Dell D630 - LATITUDE ATG NOTEBOOK, Service Manual

Page 1: ...DellTM XFR D630 Fully Rugged Notebook Service Manual ...

Page 2: ... without the written permission of Dell Inc is strictly forbidden This document is provided for informational purposes only and may contain typographical errors and technical inaccuracies The content is provided as is without express or implied warranties of any kind Trademarks used in this text Dell the DELL logo and Latitude are registered trademarks of Dell Inc DirectVue is a trademark of Augme...

Page 3: ...CKING DOOR 22 6 3 VGA DOOR 25 6 4 POWER DOOR 28 6 5 XBAY DOOR 29 6 6 AUDIO PORTS WIFI DOOR 31 6 7 USB SIDE DOOR 32 6 8 USB REAR DOOR 34 6 9 PC CARD SLOT DOOR 35 7 HINGE COVER 37 7 1 REMOVING THE HINGE COVER 37 7 2 INSTALLING THE HINGE COVER 39 8 KEYBOARDS 39 8 1 STANDARD KEYBOARD 39 8 2 RUGGED KEYBOARD 41 9 MEMORY 51 9 1 DIMM A 51 9 2 DIMM B 53 10 DISPLAY ASSEMBLY 55 10 1 REMOVING THE DISPLAY ASSE...

Page 4: ...NETWORK WLAN CARDS 81 15 1 REMOVING THE WLAN CARD 81 15 2 INSTALLING THE WLAN CARD 83 16 MODEM 84 16 1 REMOVING THE MODEM 84 16 2 INSTALLING THE MODEM 85 17 PROCESSOR THERMAL COOLING ASSEMBLY 85 17 1 REMOVING THE PROCESSOR THERMAL COOLING ASSEMBLY 86 17 2 INSTALLING THE PROCESSOR THERMAL COOLING ASSEMBLY 87 18 PROCESSOR 88 18 1 REMOVING THE PROCESSOR 88 18 2 INSTALLING THE PROCESSOR 89 19 PC CARD ...

Page 5: ...A01 24 RF PASSTHRU BOARD 102 24 1 REMOVING THE RF PASSTHRU BOARD 102 24 2 INSTALLING THE RF PASSTHRU BOARD 103 25 BOTTOM CHASSIS 104 25 1 REMOVING THE BOTTOM CHASSIS 104 25 2 INSTALLING THE BOTTOM CHASSIS 105 25 3 REMOVING THE MODEM CABLE 105 25 4 INSTALLING THE MODEM CABLE 105 ...

Page 6: ...urn off your computer 1 Shut down the operating system a Save and close any open files exit any open programs b Click Start Shut Down Shut down The computer turns off after the operating system shutdown process finishes 2 Ensure that the computer and any attached devices are turned off If your computer and attached devices do not automatically turn off when you shut down your operating system pres...

Page 7: ...he computer 4 Disconnect your computer and all attached devices from their electrical outlets 5 Turn over the computer NOTICE To avoid damaging the system board you must remove the main battery before you service the computer 6 Remove the battery a If the 2 screws that secure the quarter turn latches are installed remove the 2 screws on the latches on the battery compartment using a 1 Philips scre...

Page 8: ...oor 1 4 Screw Chart SCREW IMAGE PART NUMBER DESCRIPTION Qty Assy Total Qty 18114 SHOULDER SCREW M2 5 6 18815 XFR LCD ASSY TOUCH SCREEN 6 18279 CHEESE HEAD SCREW M1 2 X 3 3 18806 AV DOOR ASSY 1 18808 VGA DOOR ASSY 1 18812 DVD DOOR ASSY 1 18353 SHOULDER SCREW HEAT SPREADER 3 18035 HEAT SINK ASSY 3 18415 PAN HEAD SCREW M2 5 X 8 BLACK 19 PC Card Slot ...

Page 9: ...6 SCR M3X14 PHH MSCR ZPS XFR 8 18044 ASSY HANDLE 6 18824 SHOULDER STRAP ASSY 2 18417 PAN HEAD SCREW M2 X 12 BLACK 7 18815 XFR LCD ASSY TOUCH SCREEN 7 18419 PAN HEAD SCREW M2 5 X 4 BLACK 12 18810 HDD DOOR ASSY 4 18813 RJ DOOR ASSY 3 18814 USB PLASTIC DOOR ASSY 1 18034 FAN ASSY 3 9999 8024 PCMCIA HOLDER 1 18420 PAN HEAD SCREW M2 5 X 14 BLACK 1 18802 PALMREST ASSY 1 18423 CSK SCREW M2 X 5 BLACK 22 ...

