]

Basics PowerBook Screw Matrix - 7 PowerBook Screw Matrix Nine different types of screws are used in the PowerBook 500 Series. All are Torx screws and require either a T-8 or T-6 Torx screwdriver. Note: The legend for the screws follows on the next page.[...]

Basics PowerBook Screw Matrix - 8 Legend f or Po werBook 500 Series Screws 1 Feet 2 Hard drive, keyboard, bottom case (middle front), display assembly, floppy drive, daughterboard EMI shield (top edge), inside edge of top case, right side panel 3 Display bezel, display, clutch, DAA 4 Trackpad cable and actuator, daughterboard EMI shield (sides), mo[...]

Basics PowerBook Cable Matrix - 9 PowerBook Cable Matrix For a matrix of cables that work with specific models of the PowerBook family of computers, refer to the PowerBook Cable Matrix in the Hardware/Compatibility Charts tab.[...]

Basics PCMCIA Module Handling - 1 0 PCMCIA Module Handling The PCMCIA (Personal Computer Memory Card International Association) expansion module is an option for the PowerBook 500 Series. The module inserts into the computer’s second (left) battery bay and has two slots that accept a variety of third-party PCMCIA cards. There are three types of P[...]

Basics PCMCIA Module Handling - 1 1 computer will shut down and all RAM contents will be lost. • Eject the PCMCIA module using the lever at the front of the module; eject a PCMCIA card using the PCMCIA Eject control panel or the PCMCIA Quick Eject module in the computer’s Control Strip. • Keep the protective cap that comes with the module and[...]

Basics Battery Information - 12 Battery Information The PowerBook 500 Series computers include one or two nickel-metal-hydride (NiMH) batteries. Each battery provides power for up to 3.5 hours of work time, depending on the battery conservation features employed. A smart processor included in each battery pack indicates the battery’s charge statu[...]

Basics Battery Information - 13 Battery Handling ± W arning: NiMH batteries contain toxic materials. Send undamaged, dead batteries to Apple for recycling—do not discard dead batteries with other waste. If the battery is damaged, do not return it to Apple. Dispose of damaged batteries according to local ordinances. Review battery- handling and d[...]

Basics Battery Information - 14 trunk of a car). • Keep the battery in a cool, dark place; do not store it for longer than 6 months without recharging. • If you are using one battery: completely discharge and then recharge the battery once every 90 days. • If you are using two batteries: swap the left and right batteries every month. • Full[...]

Service Source K Specifications Po werBook 500 Series[...]

Specifications Introduction - 1 Introduction You can also find specifications information for this product in the Spec Database, which you can access in one of three ways: — Launch it directly by double-clicking the Apple Spec Database runtime alias at the top level of the Main Service Source CD. — Select "Apple Spec Database" from th[...]

Specifications Processor - 2 Processor PB 520/520c Motorola 68LC040 microprocessor 50/25 MHz PB 540/540c Motorola 68LC040 microprocessor 66/33 MHz Addressing 32-bit internal registers 32-bit address bus 32-bit data bus[...]

Specifications Memory - 3 Memory RAM 4 MB RAM installed on the daughterboard Expandable to 12 MB with 8 MB Apple RAM expansion card Expandable to 36 MB with third-party RAM expansion card RO M 2 MB PRAM 256 bytes of parameter memory VRAM 512K of static video display memory Clock/Calendar CMOS custom chip with long-life lithium battery[...]

Specifications Disk Storage - 4 Disk Storage Floppy Drive 15 mm high, internal, 1.4 MB Apple SuperDrive Hard Drive 2.5 in. hard drives (160 MB, 240 MB, and 320 MB capacities)[...]

Specifications I/O Interfaces - 5 I/O Interfaces SCSI HDI-30 SCSI port with 1.5 MB/sec. transfer rate Supports up to six external SCSI devices Connect SCSI device to computer with HDI-30 SCSI system cable. A pple Desktop Bus Apple Desktop Bus (ADB) port 200 mA maximum current draw for all ADB devices Serial RS-422 serial port; mini DIN-8 connector [...]

Specifications I/O Interfaces - 6 V ideo Micro DV-14 video-out port; 8 bit, 256 color video output Supports most Macintosh, VGA, and SVGA monitors Ethernet High-speed Ethernet port; Apple AUI connector Processor -Direct Slot 90-pin processor-direct slot (PDS) for PDS devices or optional Personal Computer Memory Card International Association (PCMCI[...]

Specifications I/O Devices - 7 I/O De vices K eyboard Built-in keyboard with 12 function keys 76 keys domestic, 77 keys ISO Two-level tilt adjustment T rackpad Solid-state trackpad Microphone Electret, omnidirectional Output voltage of 4 mV, peak to peak[...]

Specifications Sound and Video - 8 Sound and V ideo Sound Generator Apple sound chip provides 16-bit sound capable of driving stereo headphones or other stereo equipment through the sound jack Built-in stereo speakers PB 520 V ideo Display 9.5-in. (24 cm) diagonal screen Backlit, FSTN grayscale display (16 levels); 640 x 480 pixels PB 520c V ideo D[...]

Specifications Sound and Video - 9 PB 540c V ideo Display 9.5-in. (24 cm) diagonal screen Backlit, active-matrix color display; 640 x 400 pixels at thousands of colors; 640 x 480 pixels at 256 colors[...]

