Maintenance Manual TravelMate 5000 Series Notebook Computers 9786166-0001 March 1995 Copyright (©) 1995 Texas Instruments Incorporated All Rights Reserved — Printed in U.S.A. TravelMateTM 5000 Series Notebook Computers Maintenance Manual TI Part No. 9786166-0001 Original Issue: March 1995 Changes may be made periodically to the information in this publication. Such changes will be incorporated in new editions of this manual. Record the serial number, purchase date, and model number in the spaces provided below. The serial number and model number are recorded on the label affixed to the case. All correspondence concerning your unit should in- clude the serial number, model number, and date of purchase. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopy, recording, or otherwise, without the prior written permission of Texas Instruments Incorporated. The equipment, as well as the programs that TI has created to use with them, are tools that can help people better manage the information used in their business; but tools — including TI products — cannot replace sound judgement nor make the manager’s business decisions. Consequently, TI cannot warrant that its products are suitable for any specific customer application. The manager must rely on judgement of what is best for his or her business. Address all correspondence regarding orders to: Texas Instruments Incorporated P.O. Box 6102, M/S 3255 Temple, Texas 76503 TravelMate, 5000, 4000M, 4000E, 4000, and BatteryPro are trademarks of Texas Instruments Incorporated. The icons in the Windows Notebook and Startup groups are copyrighted by Texas Instruments Incorporated. BitCom and BotFax are trademarks of BIT Software, Inc. Hayes is a registered trademark and SmartModem2400 is a trademark of Hayes Microcomputer Products Inc. IBM, OS/2. AT. PS/2, and VGA are trademarks of International Business Machines Corporation. Intel, 386, and 387, and Pentium are trademarks of Intel Corporation. Lotus is a trademark of Lotus Development Corporation. MNP is a registered trademark and Microcom is a trademark of Microcom Inc. Microsoft, GW-Basic, MS-DOS, BallPoint, QuickPort, and MS are registered trade- marks and Windows, Xenix, and Excel are trademarks of Microsoft Corporation. Ethernet is a registered trademark of Xerox Corporation Paintbrush is a registered trademark of ZSoft Corporation NetWare is a registered trademark of Novell, Inc. UNIX is a registered trademark of American Telephone and Telegraph. SimuSCAN is a trademark of Cirrus Logic, Inc. Contents Preface 1 General Description 1.1 . Introduction . 1-1 1.2 . Product Overview . 1-3 1.2.1 . MultiMedia Features . 1-4 1.2.2 . Dual Intelligent Battery Packs . 1-6 1.2.3 . Standard Peripherals . 1-7 1.2.4 . Preloaded Software. 1-8 1.2.5 . Preloaded Online Documentation . 1-9 1.2.6 . Expansion Capabilities. 1-10 1.3 . Notebook Hardware Features . 1-14 1.3.1 . CPU/RAM Subsystem . 1-14 1.3.2 . ROM Memory . 1-15 1.3.3 . Hard Disk Subsystem . 1-16 1.3.4 . Floppy Diskette Subsystem . 1-16 1.3.5 . Keyboard Subsystem . 1-16 1.3.6 . Video Display Subsystem . 1-18 1.3.7 . Sound Subsystem . 1-18 1.3.8 . External Ports . 1-19 1.4 . Notebook Expansion Capabilities . 1-21 1.4.1 . Memory Expansion . 1-21 1.4.2 . Headset and Microphone Option Kit. 1-22 1.4.3 . PS/2 Numeric Keypad Option . 1-22 1.4.4 . External Battery Charger . 1-22 1.4.5 . Extra Battery Option . 1-22 1.4.6 . Notebook Carrying Case Options . 1-23 1.4.7 . PCMCIA Card Options . 1-23 1.5 . Standard Test Features . 1-23 1.5.1 . Built-In Self Test . 1-23 1.5.2 . Diagnostics Program . 1-24 1.6 . Product Models . 1-24 Contents iii 1.7 . Notebook Physical Description . 1-26 1.7.1 . Cover-Display Assembly. 1-27 1.7.2 . System Base Assembly. 1-28 1.8 . Notebook Functional Overview . 1-29 1.8.1 . System Processor . 1-31 1.8.2 . Memory Subsystem . 1-31 1.8.3 . I/O Subsystem. 1-32 1.8.4 . AT Peripherals Subsystem . 1-32 1.8.5 . Video Subsystem . 1-32 1.8.6 . External VGA Capability . 