Page 10: ...811 DOCKING DOOR ASSY 6 18623 KEYBOARD ASSY 4 18424 CSK SCREW M3 X 10 BLACK 4 18043 ASSY HANDLE WITH HOLDER 4 18425 CSK SCREW M2 X 10 BLACK 4 18043 ASSY HANDLE WITH HOLDER 2 18044 ASSY HANDLE 2 18426 CSK SCREW M2 X 3 BLACK 10 18806 AV DOOR ASSY 2 18808 VGA DOOR ASSY 2 18812 DVD DOOR ASSY 2 18802 PALMREST ASSY 2 18618 AV DOOR COVER ASSY 2 18427 CSK SCREW M2 5 X 6 BLACK 3 ...

Page 11: ...8 VGA DOOR ASSY 2 18802 PALMREST ASSY 2 18813 RJ DOOR ASSY 2 18814 USB PLASTIC DOOR ASSY 2 18429 CSK SCREW M2 X 6 BLACK 30 18810 HDD DOOR ASSY 2 18807 BATTERY DOOR ASSY 2 18630 USB SIDE DOOR ASSY 2 18809 DIMMS DOOR ASSY 4 18631 POWER DOOR ASSY 2 18632 PCMCIA DOOR ASSY 3 18628 RUBBER KEYBOARD ASSY 15 18444 SCR M2 5X5 PHH TF BCS 10 18815 XFR LCD ASSY TOUCH SCREEN 6 18803 MOTHERBOARD TO CHASSIS 4 ...

Page 12: ...Y 1 18043 ASSY HANDLE WITH HOLDER 4 18803 RF PASS THROUGH 2 18819 LCD TOP COVER ASSY 2 18517 SCR M3X6 PHH MSCR ZPS XFR 2 18044 ASSY HANDLE 2 18535 CSK CAPTIVE SCREW M2 X 6 19 18623 KEYBOARD ASSY 15 18816 HINGE COVER ASSY 4 18539 PAN HEAD SCREW M3 X 14 BLACK 1 18629 STYLUS KIT ASSY 1 18550 PAN HEAD SCREW M3 X 22 BLACK 2 18824 SHOULDER STRAP ASSY 2 18590 SCREW KYBD BLK PAN HEAD M2X3 19 ...

Page 13: ... 18804 CHASSIS GASKET ASSY 1 2 XBay Devices NOTICE To prevent damage to devices store them in a safe dry place when they are not installed in the computer Avoid pressing down on them or placing heavy objects on top of them NOTE If the device locking screw is not present you can remove and install devices while the computer is running and connected to a docking device docked 1 If present remove the...

Page 14: ...oss turn off your computer before removing the hard drive Do not remove the hard drive while the computer is on in standby mode or in hibernate mode NOTICE Hard drives are extremely fragile even a slight bump can damage the drive NOTE Dell does not guarantee compatibility or provide support for hard drives from sources other than Dell NOTE You need the Operating System media to install the Microso...

Page 15: ... secure the quarter turn latches are installed remove the 2 screws on the latches on the hard disk drive compartment using a 1 Philips screw driver If the 2 security screws are not installed proceed to step 4 4 Lift each latch and turn each a quarter turn towards the unlock icon to release the latching mechanism ...

Page 16: ...e motherboard 7 Continue to utilize the tab to assist in removing the hard disk drive from the compartment NOTICE When the hard drive is not in the computer store it in protective antistatic packaging 8 Remove the new drive from its packaging Save the original packaging for storing or shipping the hard drive NOTICE Use firm and even pressure to slide the drive into place If you use excessive force...

Page 17: ...and Clip DirectVue Touch Screen Display option NOTE Only Touch Screen Display configurations will include the stylus stylus housing tether and stylus clip The Touch Screen Display is an optional feature If your XFR D630 is configured with the DirectVue Touch Screen Display it will also be equipped with the optional stylus housing stylus stylus tether and stylus clip To replace the stylus stylus te...

Page 18: ...s installed with the raised part towards the center of the notebook so that the raised part of the clip is within the recessed area of the handle cover If the clip is installed the opposite way this raised metal part of the clip is now above the handle cover housing and you can easily cut or injure yourself To replace the stylus clip 1 Loosen the screw on the end of the handle cover that secures t...

Page 19: ...h the loop until the tether is free from the stylus clip 2 Remove the stylus from the tether a At the stylus loosen the looped end of the tether b Pull the stylus and tether through the loop until the stylus is free from the tether 3 Install the new stylus a Place one of the looped ends of the tether through the hole in the end of the new stylus and then place the free end of the tether through th...

Page 20: ...he top of the handle assembly that secure the handle to the handle brackets 3 Remove the 6 screws 3 on each side that secure the main handle assembly 5 2 Installing the Handle 1 Align the main handle assembly with the mounting holes in the front plate of the XFR D630 as shown in the figure above 2 Secure the main handle assembly to the XFR D630 using the 6 screws provided 3 Install the 6 screws 3 ...

Page 21: ...lus clip onto one side of the handle assembly 6 Secure the handle covers over the main handle assembly and to the XFR D630 with the 4 screws provided 2 on each side 6 Port Covers The XFR D630 utilizes port covers to secure and protect the connectors and devices of the notebook 6 1 Comms Door The Comms Door is located on the notebook s rear panel and protects the RJ 45 and RJ 11 connectors 6 1 1 Re...