Specifications Electrical - 1 0 Electrical Main Battery One or two nickel-metal-hydride (NiMH) batteries Up to 3.5 hours of usage per battery before recharging Recharge time: 2 hours in shut down or sleep mode, 4 hours while computer is running Po wer Adapter 110–240 VAC line voltage 40 W, 50–60 Hz[...]

Specifications Physical - 1 1 Physical Dimensions Height 2.25 in. (5.7 cm) Width 11.5 in. (29.2 cm) Depth 9.65 in. (24.5 cm) W eight PB 520/520c 6.4 lb. (2.9 kg) with one battery PB 540/540c 7.3 lb. (3.3 kg) with two batteries[...]

Specifications Environmental - 12 En vironmental Operating T emperature 50–104°F (10–40°C) Storage T emperature -13 to 140°F (-25 to 60°C) Relative Humidity 20–80% noncondensing Operating Altitude 0–10,000 ft. (0–3048 m) Storage Altitude 0–15,000 ft. (0–4572 m)[...]

Specifications Other - 1 3 Other Internal Modem Sends and receives data at 19.2 bps; sends and receives faxes at 14.4 bps SCSI Adapter Enables connection between PowerBook computer and desktop Macintosh (PowerBook appears as a hard drive on the desktop) PCMCIA Module Enables use of two Type I or II PCMCIA cards or one Type III card[...]

Service Source K Troubleshooting PowerBook 500 Series[...]

Troubleshooting General/ - 1 General The Symptom Charts included in this chapter will help you diagnose specific symptoms related to your product. Because cures are listed on the charts in the order of most likely solution, try the first cure first. Verify whether or not the product continues to exhibit the symptom. If the symptom persists, try the[...]

Troubleshooting Symptom Charts/ Startup - 2 Symptom Charts Startup RAM failure occurs (eight-tone error chord sounds after startup chord) 1 Reseat RAM expansion card and check connection. 2 Replace RAM expansion card. 3 Replace daughterboard. 4 Replace motherboard. Hardware failure occurs (four-tone error chord sounds after startup chord) 1 Disconn[...]

Troubleshooting Symptom Charts/ Power - 3 Power Screen is blank; computer doesn’t respond 1 Restart computer. 2 Connect power adapter and restart computer in 3–4 minutes. 3 Try known-good, charged main battery. 4 Check all interconnect board, daughterboard, and motherboard connections. 5 Reset the power manager. 6 Test fuse on motherboard to ma[...]

Troubleshooting Symptom Charts/ Power (Continued) - 4 Power (Continued) After you remove main battery, some Control Panel settings are different 1 Check cables. 2 Replace backup battery. 3 Replace interconnect board. 4 Replace daughterboard. 5 Replace motherboard. Power adapter is plugged in, but Control Strip doesn’t indicate adapter is connecte[...]

Troubleshooting Symptom Charts/ Power (Continued) - 5 Power (Continued) Low-power warning appears 1 Recharge battery or attach power adapter. 2 Verify that peripherals are low-power. 3 Reduce use of floppy or hard drive, modem, sound, backlight, or other power-consuming devices, or connect power adapter. 4 Try known-good, charged main battery. 5 Tr[...]

Troubleshooting Symptom Charts/ Power (Continued) - 6 Power (Continued) Computer won’t power up 1 Restart computer. 2 Connect power adapter and restart computer in 3–4 minutes. 3 Try known-good power adapter. Verify power adapter tip is not chipped or cracked. 4 Try known-good, charged main battery. 5 Replace fuse on motherboard. 6 Replace moth[...]

Troubleshooting Symptom Charts/ Video - 7 Video Pixel never comes on or is always on 1 PowerBook 540c, color active matrix display only: Replace display (CPRC/ international repairers only) or return computer to Apple. 2 PowerBook 540: If there are more than five voids (pixels that are always white), or two or more voids within one inch of each oth[...]

Troubleshooting Symptom Charts/ Video (Continued) - 8 Video (Continued) Display is very light or totally white 1 Adjust screen contrast and brightness settings. 2 Verify cable, inverter board, interconnect board, daughterboard, and motherboard connections. 3 Replace inverter board. 4 Replace interconnect board. 5 Replace interconnect-to-display cab[...]

Troubleshooting Symptom Charts/ Video (Continued) - 9 Video (Continued) Backlight doesn’t operate 1 Verify that backlight cable connection is secure. 2 Check cable, inverter board, interconnect board, daughterboard, and motherboard connections. 3 Verify that cables are not pinched or severed. 4 Replace inverter board. 5 Replace interconnect-to-in[...]

Troubleshooting Symptom Charts/ Video (Continued) - 1 0 Video (Continued) No display, but computer appears to operate correctly 1 Press any key to wake computer from system sleep. 2 Adjust screen contrast and brightness settings. 3 Verify cable, inverter board, trackpad, keyboard, inter- connect board, daughterboard, and motherboard connections. 4 [...]

Troubleshooting Symptom Charts/ Floppy Drive - 11 Floppy Drive Audio and video present, but internal floppy drive does not operate 1 Try known-good floppy disk. 2 Check floppy drive cable connection. 3 Replace floppy drive cable. 4 Replace floppy drive. 5 Replace motherboard. Disk ejects while booting; display shows Mac icon with blinking X 1 Try k[...]

Troubleshooting Symptom Charts/ Floppy Drive (Continued) - 1 2 Floppy Drive (Continued) Disk does not eject 1 Switch off system and hold trackpad button down while you switch system on. 2 Eject disk manually by carefully inserting opened paper clip into hole near floppy drive slot. 3 If PowerBook serial number is between FC410 and FC414 or between [...]