1-33 1.8.7 . Sound Subsystem . 1-33 1.8.8 . Pointing Device Subsystem . 1-34 1.8.9 . Keyboard Subsystem. 1-34 1.8.10 . Hard Disk Subsystem . 1-37 1.8.11 . Floppy Diskette Drive Subsystem . 1-38 1.8.12 . Power Subsystem . 1-38 1.9 . TravelMate 5000 Series Notebook Specifications . 1-41 2 Installation 2.1 . Introduction . 2-1 2.2 . Unpacking Instructions. 2-1 2.3 . Installing Internal Notebook Options . 2-3 2.3.1 . Installing RAM Expansion (Optional) . 2-3 2.3.2 . Installing PCMCIA Options. 2-6 2.4 . Installing External Notebook Options . 2-7 2.4.1 . Installing the Optional Numeric Keypad . 2-7 2.4.2 . Installing External Mic and Headphone Kit . Option . 2-8 2.4.3 . Installing the EZ-Dock /EZ-Dock Plus Port . Replicator (Option) . 2-9 2.5 . Removing/Installing Battery Packs . 2-11 2.6 . Installing Desktop Devices. 2-12 2.6.1 . Installing an External Keyboard/Mouse/Keypad . 2-13 2.6.2 . Installing External Parallel Printer . 2-14 2.6.3 . Installing External Serial Port Device . 2-15 2.6.4 . Installing External VGA Monitor. 2-16 iv Contents 2.6.5 . Installing External Headphone/Microphones . 2-17 2.6.6 . Installing Devices With IR Interface . 2-18 2.7 . Installing the AC Power Adapter . 2-19 2.8 . Initial System Checkout . 2-20 2.9 . Configuring the System . 2-20 2.10 . Making Backups of System Software . 2-21 2.11 . Loading Application Software . 2-21 2.12 . Securing Notebook to Workstation. 2-21 3 Operating Instructions 3.1 . Introduction . 3-1 3.2 . Notebook Controls and Indicators . 3-1 3.2.1 . Notebook Switches and Controls . 3-2 3.2.2 . Cover Release Latches . 3-3 3.2.3 . Notebook LED Displays . 3-4 3.3 . Internal Speaker/Microphone . 3-7 3.4 . Operating Procedures . 3-7 3.4.1 . Adjusting Sound Volume . 3-7 3.4.2 . Using Sound Utilities . 3-8 3.4.3 . Warm Start or Warm Boot . 3-8 3.4.4 . Responding to Low Battery Conditions . 3-8 3.4.5 . Minimizing Power Usage. 3-8 3.4.6 . Removing Battery Packs. 3-9 3.4.7 . Recharging the Battery Packs. 3-10 3.4.8 . Running the DOS-Based Setup Program . 3-10 3.4.9 . Backing Up Your System Software . 3-10 3.4.10 . Restoring Missing System Files . 3-10 3.4.11 . Rebuilding the System Software . 3-11 4 Troubleshooting Procedures 4.1 . Overview of Fault Isolation Process . 4-1 4.2 . Troubleshooting Procedures . 4-4 4.2.1 . Troubleshooting a Power Supply Problem. 4-4 4.2.2 . Troubleshooting a Display Problem . 4-4 4.2.3 . Fault Isolation Using Selftest . 4-5 Contents v 4.2.4 . PCMCIA Modem Problems . 4-10 4.2.5 . Fault Isolation Using Diagnostics . 4-10 5 Field Service 5.1 . Introduction . 5-1 5.2 . Preventive Maintenance. 5-1 5.2.1 . Cleaning the Computer . 5-1 5.2.2 . Protecting the Disk Drives . 5-1 5.2.3 . Handling the Computer Battery Packs . 5-2 5.2.4 . Restoring System Software. 5-2 5.3 . Required Tools and Equipment . 5-2 5.4 . Notebook Field-Replaceable Parts and Assemblies . 5-3 5.4.1 . Cover-Display Assembly. 5-4 5.4.2 . System Base Assembly. 5-6 5.5 . Notebook Sub-Assembly Removal and . Replacement Procedures . 5-9 5.5.1 . Removing/Replacing the Notebook . Battery Pack . 5-9 5.5.2 . Removing/Replacing PCMCIA Options . 5-10 5.5.3 . Removing/Replacing the Keyboard Assembly . 5-10 5.5.4 . Removing/Replacing the Hard Drive Assembly. 5-12 5.5.5 . Removing/Replacing Expansion RAM Boards. 5-13 5.5.6 . Opening/Replacing the Base Cover Assembly. 5-14 5.5.7 . Removing/Replacing the Keyscan Board . 5-16 5.5.8 . Removing/Replacing the IR Board . 5-17 5.5.9 . Removing/Replacing the Floppy Drive . 5-18 5.5.10 . Removing/Replacing the LED Board . 5-19 5.5.11 . Removing/Replacing the Sleep Switch Board . 5-20 5.5.12 . Removing/Replacing the Sound/PCMCIA Board . 5-21 5.5.13 . Removing/Replacing the Main Board . 5-22 5.5.14 . Removing/Replacing the Display Bezel. 5-24 5.5.15 . Removing and Replacing the DAB Board . 5-25 5.5.16 . Removing and Replacing the LCD . Cover Assembly . 5-26 5.6 . Removing/Replacing the Inverter Board . 5-28 vi Contents 6 Illustrated Parts Listing 6.1 . Introduction . 6-1 6.2 . TM5000.