Page 22: ...mms Door with the Comms Door mounting holes on the notebook 2 Use the 2 screws to secure the Comms Door to the notebook 6 2 Docking Door The Docking Door is located on the bottom of the notebook and protects the docking connector 6 2 1 Removing the Docking Door 1 Remove the 6 screws that secure the Docking Door to the notebook ...

Page 23: ...DellTM XFR D630 Fully Rugged Notebook Service Manual Page 23 of 106 Revision A01 2 Remove the 2 brackets that secure the Docking Door 3 Lift the Docking Door away from the notebook ...

Page 24: ...book Service Manual Page 24 of 106 Revision A01 6 2 2 Installing the Docking Door 1 Place the Docking Door onto the notebook aligning it with the 6 mounting holes 2 Place the two mounting brackets onto the docking door see figure below ...

Page 25: ...ectors 6 3 1 Removing the VGA Door NOTE The VGA Door is secured by 3 screws To access all the screws the notebook must be turned over When facing the VGA Door the right screw is accessed from the top and the 2 left screws are accessed from the front 1 Turn the notebook top side down to access the VGA Door on the rear panel of the notebook 2 Remove the 3 screws that secure the VGA Door one screw on...

Page 26: ...DellTM XFR D630 Fully Rugged Notebook Service Manual Page 26 of 106 Revision A01 3 Remove the VGA Door from the notebook 4 Remove the 2 screw mounts from the VGA Door hinge and set aside for later use ...

Page 27: ...the VGA Door hinge NOTE Be careful to ensure that the single screw mount is placed on the right side of the hinge while the 2 screw mount is placed on the left side of the hinge 2 Place the VGA Door and screw mounts onto the notebook and align with the mounting holes provided 3 Secure the VGA Door to the notebook using the 3 screws provided ...

Page 28: ...otebook and protects the notebook s power connector 6 4 1 Removing the Power Door 1 Remove the 2 screws that secure the Power Door to the notebook 2 Remove the screw plate and the Power Door from the notebook 6 4 2 Installing the Power Door 1 Align the Power Door and the screw plate with the screw holes provided on the rear panel for the Power Door ...

Page 29: ...screws provided to secure the screw plate and Power Door to the notebook 6 5 XBay Door 6 5 1 Removing the XBay Door The XBay Door is located on the notebook s right side and protects the notebook s optical drive 1 Turn the notebook top side down and remove the 2 screws that secure the XBay Door ...

Page 30: ...Fully Rugged Notebook Service Manual Page 30 of 106 Revision A01 2 Remove the XBay Door from the notebook 6 5 2 Installing the XBay Door 1 Place the XBay Door onto the notebook aligning it with the 2 screw mount holes ...

Page 31: ... of the notebook and protects the notebook s audio connectors smart card slot 1394 connector and wireless switch To access the Audio Ports WiFi Door for service turn the notebook bottom side up 6 6 1 Removing the Audio Ports WiFi Door 1 Remove the 4 screws that secure the Audot Ports WiFi Door s hinge retaining bar 2 Lift the hinge retaining bar away from the notebook which then allows the door to...

Page 32: ...Door s onto the notebook aligning the door hinge into the slot on the notebook 2 Place the hinge retaining bar over the hinge 3 Align the holes in the retaining bar with the holes in the notebook 4 Use the 4 screws to secure the hinge retaining bar 6 7 USB Side Door The USB Side Door is located on the notebook s right side and protects 2 USB connectors ...

Page 33: ...de Door 1 Remove the 2 screws that secure the USB Side Door to the notebook 2 Remove the USB Side Door from the notebook 6 7 2 Installing the USB Side Door 1 Place the USB Side Door onto the notebook aligning it with the 2 screw mount holes 2 Install the 2 screws to secure the USB Side Door to the notebook ...

Page 34: ...he USB Rear Door is located on the notebook s rear panel and protects 2 USB connectors 6 8 1 Removing USB Rear Door 1 Remove the 2 screws that secure the USB Rear Door to the chassis Also remove the gasket which is positioned between the screws and the door 2 Remove the USB Rear Door from the notebook ...

Page 35: ...he notebook Then align the gasket with the screw holes on the USB Rear Door 2 Using the 2 screws provided secure the USB Rear Door and the gasket to the notebook 6 9 PC Card Slot Door The PC Card Slot Door is located on the notebook s left side and protects the notebook s PC Card ExpressCard Slot 6 9 1 Removing the PC Card Slot Door 1 Remove the 3 screws that secure the PC Card Slot Door to the no...

Page 36: ...36 of 106 Revision A01 2 Remove the PC Card Slot Door from the notebook 6 9 2 Installing the PC Card Slot Door 1 Align the PC Card Slot Door with the 3 screw mount holes on the notebook 2 Using the 3 screws provided secure the PC Card Slot Door to the notebook ...