Troubleshooting Symptom Charts/ Floppy Drive (Continued) - 1 3 Floppy Drive (Continued) Disk initialization fails 1 Try known-good floppy disk. 2 Check floppy drive cable connection. 3 Replace floppy drive cable. 4 Replace floppy drive. Read/write/copy error 1 Try known-good floppy disk. 2 Check floppy drive cable connection. 3 Try application disk[...]

Troubleshooting Symptom Charts/ Hard Drive - 14 Hard Drive Internal hard drive does not operate 1 Make sure power adapter is connected. 2 Disconnect external SCSI devices. 3 Check hard drive cable connection. 4 Use HD SC Setup to reinitialize drive. 5 Replace hard drive cable. 6 Replace hard drive. 7 Replace motherboard.[...]

Troubleshooting Symptom Charts/ Peripheral - 15 Peripheral After you connect external SCSI device, computer does not boot 1 Switch on external SCSI device before starting computer. 2 Check cable connections. 3 Verify that SCSI chain is terminated correctly. 4 Verify that SCSI select switch setting on external device is unique. 5 Verify operation of[...]

Troubleshooting Symptom Charts/ Peripheral (Continued) - 1 6 Peripheral (Continued) Cursor does not move when you are using trackpad 1 Reset the power manager. 2 Check trackpad connections. 3 Check interconnect board, keyboard, and motherboard connections. 4 Connect low-power mouse and try to move cursor. If cursor moves, try using trackpad and key[...]

Troubleshooting Symptom Charts/ Peripheral (Continued) - 1 7 Peripheral (Continued) Cursor intermittently does not move or moves erratically 1 Reset the power manager. 2 Clean trackpad surface. 3 Check trackpad connections. 4 Replace trackpad. 5 Replace keyboard. 6 Replace interconnect board. 7 Replace motherboard. Cursor does not move when you are[...]

Troubleshooting Symptom Charts/ Peripheral (Continued) - 1 8 Peripheral (Continued) Cursor moves, but clicking trackpad button has no effect 1 Reset the power manager. 2 Check trackpad connections. 3 Check interconnect board, keyboard, and motherboard connections. 4 Replace trackpad. 5 Replace keyboard. 6 Replace interconnect board. 7 Replace mothe[...]

Troubleshooting Symptom Charts/ Peripheral (Continued) - 1 9 Peripheral (Continued) Known-good direct- connect printer does not print 1 Verify that System is 7.1.1 or later. 2 Verify that Chooser and Control Panel settings are correct. 3 Check cables. 4 Replace printer cable. 5 Try known-good printer. 6 Replace daughterboard. 7 Replace motherboard.[...]

Troubleshooting Symptom Charts/ Peripheral (Continued) - 2 0 Peripheral (Continued) Known-good network printer does not print 1 Verify that System is 7.1.1 or later. 2 Verify that Chooser and Control Panel settings are correct. 3 Check cables. 4 Replace printer cable. 5 Try known-good printer. If printer works, troubleshoot network. 6 Replace daugh[...]

Troubleshooting Symptom Charts/ Peripheral (Continued) - 2 1 Peripheral (Continued) Device connected to external modem port doesn’t work 1 Verify that External Modem is selected in CDEV. 2 Verify that System is 7.1.1 or later. 3 Check cables. 4 Test device with known-good computer. 5 Replace daughterboard. 6 Replace motherboard. I/O devices are u[...]

Troubleshooting Symptom Charts/ Internal Modem - 22 Internal Modem Internal modem options do not appear in CDEV 1 Verify that System is 7.1.1 or later. 2 Reseat modem card. 3 Replace modem card. 4 Replace motherboard. Modem does not respond properly to AT command set instructions 1 Verify that baud rate and data format settings of communications ap[...]

Troubleshooting Symptom Charts/ Internal Modem (Continued) - 2 3 Internal Modem (Continued) Strange mix of characters appears on screen 1 Verify that baud rate and data format settings of communications application are compatible with internal modem and remote modem. 2 Check phone cord connection and operation. 3 Verify that System is 7.1.1 or late[...]

Troubleshooting Symptom Charts/ Internal Modem (Continued) - 2 4 Internal Modem (Continued) Modem does not respond to incoming call 1 If computer is in sleep mode, verify that Wake On Ring option in CDEV is selected. 2 Check phone cord connection and operation. 3 Replace modem card. 4 Replace motherboard. Modem has no sound output 1 Verify that Con[...]

Troubleshooting Symptom Charts/ Internal Modem (Continued) - 2 5 Internal Modem (Continued) Modem connects but does not communicate with remote modem 1 Verify that remote modem needs error correction (error correction is internal modem default). 2 If remote modem does not need error correction, type AT &Q0 to disable error correction.[...]

Troubleshooting Symptom Charts/ Internal Modem (Continued) - 2 6 Internal Modem (Continued) You are using System 7.5 and two messages appear: “This Macintosh may not have been shut down properly” and “Incoming fax cannot be received because internal modem could not be identified...” Following the messages, the system “hangs.” 1 Restart [...]

Troubleshooting Symptom Charts/ PCMCIA Module - 2 7 PCMCIA Module PCMCIA card won’t eject 1 Make sure PCMCIA slot is not blocked. 2 Insert straightened paper clip into hole next to slot. PCMCIA card is inserted but doesn’t appear on desktop If “defective card” or “unrecognizable card” appears in place of card name in PCMCIA Eject contro[...]

