Lenovo ThinkStation 4215 Owner's manual

ThinkStation
Hardware Maintenance Manual

Note
Before using this information and the product it supports, be sure to read and understand the Chapter 2, “Safety
information,” on page 3 and “Notices,” on page 171.
First Edition (February 2010)
© Copyright Lenovo 2010.
LENOVO products, data, computer software, and services have been developed exclusively at private expense and
are sold to governmental entities as commercial items as defined by 48 C.F.R. 2.101 with limited and restricted
rights to use, reproduction and disclosure.
LIMITED AND RESTRICTED RIGHTS NOTICE: If products, data, computer software, or services are delivered
pursuant a General Services Administration ″GSA″contract, use, reproduction, or disclosure is subject to restrictions
set forth in Contract No. GS-35F-05925.

Contents
Chapter 1. About this manual .....1
Important Safety Information .........1
Important information about replacing RoHS
compliant FRUs .............2
Chapter 2. Safety information .....3
General safety ..............3
Electrical safety .............3
Voltage-selection switch...........5
Safety inspection guide ...........5
Handling electrostatic discharge-sensitive devices . . 6
Grounding requirements ..........7
Safety notices (multi-lingual translations) .....7
Chapter 3. General information ....39
Online Books folder ...........39
Lenovo ThinkVantage Tools .........39
Lenovo Welcome ............39
Additional information resources .......40
Specifications ..............40
Chapter 4. General Checkout .....41
Problem determination tips .........41
Chapter 5. Diagnostics ........43
Lenovo ThinkVantage Toolbox ........43
Lenovo System Toolbox ..........43
PC-Doctor for Rescue and Recovery ......44
PC-Doctor for DOS ............44
Creating a diagnostic disc ........44
Running the diagnostic program from a
diagnostic disc ............45
Navigating through the diagnostics programs . . 45
Running tests.............45
Viewing the test log ..........47
Chapter 6. Using the Setup Utility
program ..............49
Starting the Setup Utility program.......49
Viewing and changing settings ........49
Using passwords ............49
Password considerations .........50
Power-On Password ..........50
Administrator Password .........50
Hard Disk Password ..........50
Setting, changing, and deleting a password. . . 50
Enabling or disabling a device ........51
Selecting a startup device..........51
Selecting a temporary startup device .....51
Selecting or changing the startup device sequence 52
Advanced settings ............52
Exiting from the Setup Utility program .....52
Chapter 7. Configuring RAID .....53
RAID Level ..............53
Configuring the system BIOS to enable SATA RAID
functionality ..............53
Creating RAID volumes ..........53
Deleting RAID volumes ..........54
Chapter 8. Symptom-to-FRU Index . . . 55
Hard disk drive boot error .........55
Power Supply Problems ..........55
Diagnostic error codes...........56
Beep symptoms .............77
POST error codes ............78
Miscellaneous error messages ........80
Undetermined problems ..........81
Chapter 9. Replacing FRUs ......83
Locations ...............83
Locating connectors on the front of your
computer ..............83
Locating connectors on the rear of your computer 84
Locating components ..........85
Locating parts on the system board .....86
Locating internal drives .........86
Removing the computer cover ........87
Removing and reinstalling the front bezel ....89
Installing or replacing a PCI card .......90
Installing or replacing a memory module ....92
Installing or replacing the optical drive .....94
Replacing the power supply assembly.....97
Replacing the battery ...........98
Replacing the heat sink and fan assembly ....99
Replacing the microprocessor ........101
Replacing the system board ........103
Replacing the primary hard disk drive .....106
Replacing the secondary hard disk drive ....109
Replacing the card reader .........112
Replacing the front fan assembly .......114
Replacing the rear fan assembly .......117
Replacing the front audio and USB assembly . . . 119
Replacing the internal speaker........120
Completing the FRU replacement ......122
Chapter 10. FRU lists ........125
Machine Type 4215 ...........125
Machine Type 4219 ...........133
Machine Type 4220 ...........141
Machine Type 4221 ...........150
Machine Type 4222 ...........158
Chapter 11. Additional service
information ............167
Security features ............167
Hardware-controlled passwords ......167
Operating system password .......167
© Copyright Lenovo 2010 iii

Vital product data ...........167
BIOS levels ..............167
Updating (flashing) the BIOS ........167
Updating (flashing) the BIOS from a disc . . . 168
Updating (flashing) BIOS from your operating
system ..............168
Recovering from a POST/BIOS update failure . . 168
Power management ...........170
Automatic configuration and power interface
(ACPI) BIOS.............170
Automatic Power-On features .......170
Appendix. Notices .........171
Television output notice ..........172
Trademarks ..............172
iv Hardware Maintenance Manual