Page 37: ...cally touching an unpainted metal surface such as a connector on the back of the computer NOTICE The hinge cover is fragile and can be damaged if extreme force is used Be careful when removing the hinge cover 7 1 Removing the Hinge Cover 1 Follow the procedures in 98HBefore You Begin 2 Turn the computer top side up and then open the display all the way 160 degrees NOTICE To avoid damaging the hing...

Page 38: ... of 106 Revision A01 Keyboard palm rest overlay 3 Remove keyboard palm rest overlay first Start in top corners next to each hinge to remove the overlay The overlay peels off 4 Remove the 4 M2 x 5 mm screws that secure the hinge cover to the base See image below ...

Page 39: ... and place the hinge cover over the hinges 2 Ensure that the hinge cover edges line up with those on the palm rest 3 Install the 4 screws to secure the hinge cover to the base 4 Install the new keyboard palm rest overlay a Remove the backing from the new keyboard palm rest overlay b Start applying the overlay around the touchpad area to align the overlay c Press evenly and firmly as the overlay is...

Page 40: ... open it 3 Remove the hinge cover see 100HRemoving the Hinge Cover NOTICE Do not remove the keyboard from the keyboard tray You are removing the entire tray not just the keyboard The normal keyboard screws above the keyboard attach the keyboard to the tray See next step for keyboard tray removal 4 Loosen the fifteen keyboard tray captive screws 1 Keyboard tray captive screw 15 NOTE Lift the keyboa...

Page 41: ...tructions in the XFR D630 Product Information Guide and in the XFR D630 User s Guide NOTICE To avoid electrostatic discharge ground yourself by using a wrist grounding strap or by periodically touching an unpainted metal surface such as a connector on the back of the computer 1 Follow the instructions in 102HBefore You Begin 2 Turn the computer right side up and open it 3 Remove the hinge cover se...

Page 42: ...er lip around the keyboard to lift the keyboard away from the system Be sure to locate and remove the keyboard stiffener bar located at the top of the keyboard above the power and audio buttons 6 Rotate the keyboard towards yourself so that the bottom of the keyboard and the keyboard cables are viewable ...

Page 43: ...the backlight power cable in place 8 Disconnect the keyboard backlight power cable from the back of the keyboard 9 Disconnect the keyboard backlight cable from the touch screen splice coming from the mother board If this is a touch screen system also disconnect the keyboard to backlight cable from the touch screen splice coming from the LCD ...

Page 44: ...ok Service Manual Page 44 of 106 Revision A01 9 Disconnect the rugged keyboard connector from the motherboard connector 8 2 2 Installing the Rugged Keyboard The following parts are required to assemble the rugged keyboard to the Dell XFR ...

Page 45: ...87 US ENG RGD XFR 2 Rubber keyboard stiffener bar 3 CLMP SPRT PLMST MET BOTTOM XFR 4 CLMP SPRT PLMST MET TOP XFR 5 CSK CAPTIVE SCREW M2x6 BLACK x15 6 CABLE ASSY KYBD BACKLIGHT not shown in image above Installation Steps 1 Connect the rugged keyboard connector to the mother board connector ...

Page 46: ...A01 2 Connect keyboard backlight cable to the touch screen splice coming from the mother board 3 Connect keyboard to backlight cable to the touch screen splice coming from the LCD if this is a touch screen system 4 Connect the keyboard backlight cable to the back of the keyboard ...

Page 47: ...power cable in the recessed area of the thermal solution Stack them and use a 2 5 piece of Kapton tape to hold them in place below the level of the palmrest 6 Assemble the keyboard stiffener bar into the slot above the power and audio buttons Do this before assembling the keyboard to the palmrest Connectors should not stack above this level ...

Page 48: ...ion A01 7 Assemble the keyboard onto the palmrest a Apply pressure around the perimeter to ensure the keyboard lip is properly fitted to the palmrest bucket b Apply pressure on the area around the keyboard stiffener bar and near the right hinge to ensure there is no bulging ...

Page 49: ... attention to the lower right corner Move the bracket in the direction shown in the image below The bracket should fit in place pressing the rubber lip against the palmrest Make sure the rubber lip looks uniform throughout the perimeter and that it has not folded under the bracket Any gaps will compromise the quality of the seal ...

Page 50: ... screws around the bracket are secured ensure that the rubber lip is not folded under the bracket 10 Assemble the top metal bracket ensuring the rubber lip is not folded under the bracket Move the bracket into position in the direction shown in the image below 11 Fasten the 2 M2x6 screws shown in the image below to the left side of the top metal bracket 2 1 1 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 11 ...

Page 51: ...only one memory module install the memory module in the connector labeled DIMM A which is underneath the keyboard NOTICE If you remove your original memory modules from the computer during a memory upgrade keep them separate from any new modules that you may have even if you purchased the new modules from Dell If possible do not pair an original memory module with a new memory module Otherwise you...