Troubleshooting Symptom Charts/ Miscellaneous - 28 Miscellaneous Screen goes blank and computer shuts down every few minutes Computer is going into system sleep to conserve battery power. Adjust sleep delays in Control Panel or connect power adapter. Application seems to run slower after a few seconds Computer is switching to system rest. If system[...]

Troubleshooting Symptom Charts/ Miscellaneous (Continued) - 2 9 Miscellaneous (Continued) No sound from speaker 1 Verify that volume setting in Control Panel is above 0. 2 Verify that no external speaker is plugged in. 3 Check connections of speaker to interconnect board and interconnect board to motherboard. 4 Replace interconnect board. 5 Replace[...]

Troubleshooting PowerBook 500 Series Startup Problems Flowchart/ PowerBook 500 Series Startup Problems Flowchart START Reset the power manager. Press the power button to begin the startup sequence. Do the startup tones sound? No Yes Is the startup tone normal? Yes Does any video appear? No Yes See Startup Problems in the Symptom/Cure Chart. No 1. C[...]

Troubleshooting PowerBook 500 Series Startup Problems Flowchart/ PowerBook PowerBook 500 Series Startup Problems Flowchart (continued) 1. Replace the daughterboard. 2. Replace the motherboard. END Does the desktop appear? No Yes No Yes No Do the trackball and keyboard function? 1. Reset the power manager. 2. Check the cables. 3. Replace the trackba[...]

Service Source K T ake Apart Po werBook 500 Series[...]

Take Apart Battery/PCMCIA Module - 1 Battery/PCMCIA Module Before you begin, discon- nect the power adapter. Note: This procedure covers removal of the main battery, second battery or PCMCIA expansion module, and battery contact cover. Important: Before removing the battery, use the Macintosh Shut Down command. Otherwise, all RAM contents will be l[...]

Take Apart Battery/PCMCIA Module - 2 Caution: The PowerBook 500 Series contains devices that are very susceptible to ESD damage. To prevent damage, wear a grounding wriststrap. Review the ESD precautions in Bulletins/ Safety. 1 Slide the release button toward you and pull out the main battery on the right side of the computer. 2 Repeat the procedur[...]

Take Apart Battery/PCMCIA Module - 3 3 If you are replacing the battery contact cover, press in on the sides of the cover and slide it off the main battery. Battery Contact Cover[...]

Take Apart Battery/PCMCIA Module - 4 4 Note: Complete the following step if a PCMCIA expansion module is installed in the computer. Using the tip of your finger, rotate the lever at the front of the PCMCIA module toward you. 5 Note: You may have to use some force when pulling the module out of the computer. Holding onto the lever, pull the PCMCIA m[...]

Take Apart Keyboard - 5 Keyboard Before you begin, remove the battery/PCMCIA module. Keyboard[...]

Take Apart Keyboard - 6 1 Using a T-8 torx driver, remove the middle two bottom housing screws.[...]

Take Apart Keyboard - 7 2 Using a small flat-blade screwdriver, lift the front of the keyboard and pull it forward slightly. 3 Rotate the keyboard so that it is perpendicular to the top cover. Keyboard[...]

Take Apart Keyboard - 8 4 Release the locking tabs on the two keyboard cable connectors and disconnect the cables from the motherboard. 5 Lift off the keyboard. Locking Tabs[...]

Take Apart Hard Drive - 9 Hard Drive Before you begin, remove the following: • Battery/PCMCIA module • Keyboard Hard Drive[...]

Take Apart Hard Drive - 10 1 Using a T-8 torx driver, remove the hard drive mounting screw.[...]

Take Apart Hard Drive - 11 2 Using a small flat-blade screwdriver, pry up the front of the hard drive and slide it forward 1/2 inch. 3 Note: Use a rocking motion to disconnect the hard drive cable from the hard drive. Lift the drive partway out of the unit and disconnect the hard drive cable. 4 Remove the hard drive. Hard Drive Hard Drive Cable[...]

Take Apart Hard Drive - 12 5 If you are replacing the hard drive, remove the four screws and remove the hard drive bracket and insulator. Replacement Note: Reinstall the hard drive bracket and insulator on the replacement hard drive. Insulator Bracket[...]

Take Apart Clutch Covers - 1 3 Clutch Covers Before you begin, remove the battery/PCMCIA module. Clutch Cover Clutch Cover[...]

Take Apart Clutch Covers - 1 4 1 Open the unit and rotate the display assembly as far back as it will go. 2 Using a flat-blade screwdriver and your fingers, press in on both sides of the wide end of the right clutch cover and release the two front latches. 3 Rotate the clutch cover up, release the third latch, and remove the cover. 4 Repeat for the[...]

Take Apart Clutch Covers - 1 5 Replacement Caution : Be careful not to pinch or rip the display cable when you replace the right clutch cover.[...]

Take Apart Display Access Cover - 1 6 Display Access Cover Before you begin, remove the battery/PCMCIA module. Display Access Cover[...]

Take Apart Display Access Cover - 1 7 1 Open the unit and rotate the display assembly as far back as it will go. 2 Using a small flat-blade screwdriver, pry up the display access cover at the three slots in the front of the cover. 3 Remove the display access cover.[...]

Take Apart Display Assembly - 1 8 Display Assembly Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover Display Assembly[...]

Take Apart Display Assembly - 1 9 Caution: Support the display assembly from beneath before removing it. 1 Open the unit and rotate the display assembly as far back as it will go. 2 Disconnect the interconnect-to-logic- board cable. 3 Using a T-8 torx driver, remove the two display mounting screws. 4 Slide the display assembly to the left so that t[...]