Page 52: ...ng clips on each end of the memory module connector until the module pops up b Remove the module from the connector 1 securing clips 2 2 memory module 5 Ground yourself and install the new memory module a Align the notch in the module connector with the tab in the connector slot b Slide the module firmly into the slot at a 45 degree angle and rotate the module down until it clicks into place If yo...

Page 53: ...f you need to install memory modules in two connectors install a memory module in the connector labeled DIMM A before you install a module in the connector labeled DIMM B NOTICE Insert memory modules at a 45 degree angle to avoid damaging the connector 1 Follow the procedures in 110HBefore You Begin 2 Turn the computer bottom side up remove the 4 screws that secure the memory module cover and then...

Page 54: ...ory module ground yourself and remove the existing module a Use your fingertips to carefully spread apart the securing clips on each end of the memory module connector until the module pops up b Remove the module from the connector 1 securing clips 2 2 memory module NOTICE Insert memory modules at a 45 degree angle to avoid damaging the connector 4 Ground yourself and install the new memory module...

Page 55: ...ule cover and use the 4 screws to secure the cover NOTICE If the cover is difficult to close remove the module and reinstall it Forcing the cover to close may damage your computer 6 Insert the battery into the battery bay or connect the AC adapter to your computer and an electrical outlet 7 Turn on the computer As the computer boots it detects the additional memory and automatically updates the sy...

Page 56: ... the cables in the appropriate cable channels when replacing the display Route the gray and black antenna cables beneath the white antenna cable and the black display cable on top of the white antenna cable NOTICE For the optional Touch Screen Display remove the touch controller cable from the I O board on the right side near the right hinge 4 Unplug the display cable a Pull straight up on the pul...

Page 57: ...he display cable from their routing guides 7 Close the display 8 Turn the computer upside down with the back of the computer facing you 9 From the back of the computer remove the two M2 5 x 8 mm screws 10 From the bottom of the computer remove the two M2 5 x 8 mm screws 11 Turn the computer right side up and open the display ...

Page 58: ...contain the grommet tool that you need to perform the following steps If your replacement kit does not contain the grommet tool do not perform the following steps Grommet tool 13 Follow these steps to remove the grommets from the left and right side of the display assembly Location of left and right display grommets a To remove the right side grommet i Lift and slide the grommet partially down the...

Page 59: ...pen the grommet tool to allow the tool to stretch the grommet open iv With the grommet stretched pull the ends of the cables through the grommet b To remove the left side grommet i Lift and slide the grommet partially down the set of antenna cables ii Slide the cables through the grommet ...

Page 60: ...assembly was disassembled the grommets had to be removed The following steps explain how to install the grommets If the grommets are already installed on the display cables skip to step 2 1 Install the display cable grommets on the left and right side of the display assembly a To install the right side grommet use the grommet tool to spread the grommet open and slide the cables through the grommet...

Page 61: ...uting guides 1 Left side grommet 2 Antenna cable 3 Right side grommet 4 Antenna cables 5 Display cable 5 Connect the antenna cables to their card s see 116HWLAN Card and 117HRF Passthru Board 6 Connect the display cable a Attach the display feed flex cable to the system board NOTE The following step is only for the optional Touch Screen display b Attach the touch controller cable to the motherboar...

Page 62: ...tic discharge ground yourself by using a wrist grounding strap or by periodically touching an unpainted metal surface such as a connector on the back of the computer NOTE Replacing the display bezel does not require removing the display assembly from the base NOTE Replacement keyboard palm rest overlays are not included in the bezel service kits 1 Follow the instructions in 120HBefore You Begin 2 ...

Page 63: ... release the corners of the bezel from the display panel 10 4 Installing the Display Bezel NOTICE To avoid damaging the computer when replacing the display bezel ensure that the bezel edges line up with those on the display back cover and snap into place around the entire perimeter of the display back cover 1 Align the display bezel and install the fifteen 15 screws that secure the bezel Two SCR M...

Page 64: ... see 122HRemoving the Display Assembly NOTE Ensure the display cable grommets were removed by following the grommet removal instructions provided in 123HRemoving the Display Assembly at step 13 3 Remove the display bezel see 124HRemoving the Display Bezel 4 Remove hinges Remove 3 M2 5 x 5 mm screws from each side of the display panel and remove the hinge from each side CAUTION To avoid damage to y...

Page 65: ... will have packing material covering the LVDS connector The LVDS cable will be taped to the back of the panel on top of the copper foil backing so care is needed during tape removal NOTE For optional Touch Screen Display panels the touch controller cable is also taped to the back of the panel on top of the copper foil backing and similar care is needed during tape removal 1 Connect the LED cable 2...

Page 66: ...D630 Product Information Guide and in the XFR D630 User s Guide NOTICE To avoid electrostatic discharge ground yourself by using a wrist grounding strap or by periodically touching an unpainted metal surface such as a connector on the back of the computer 1 Follow the instructions in 128HBefore You Begin 2 Remove the display assembly see 129HRemoving the Display Assembly NOTE Ensure the display ca...

Page 67: ...orking inside your computer follow the safety instructions in the XFR D630 Product Information Guide and in the XFR D630 User s Guide NOTICE To avoid electrostatic discharge ground yourself by using a wrist grounding strap or by periodically touching an unpainted metal surface such as a connector on the back of the computer NOTE Replacing the display latch does not require removing the display ass...

Page 68: ...ctions in your XFR D630 Product Information Guide and in the XFR D630 User s Guide NOTICE To avoid electrostatic discharge ground yourself by using a wrist grounding strap or by periodically touching a connector on the back panel of the computer NOTICE To avoid damaging the system board you must remove the main battery before you begin working inside the computer see 141HBefore Working Inside Your...

Page 69: ... the card cable with excessive force 1 Wireless card 2 Wireless card cable 6 Disconnect the card from the cable and remove the card from the computer 11 2 Installing the Bluetooth Wireless Card 1 Grasp the Bluetooth Wireless cable and gently extend it 2 Connect the Bluetooth Wireless Card to the cable 3 Gently insert the card into its compartment 1 2 ...

Page 70: ... of the computer NOTE The WWAN card slot is located on the left center next to the keyboard connector 1 Follow the procedures in 147HBefore You Begin 2 Remove the hinge cover see 148HRemoving the Hinge Cover 3 Remove the keyboard see 149HKeyboards NOTICE To prevent damage to the connector do not use tools to release the securing tabs NOTICE Do not insert a WLAN card into the Mobile Broadband netwo...

Page 71: ...DellTM XFR D630 Fully Rugged Notebook Service Manual Page 71 of 106 Revision A01 1 WWAN card 2 antenna cable connectors 1 metal securing tabs 2 ...

Page 72: ...ork card never place cables on top of or under the card and ensure that you route the cables properly b Insert the card into the system board connector at a 45 degree angle and press the card into the metal securing tabs until you feel a click NOTE For more specific information about which cable to connect to which connector see the documentation that came with your Mobile Broadband network card 6...

Page 73: ...de and in the XFR D630 User s Guide NOTICE To avoid electrostatic discharge ground yourself by using a wrist grounding strap or by periodically touching an unpainted metal surface such as a connector on the back of the computer NOTE The WWAN card slot is located on the left center next to the keyboard connector The FCM is installed into the WWAN card slot 12 2 1 Removing the Flash Cache Module 1 F...

Page 74: ...m the card until the card pops up slightly 5 Remove the FCM 1 FCM Card 2 metal securing tabs 2 12 2 2 Installing the Flash Cache Module NOTICE Install the FCM in the WWAN FCM slot Do not install an FCM in the WLAN card slot Doing so may cause damage to your computer NOTICE Ensure that the antenna cables remain out of the way The antenna cables need to be routed above the WWAN FCM slot in the area ...

Page 75: ...rly b Insert the card into the system board connector at a 45 degree angle and press the card into the metal securing tabs until you feel a click 2 Install the keyboard see 155HKeyboards 3 Install the hinge cover see 156HInstalling the Hinge Cover 12 3 Subscriber Identity Module SIM Card CAUTION Before you begin any of the procedures in this section follow the safety instructions in the XFR D630 P...

Page 76: ...hown so that it slides under the metal bracket on the sides 5 Replace the battery and battery cover 13 Coin Cell Battery CAUTION Before working inside your computer follow the safety instructions in your XFR D630 Product Information Guide and in the XFR D630 User s Guide NOTICE To avoid electrostatic discharge ground yourself by using a wrist grounding strap or by periodically touching a connector...

Page 77: ... plastic tab until it has been removed from the battery compartment 13 2 Installing the Coin Cell Battery 1 Being careful not to break the plastic lift the plastic tab slightly and gently toe in the coin cell battery at an angle and push into the battery compartment 2 Connect the battery cable connector to the connector on the system board 3 Install the keyboard see 162HKeyboards 4 Install the hin...

Page 78: ...Palm Rest 1 Follow the instructions in 164HBefore You Begin 2 Remove the hinge cover see 165HRemoving the Hinge Cover 3 Remove any installed media bay device see 166HXBay Devices 4 Remove the keyboard see 167HKeyboards 5 Remove the display assembly see 168HRemoving the Display Assembly 6 Disconnect the coin cell battery from the system board see 169HCoin Cell Battery NOTE You can leave the coin ce...

Page 79: ...n the Docking Door Two of the palm rest screws are located beneath this door see 171HRemoving the Docking Door 9 Remove the 11 screws that secure the palm rest NOTICE Carefully separate the palm rest from the base to avoid damage to the palm rest 10 Turn the computer top side up slightly raise the palm rest and then disconnect the touch pad cable connector from the system board 11 Continue to rais...

Page 80: ...touch pad cable connector to the system board before replacing the palm rest screws NOTE If you are replacing the palm rest remove the USB Control cable from the original palm rest and route the same way in the new palm rest Underside of Palm Rest showing Touchpad Cable Route 1 Install the 5 top side screws 2 Turn the system over 3 Install the 11 bottom screws 4 Reconnect the coin cell battery see...