Take Apart Display Assembly - 20 interconnect-to-logic- board cable. 5 Remove the display assembly.[...]

Take Apart Center Base Cover - 2 1 Center Base Cover Before you begin, remove the following: • Battery/PCMCIA module • Keyboard Center Base Cover[...]

Take Apart Center Base Cover - 2 2 1 Using a T-8 torx driver, remove the two rear panel screws. Replacement Caution: When replacing the rear panel screws, be sure to install the right screw first (the screw nearest the SCSI port).[...]

Take Apart Center Base Cover - 2 3 2 Pull the center base cover forward slightly and slide it 1/2 inch to the right to release the two screw carriers. 3 Remove the center base cover. Screw Carrier[...]

Take Apart Floppy Drive - 24 Floppy Drive Before you begin, remove the following: • Battery/PCMCIA module • Keyboard • Center base cover Floppy Drive[...]

Take Apart Floppy Drive - 25 1 Using a T-8 torx driver, remove the two floppy drive screws.[...]

Take Apart Floppy Drive - 26 2 Using a small flat-blade screwdriver, pry up the cable end of the floppy drive and slide the drive 1/2 inch to the left. 3 Slide the drive forward slightly and lift it partway out of the unit. 4 Disconnect the floppy drive cable from the motherboard and remove the drive. Floppy Drive Cable[...]

Take Apart Floppy Drive - 27 Replacement Caution: Before disconnecting the floppy drive cable from the drive, note the cable folds and the correct orientation of the cable connection. Because the cable connector is not keyed, the floppy drive cable could be reinserted upside down. Replacement Caution: When you reinstall the floppy drive, make sure [...]

Take Apart Floppy Drive - 28 5 If you are replacing the floppy drive or floppy drive cable, release the locking tabs and disconnect the cable from the drive. Locking Tab Floppy Drive Cable[...]

Take Apart Floppy Drive - 29 6 If you are replacing the floppy drive, remove the two right bracket screws and remove the right bracket. 7 Remove the two left bracket screws and remove the left bracket.[...]

Take Apart Floppy Drive - 30 Replacement Note: Reinstall the floppy drive brackets and floppy drive cable on the replacement floppy drive. Use the following procedure for the brackets: • Start the screws in the right bracket. • Push the front of the bracket toward the top of the floppy drive. • Hold the bracket in this position and retighten [...]

Take Apart Floppy Drive - 31 Replacement Caution: If the brackets are not pushed toward the top of the floppy drive, the floppy disk may not eject properly.[...]

Take Apart Daughterboard EMI Shield - 3 2 Daughterboard EMI Shield Before you begin, remove the following: • Battery/PCMCIA module • Keyboard • Center base cover Daughterboard EMI Shield[...]

Take Apart Daughterboard EMI Shield - 3 3 1 Remove the three mounting screws. 2 Using a small flat-blade screwdriver, pry up and remove the daughterboard EMI shield. Replacement Caution: Make sure all the tabs on the sides of the shield fit inside the daughterboard guide. Daughterboard EMI Shield[...]

Take Apart Daughterboard - 3 4 Daughterboard Before you begin, remove the following: • Battery/PCMCIA module • Keyboard • Center base cover • Daughterboard EMI shield • RAM card (if installed) • Modem card (if installed) Daughterboard[...]

Take Apart Daughterboard - 3 5 Note: To remove the daughterboard, you will need to adapt an IC extractor so that it has a wide grip. 1 Grasp an IC extractor by the legs and pull outward.[...]

Take Apart Daughterboard - 3 6 2 Remove the plastic retainer bar. 3 Note: The daughterboard is connected to the motherboard below the RAM card connector. Caution: You may have to use some force to disconnect the daughter- board. Use an IC extractor, as illustrated. Do not pry up the board with a screwdriver. Place the legs of the IC extractor in th[...]

Take Apart Top Case - 3 7 Top Case Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive Top Case[...]

Take Apart Top Case - 3 8 1 Rotate the feet to the up position. 2 Using a T-8 torx driver, remove the screw located under each foot. 3 Remove the four screws at the front edge of the bottom case. Small Screw Small Screw[...]

Take Apart Top Case - 3 9 4 Remove the remaining screw on the inside top edge of the case.[...]

Take Apart Top Case - 4 0 5 Caution: The top case is connected to the motherboard by the trackpad cable. Be careful not to lift the top case too far off the unit or you may damage the cable. Carefully lift and rotate the top case toward you and disconnect the trackpad cable from the motherboard. Trackpad Cable Trackpad Cable Connector[...]

Take Apart Top Case - 4 1 6 Remove the interconnect-to-logic board cable from the opening for the right clutch. 7 Remove the top case. Replacement Note: Before securing the top case to the bottom case, thread the interconnect-to-logic board cable through the opening for the right clutch. Form a loop around the EMI clip by wrapping the cable from be[...]

Take Apart Fuse - 4 2 Fuse Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Top case Fuse[...]

Take Apart Fuse - 4 3 Using a small flat-blade screwdriver, pry up and remove the fuse. Fuse[...]

Take Apart Interconnect-to-Logic-Bd. Cable - 4 4 Interconnect-to- Logic-Bd. Cable Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Top case Interconnect-to- Logic-Board Cable[...]