Page 81: ...y periodically touching an unpainted metal surface such as a connector on the back of the computer 15 1 Removing the WLAN Card 1 Follow the procedures in 177HBefore You Begin 6 Remove the hinge cover see 178HRemoving the Hinge Cover 3 Remove the keyboard see 179HKeyboards 4 Remove the display assembly see 180HRemoving the Display Assembly 5 Remove the palm rest see 181HRemoving the Palm Rest NOTIC...

Page 82: ...sure correct insertion If you feel resistance check the connector and realign the card NOTICE Do not insert a Mobile Broadband network WWAN card into the WLAN card connector 1 WLAN card 2 antenna cable connectors 1 metal securing tabs 2 NOTICE To avoid damaging the WLAN card never place cables on top of or under the card ...

Page 83: ...N card 2 Insert the WLAN card into the system board connector at a 45 degree angle and press the card into the metal securing tabs until you feel a click 3 Connect the antenna cables to the WLAN card ensuring that you route the cables correctly NOTE For more specific information about which cable to connect to which connector see the documentation that came with your WLAN card ...

Page 84: ...odically touching an unpainted metal surface such as a connector on the back of the computer NOTICE To avoid damaging the system board you must remove the main battery before you begin working inside the computer see 186HBefore Working Inside Your Computer 16 1 Removing the Modem 1 Follow the instructions in 187HBefore You Begin 2 Remove the hinge cover see 188HRemoving the Hinge Cover 3 Remove an...

Page 85: ...o connect the modem cable to the modem before you press the modem into the system board connector 1 Connect the modem cable to the modem 2 Connect the modem to the connector on the system board 3 Install the M2 x 3mm screw that attaches the modem to the system board 4 Replace the palm rest see 193HInstalling the Palm Rest 5 Replace the display assembly see 194HInstalling the Display Assembly 6 Rep...

Page 86: ...d metal surface such as a connector on the back of the computer 1 Follow the instructions in 197HBefore You Begin 2 Remove the hinge cover see 198HRemoving the Hinge Cover 3 Remove any installed media bay device see 199HXBay Devices 4 Remove the keyboard see 200HKeyboards 5 Remove the display assembly see 201HRemoving the Display Assembly 6 Remove the palm rest see 202HRemoving the Palm Rest 7 Rem...

Page 87: ...ponents You can do so by touching an unpainted metal surface 1 If you are installing the original processor thermal cooling assembly skip to step 5 otherwise continue to the next step 2 Clean the heat sink Use the cleaning pad provided with the processor thermal cooling assembly kit to clean the area between the 4 captive screws 3 Apply the thermal grease Follow the instructions provided with the ...

Page 88: ...rocessor 18 1 Removing the Processor CAUTION Before working inside your computer follow the safety instructions in the XFR D630 Product Information Guide and in the XFR D630 User s Guide NOTICE To avoid electrostatic discharge ground yourself by using a wrist grounding strap or by periodically touching an unpainted metal surface such as a connector on the back of the computer NOTICE To prevent int...

Page 89: ...rner of processor 3 ZIF socket 4 ZIF socket cam screw 9 Use a processor extraction tool to remove the processor 18 2 Installing the Processor NOTICE Ensure that the cam lock is in the fully open position before seating the processor Seating the processor properly in the ZIF socket does not require force NOTICE A processor that is not properly seated can result in an intermittent connection or perm...

Page 90: ...or kit to use the syringe to apply thermal grease in a spiral pattern to the processor thermal cooling assembly 5 Replace the processor thermal cooling assembly see 216HInstalling the Processor Thermal Cooling Assembly 6 Replace the palm rest see 217HInstalling the Palm Rest NOTE Ensure that you reconnect the coin cell battery see 218HCoin Cell Battery before you replace the keyboard 219HInstallin...

Page 91: ...evices 4 Remove the keyboard see 227HKeyboards 5 Remove the display assembly see 228HRemoving the Display Assembly 6 Remove the palm rest see 229HRemoving the Palm Rest 7 Remove the four M2 x 3 mm screws that secure the PC Card reader to the computer NOTICE To avoid damaging the PC Card reader connector do not rotate or rock the connector as you remove it Use firm and even pressure to lift the pul...

Page 92: ...est NOTE Ensure that you reconnect the coin cell battery see 231HCoin Cell Battery before you replace the keyboard 4 Replace the display assembly see 232HInstalling the Display Assembly 5 Replace the keyboard see 233HKeyboards 6 Replace the media bay device see 234HXBay Devices 7 Replace the hinge cover see 235HInstalling the Hinge Cover 8 Replace the battery 20 Speaker CAUTION Before working insi...