Take Apart Interconnect-to-Logic-Bd. Cable - 4 5 Caution: Before discon- necting the interconnect- to-logic-board cable, note the correct orientation of the cable connection. Because the connector is not keyed, the cable could be reinserted upside down. Disconnect the interconnect-to-logic- board cable from the motherboard and remove the cable. Int[...]

Take Apart Side Panels - 46 Side Panels Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Top case Right Side Panel Left Side Panel[...]

Take Apart Side Panels - 47 1 Using a T-8 torx driver, remove the right side- panel mounting screw. 2 Lift the panel slightly, slide it back, and remove it from the CPU stiffener. 3 Using a T-8 torx driver, remove the three left side-panel mounting screws. 4 Slide the panel to the left and remove it from the CPU stiffener.[...]

Take Apart CPU Stiffener - 48 CPU Stiffener Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Daughterboard EMI shield • Top case • Interconnect-to-logic- bd. cable CPU Stiffener[...]

Take Apart CPU Stiffener - 49 Note: In this take-apart procedure, the CPU stiffener is removed with the side panels attached. This procedure also explains how to remove the panels from the stiffener. 1 Unlatch the left side panel from the back panel. Left Side Panel Latch[...]

Take Apart CPU Stiffener - 50 2 Rotate the feet to the up position. 3 Lift the CPU stiffener straight off the unit. Stiffener CPU[...]

Take Apart CPU Stiffener - 51 Note: If you are replacing the CPU stiffener, remove the side panels. 4 Using a T-8 torx driver, remove the right side- panel screw. 5 Lift the panel slightly, slide it back, and remove it from the CPU stiffener. 6 Using a T-8 torx driver, remove the three left side-panel screws. 7 Slide the panel to the left and remov[...]

Take Apart CPU Stiffener - 52 Replacement Caution: Make sure both EMI clips fold on top of the clutch pegs. If the right clip accidentally folds backward and touches the pins for the power connector, the contact could short out the motherboard. EMI Clip Clutch Peg[...]

Take Apart Motherboard - 5 3 Motherboard Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Daughterboard EMI shield • Top case • Interconnect-to-logic- bd. cable • CPU stiffener • DAA card (i[...]

Take Apart Motherboard - 5 4 1 Remove the motherboard mounting screw and standoff. 2 Carefully pry the motherboard from the positioning peg located below the standoff. 3 Slide the board forward 1/4 inch. 4 Caution: In lifting the motherboard, be careful that the sound-in and sound-out ports clear the openings in the rear panel. Lift off the motherb[...]

Take Apart Motherboard - 5 5 5 If you are replacing the motherboard, discon- nect the RAM card (if installed), daughter- board, and modem card (if installed). Daughterboard[...]

Take Apart Motherboard - 5 6 Replacement Note: Make sure the front of the motherboard fits securely below the positioning peg on the bottom case. Positioning Peg[...]

Take Apart Hard Drive Cable - 5 7 Hard Drive Cable Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Daughterboard EMI shield • Top case • Interconnect-to-logic- bd. cable • CPU stiffener • M[...]

Take Apart Hard Drive Cable - 5 8 1 Turn over the motherboard. 2 Disconnect the hard drive cable from the motherboard. Hard Drive Cable[...]

Take Apart Rear Door - 5 9 Rear Door No preliminary steps are required. Rear Door[...]

Take Apart Rear Door - 6 0 1 Open the rear door. 2 Carefully bend the door so that the middle bows downward. 3 Unhinge the bottom door pegs and remove the rear door. Door Peg Door Peg[...]

Take Apart Bottom Case - 6 1 Bottom Case To remove the bottom case, remove the following: • Battery/PCMCIA module • Rear door • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Daughterboard EMI shield • Top case • Interconnect-to-logic- bd. cable • Side p[...]

Take Apart Bottom Case - 6 2 • CPU stiffener • Motherboard[...]

Take Apart Mi crophone Assembly - 6 3 Microphone Assembly Before you begin, remove the following: • Battery/PCMCIA module • Display access cover Microphone Assembly[...]

Take Apart Mi crophone Assembly - 6 4 1 Carefully disconnect the microphone cable from the interconnect board. 2 Using a small flat-blade screwdriver, pry up and remove the microphone assembly. Microphone Cable Microphone Assembly[...]

Take Apart Backup Battery - 65 Backup Battery Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Top case Backup Battery[...]

Take Apart Backup Battery - 66 1 Using a small flat-blade screwdriver, pry up and remove the backup battery cover. Backup Battery Cover[...]

Take Apart Backup Battery - 67 2 Carefully disconnect the backup battery cable. 3 Remove the cable from the cable guides. 4 Pry up and remove the backup battery and cable. Backup Battery Cable Connector Backup Battery Cable Cable Guides[...]

Take Apart Trackpad Assembly - 6 8 Trackpad Assembly Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Top case Trackpad Assembly[...]

Take Apart Trackpad Assembly - 6 9 1 Disconnect the backup battery cable. 2 Using a T-8 torx driver, remove the front two mounting screws. Backup Battery Cable Connector[...]

Take Apart Trackpad Assembly - 7 0 3 Note: The trackpad cable assembly includes the display actuator switch and the trackpad button. Disconnect the trackpad cable assembly and remove it from the unit. Replacement Note: Recon- nect the backup battery cable before reconnecting the trackpad cable assembly. Replacement Note: Before securing the two scr[...]

Take Apart Trackpad Assembly - 7 1 4 Using a T-8 torx driver, remove the remaining two mounting screws. 5 Pry up and remove the trackpad actuator assembly. Trackpad Actuator Assembly[...]

Take Apart Trackpad Assembly - 7 2 6 With your fingers, push up from underneath the trackpad logic board and remove it from the top case. Trackpad Logic Board[...]

Take Apart Display Bezel Assembly - 7 3 Display Bezel Assembly Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly Display Bezel Assembly[...]

Take Apart Display Bezel Assembly - 7 4 1 Remove the microphone from the plastic retainer. 2 Disconnect the speaker cable from the interconnect board. 3 Remove the bottom two bezel mounting screws. Speaker Cable Microphone[...]

Take Apart Display Bezel Assembly - 7 5 4 Pry off the two rubber bumpers. 5 Remove the top two bezel mounting screws. Rubber Bumper[...]

Take Apart Display Bezel Assembly - 7 6 6 Note: Two hooks on each side of the bezel secure it to the rear housing. Pull the display bezel forward and lift it off the rear housing. Display Bezel[...]

Take Apart Display - 77 Display Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Display bezel assembly Note: The PowerBook 540 and 540c display modules are available only to international and CPRC service providers. Display[...]

Take Apart Display - 78 1 Remove the four mounting screws. 2 Disconnect the backlight cable from the inverter board. 3 Disconnect the interconnect-to- display cable from the interconnect board. 4 Lift the display from the rear housing. Interconnect-to- Display Cable Back- light Cable[...]

Take Apart Display - 79 5 Note: Return the PowerBook 540c display with the interconnect- to-display cable attached. Return the PowerBook 520, 520c, and 540 without the cable. If you are replacing the PowerBook 520, 520c, or 540 display, discon- nect and remove the interconnect-to- display cable from the back of the display. Connector Interconnect-t[...]

Take Apart Inverter Board - 80 Inverter Board Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Display bezel assembly Inverter Board[...]

Take Apart Inverter Board - 81 1 Remove the two mounting screws. 2 Disconnect the interconnect-to- inverter cable and the backlight cable. 3 Remove the inverter board. Interconnect-to- Inverter Cable Backlight Cable[...]

Take Apart Interconnect Board - 8 2 Interconnect Board Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Display bezel assembly Interconnect Board[...]

Take Apart Interconnect Board - 8 3 1 Disconnect the interconnect-to- display cable and the interconnect-to- inverter cable. 2 Remove the two mounting screws. 3 Remove the interconnect board. Interconnect- to-Display Cable Interconnect-to- Inverter Cable[...]

Take Apart Interconnect-to-Inverter Cable - 84 Interconnect-to- Inverter Cable Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Display bezel assembly • Display Interconnect-to- Inverter Cable[...]

Take Apart Interconnect-to-Inverter Cable - 85 1 Disconnect the interconnect-to- inverter cable from the interconnect and inverter boards. 2 Remove the cable. Interconnect-to- Inverter Cable Interconnect Inverter Board Board[...]

Take Apart Interconnect-to-Display Cable - 86 Interconnect-to- Display Cable Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Display bezel assembly • Display Interconnect-to-Display Cable[...]

Take Apart Interconnect-to-Display Cable - 87 1 Disconnect the interconnect-to- display cable from the back of the display. 2 Remove the cable. Interconnect-to-Display Cable Connector[...]

Take Apart Clutches - 8 8 Clutches Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Display bezel assembly Clutch Clutch[...]

Take Apart Clutches - 8 9 1 Remove the mounting screw for the right clutch and remove the clutch. 2 Repeat for the left clutch.[...]

Take Apart Display Rear Housing - 9 0 Display Rear Housing To remove the rear housing, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Display bezel assembly • Display • Inverter board • Interconnect board • Interconnect-to- inverter cable • Clutches • Display EMI shiel[...]

Service Source K Upgrades Po werBook 500 Series[...]

Upgrades RAM Card - 1 RAM Card Before you begin, remove the following: • Battery/PCMCIA module • Keyboard • Center base cover • Daughterboard EMI shield Caution: Handle the RAM expansion card by the edges only. Do not touch any components on the card. Note: The RAM card is a PowerBook 500 option. This procedure explains how to install the c[...]

Upgrades RAM Card - 2 1 Remove the plastic retainer bar. 2 Caution: An incorrectly installed RAM card could damage the daughter- board. Note that the expansion connector and the RAM card are keyed for proper installation. Do not defeat the key by forcing the card into the connector. Caution: When installing the card, press down on the edge directly[...]

Upgrades RAM Card - 3 not to apply pressure to any components or you may permanently damage the card. Place the edge of the RAM card in the two guides. Using the RAM card alignment tool for correct positioning, connect the card to the expansion connector on the daughterboard. RAM Card Expansion Connector RAM Card Guides[...]

Upgrades RAM Card - 4 Note: To verify that the upgrade is successful, check the Total Memory message (for systems with virtual memory switched off) or the Built-in Memory message (for systems with virtual memory switched on). The memory size should be 4 MB of soldered RAM plus the RAM on the expansion card. If the memory size is incorrect, replace [...]

Upgrades Modem and DAA Cards - 5 Modem and DAA Cards Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly • Keyboard • Hard drive • Center base cover • Floppy drive • Daughterboard EMI shield • Top case • Interconnect-to-logic- board cable Modem Card DAA Card[...]

Upgrades Modem and DAA Cards - 6 • CPU stiffener • RAM card (if installed) Note: The modem is a PowerBook 500 option. This procedure explains how to install the modem and DAA cards and also includes special instructions on how to remove the modem.[...]