Page 93: ...t you reconnect the coin cell battery see 243HCoin Cell Battery before you replace the keyboard 3 Replace the display assembly see 244HInstalling the Display Assembly 4 Replace the keyboard see 245HKeyboards 5 Replace the media bay device see 246HXBay Devices 6 Replace the hinge cover see 247HInstalling the Hinge Cover 7 Replace the battery 21 Fan CAUTION Before working inside your computer follow...

Page 94: ...Thermal Cooling Assembly 8 Remove the 3 M3 x 4 mm screws that secure the fan to the base 1 Fan connector 2 Fan cable 3 Fan cable grommet 4 Fan 9 Disconnect the fan cable from the system board and remove the fan 21 2 Installing the Fan 1 Install the fan and attach to the base using the 3 M3 x 4 mm screws 2 Attach the fan cable to the system board Then attach the grommet on the fan cable to the cage...

Page 95: ...ble on a barcode label on the bottom of the computer The replacement kit for the system board includes a CD that provides a utility for transferring the Service Tag to the replacement system board 1 Follow the instructions in 262HBefore You Begin 2 Remove the hard disk drive see 263HHard Drive 3 Remove the hinge cover see 264HRemoving the Hinge Cover 4 Remove the keyboard see 265HKeyboards 5 Remov...

Page 96: ...sor Thermal Cooling Assembly 13 Remove the processor see 276HRemoving the Processor 14 Disconnect the fan cable from the system board 16 Disconnect the cables near the WLAN card and the modem connector from the system board 17 Remove the four M2 5 x 5 mm screws labeled with silver triangles on the system board WLAN Connector Modem Connector Fan Connector 1 Speaker Connector ...

Page 97: ...stem board a Lift the lower corner near the speaker b Grasp the system board next to the I O dash board and lift up until the USB connectors and the gasket on the right side clear the base c While keeping the system board raised on the right side push on the VGA connector to clear the base Pull the system board towards the front and right to clear the audio ports and Wi Fi switch on the left side ...

Page 98: ...ard with instructions 1 If you are installing a new system board follow these instructions a Remove the 2 M2 x 3 mm screws on the bottom of the original system board to separate the system board from the IO dash board b Use the 2 M2 x 3 mm screws just removed to secure the new IO dash board to the new system board c On the original system board remove the 3 gaskets from the power port rear USB por...

Page 99: ...es and the 3 modem cables are clear of the system board before fitting it into the base that the audio connectors are properly seated and that the tab for the wireless switch fits properly into the detent on the slider mechanism before installing the system board into the base Once system board is partially seated position the modem cables and the antenna cables by the RF passthru board so they ar...

Page 100: ...rocessor thermal cooling assembly see 279HInstalling the Processor Thermal Cooling Assembly 8 Install any smart cards or smart card blanks into the smart card slot 9 Install the PC card reader see 280HInstalling the PC Card Reader Cage 10 Install the speaker see 281HInstalling the Speaker 11 Install any wireless communication cards see 282HWWAN FCM SIM Cards 283HWireless Local Area Network WLAN Ca...

Page 101: ... provided with the new system board flash the BIOS from the CD If you do not have a BIOS update program CD flash the BIOS from the hard drive 23 1 Flashing the BIOS From a CD 1 Ensure that the AC adapter is plugged in and that the main battery is installed properly NOTE If you use a BIOS update program CD to flash the BIOS set up the computer to boot from a CD before inserting the CD 2 Insert the ...

Page 102: ...rs on your desktop and is titled the same as the downloaded BIOS update file 9 Double click the file icon on the desktop and follow the instructions on the screen 24 RF Passthru Board 24 1 Removing the RF Passthru Board CAUTION Before working inside your computer follow the safety instructions in the XFR D630 Product Information Guide and in the XFR D630 User s Guide NOTICE To avoid electrostatic ...

Page 103: ...m of the RF Passthru Board remove the gasket from the base 24 2 Installing the RF Passthru Board NOTE If a new RF Passthru Board is being installed the replacement kit will include the RF Passthru Board gasket and 2 antenna cables 1 Install the gasket to the bottom of the RF Passthru Board 2 Attach the RF Passthru Board to the base using the 2 screws RF Passthru Board WWAN Board RF Passthru Board ...

Page 104: ...Information Guide and in the XFR D630 User s Guide NOTICE To avoid electrostatic discharge ground yourself by using a wrist grounding strap or by periodically touching an unpainted metal surface such as a connector on the back of the computer 1 Follow the instructions in 296HBefore You Begin 2 Remove the system board see 297HRemoving the System Board NOTE When removing the system board you do not ...

Page 105: ...ing the Modem Cable CAUTION Before working inside your computer follow the safety instructions in the XFR D630 Product Information Guide and in the XFR D630 User s Guide NOTICE To avoid electrostatic discharge ground yourself by using a wrist grounding strap or by periodically touching an unpainted metal surface such as a connector on the back of the computer 1 Follow the instructions in 306HBefor...

Page 106: ...DellTM XFR D630 Fully Rugged Notebook Service Manual Page 106 of 106 Revision A01 2 Replace the system board see 309HInstalling the System Board Modem Cable ...