Upgrades Modem and DAA Cards - 7 1 Slide the modem card under the RAM card guides and connect the modem card to the motherboard. 2 Pull up and remove the modem cap. Modem Cap Modem Card[...]

Upgrades Modem and DAA Cards - 8 3 Install the modem port frame on the DAA card. 4 Note: The connector for the DAA card is on the underside of the right end of the card. Connect the DAA card to the motherboard. 5 Install the DAA mounting screw. Modem Card with Modem Port Frame[...]

Upgrades Modem and DAA Cards - 9 6 Note: The following page explains how to remove the modem card. To remove the card, you will need to adapt an IC extractor so that it has a wide grip. Grasp an IC extractor by the legs and pull outward.[...]

Upgrades Modem and DAA Cards - 1 0 7 To remove the modem card, place the legs of the IC extractor in the notches at the end of the board and pull up. Notch Notch[...]

Upgrades PCMCIA Module Upgrade - 1 1 PCMCIA Module Upgrade Before you begin, remove the second (left) battery. Important: Before removing the battery or inserting the PCMCIA expansion module into the computer, use the Macintosh Shut Down command. Otherwise, the computer will shut down automatically and all RAM contents will be lost. Note: The PCMCI[...]

Upgrades PCMCIA Module Upgrade - 1 2 PowerBook 500 option. The module comes with a protec- tive cap and PCMCIA driver software. 1 Note: You will feel some resistance when you insert the PCMCIA expansion module into the computer. Continue to press the module in until it is firmly seated. Insert the PCMCIA expansion module into the left battery bay. [...]

Upgrades PCMCIA Module Upgrade - 1 3 2 Note: Refer to the “PCMCIA Expansion Module User’s Guide” for directions on how to install the module software. Install the PCMCIA expansion module software. Note: Refer to “Battery/ PCMCIA Module” in Take Apart for directions on how to eject the module from the computer.[...]

Upgrades PB 540c Upgrade - 1 4 PB 540c Upgrade Before you begin, remove the following: • Battery/PCMCIA module • Clutch covers • Display access cover • Display assembly Note: This information is for reference purposes only; the Finished Goods upgrade is no longer available. PB 540c Display[...]

Upgrades PB 540c Upgrade - 1 5 Note: A PowerBook 540c upgrade kit upgrades the display of a PowerBook 520, PowerBook 520c, or PowerBook 540 to a PowerBook 540c display. The upgrade kit consists of a PowerBook 540c display assembly. Install the PowerBook 540c display assembly. (See “Display Assembly” in the Take Apart chapter.)[...]

Upgrades Ma ci nt o sh Po werBook Processor Card Upgrade - 1 6 Macintosh PowerBook Processor Card Upgrade The Macintosh PowerBook Processor Card Upgrade Kit upgrades the daughter- board of PowerBook 500 Series computers to a 100 MHz PowerPC 603e micro- processor. The upgrade kit consists of the 603e daughterboard and system software 7.5.2 (or later[...]

Upgrades Ma ci nt o sh Po werBook Processor Card Upgrade - 1 7 topic in Take Apart for instruction on how to replace the daughterboard. Be sure to install the new software after upgrading the daughterboard. Note: Rev. A and B versions of the PCMCIA expansion module will not work with an upgraded daughterboard. Customers with these modules must upgr[...]

Service Source K Additional Procedures Po werBook 500 Series[...]

Additional Procedures Battery Verification - 1 Battery Verification The Control Strip on the PowerBook 500 Series desktop shows the battery charge and the rate at which the battery is being used. Use a voltmeter to measure the actual battery charge: 1 Set the voltmeter to the 10 volts DC scale. 2 Hold the positive probe of the voltmeter to the posi[...]

Additional Procedures Battery Verification - 2 negative probe to the negative terminal. 3 A fully charged battery measures approximately 10.8 volts; a fully discharged battery measures 7.8 volts. Note: If a battery is stored outside the computer for extended periods, its voltage may drop to 5.0.[...]

Additional Procedures Backup Battery Verification - 3 Backup Battery Verification The backup battery saves the PRAM and power management information on the logic board when the computer is shut down. To check that the backup battery is working, follow the procedures below. 1 Set the date and time. 2 Perform a Shut Down from the Apple Menu or Specia[...]

Additional Procedures Backup Battery Verification - 4 6 To recharge the backup battery, leave the PowerBook plugged in for 48 hours. It is ok to use it while it is charging. 7 If the backup battery appears dead or will not charge, replace the backup battery.[...]

Additional Procedures A C Adapter Voltage Test - 5 AC Adapter Voltage Test To test the AC adapter voltage: • Use narrow test probes for the leads on your voltmeter. • Make all measurements with the negative or common lead touching the outer shield of the connector (ground). • Use the following table to identify the connector pin number, signa[...]

Additional Procedures Power Manager Reset - 6 Power Manager Reset Reset the power manager if: • The battery and power adapter are proven good, but the computer will not power on. • The computer will not reset after a system crash. To reset the power manager in the PowerBook 500 Series, 1 Remove the AC adapter and the battery. 2 Let the unit sit[...]

Service Source K Exploded V ie w Po werBook 500 Series[...]

Exploded View 1 PowerBook 500 Series Display Bezel Kit 076-0464 Display EMI Shield*   Microphone  922-0783 Inverter Board 922-0774 Interconnect-to-Inverter Cable 922-0776  Clutch  922-2199 Interconnect-to-Display Cable* Clutch Cover 922-0771 Battery  Contact  Cover 922-1182 Main Battery W/Door 661-0055 Modem C[...]