Chapter 1. About this manual
This manual contains service and reference information for ThinkStation™
computers listed on the cover. It is intended only for trained servicers who are
familiar with Lenovo®computer products.
Before servicing a Lenovo product, be sure to read the Safety Information in
Chapter 2, “Safety information,” on page 3.
Chapter 8, “Symptom-to-FRU Index,” on page 55 and Chapter 11, “Additional
service information,” on page 167 chapters are not specific to any machine type
and are applicable to all ThinkStation computers.
This manual includes a complete FRU part number listing for each machine type
and model listed on the cover. If you have Internet access, FRU part numbers are
also available at:
http:/www.lenovo.com/support
Important Safety Information
Be sure to read all caution and danger statements in this book before performing
any of the instructions.
Veuillez lire toutes les consignes de type DANGER et ATTENTION du présent
document avant d’exécuter les instructions.
Lesen Sie unbedingt alle Hinweise vom Typ ″ACHTUNG″oder ″VORSICHT″in
dieser Dokumentation, bevor Sie irgendwelche Vorgänge durchführen
Leggere le istruzioni introdotte da ATTENZIONE e PERICOLO presenti nel
manuale prima di eseguire una qualsiasi delle istruzioni
Certifique-se de ler todas as instruções de cuidado e perigo neste manual antes de
executar qualquer uma das instruções
Es importante que lea todas las declaraciones de precaución y de peligro de este
manual antes de seguir las instrucciones.
© Copyright Lenovo 2010 1

Important information about replacing RoHS compliant FRUs
RoHS, The Restriction of Hazardous Substances in Electrical and Electronic
Equipment Directive (2002/95/EC) is a European Union legal requirement
affecting the global electronics industry. RoHS requirements must be
implemented on Lenovo products placed on the market and sold in the
European Union after June 2006. Products on the market before June 2006 are
not required to have RoHS compliant parts. If the parts are not compliant
originally, replacement parts can also be noncompliant, but in all cases, if the
parts are compliant, the replacement parts must also be compliant.
Note: RoHS and non-RoHS FRU part numbers with the same fit and function are
identified with unique FRU part numbers.
Lenovo plans to transition to RoHS compliance well before the implementation
date and expects its suppliers to be ready to support Lenovo’s requirements and
schedule in the EU. Products sold in 2005 will contain some RoHS compliant
FRUs. The following statement pertains to these products and any product Lenovo
produces containing RoHS compliant parts.
RoHS compliant ThinkStation parts have unique FRU part numbers. Before or after
June 2006, failed RoHS compliant parts must always be replaced using RoHS
compliant FRUs, so only the FRUs identified as compliant in the system hardware
maintenance manual or direct substitutions for those FRUs can be used.
Products marketed before June 2006 Products marketed after June 2006
Current or original
part
Replacement FRU Current or original
part
Replacement FRU
Non-RoHS Can be Non-RoHS Must be RoHS Must be RoHS
Non-RoHS Can be RoHS
Non-RoHS Can substitute for
RoHS
RoHS Must be RoHS
Note: A direct substitution is a part with a different FRU part number that is
automatically shipped by the distribution center at the time of order.
2Hardware Maintenance Manual

Chapter 2. Safety information
This chapter contains the safety information that you need to be familiar with
before servicing a computer.
General safety
Follow these rules to ensure general safety:
vObserve good housekeeping in the area of the machines during and after
maintenance.
vWhen lifting any heavy object:
1. Ensure you can stand safely without slipping.
2. Distribute the weight of the object equally between your feet.
3. Use a slow lifting force. Never move suddenly or twist when you attempt to
lift.
4. Lift by standing or by pushing up with your leg muscles; this action removes
the strain from the muscles in your back. Do not attempt to lift any objects that
weigh more than 16 kg (35 lb) or objects that you think are too heavy for you.
vDo not perform any action that causes hazards to the customer, or that makes
the equipment unsafe.
vBefore you start the machine, ensure that other service representatives and the
customer’s personnel are not in a hazardous position.
vPlace removed covers and other parts in a safe place, away from all personnel,
while you are servicing the machine.
vKeep your tool case away from walk areas so that other people will not trip over
it.
vDo not wear loose clothing that can be trapped in the moving parts of a
machine. Ensure that your sleeves are fastened or rolled up above your elbows.
If your hair is long, fasten it.
vInsert the ends of your necktie or scarf inside clothing or fasten it with a
nonconductive clip, approximately 8 centimeters (3 inches) from the end.
vDo not wear jewelry, chains, metal-frame eyeglasses, or metal fasteners for your
clothing.
Remember: Metal objects are good electrical conductors.
vWear safety glasses when you are: hammering, drilling, soldering, cutting wire,
attaching springs, using solvents, or working in any other conditions that might
be hazardous to your eyes.
vAfter service, reinstall all safety shields, guards, labels, and ground wires.
Replace any safety device that is worn or defective.
vReinstall all covers correctly before returning the machine to the customer.
Electrical safety
© Copyright Lenovo 2010 3

CAUTION:
Electrical current from power, telephone, and communication cables can be
hazardous. To avoid personal injury or equipment damage, disconnect the
attached power cords, telecommunication systems, networks, and modems before
you open the server/workstation covers, unless instructed otherwise in the
installation and configuration procedures.
Observe the following rules when working on electrical equipment.
Important: Use only approved tools and test equipment. Some hand tools have
handles covered with a soft material that does not insulate you when
working with live electrical currents.
Many customers have, near their equipment, rubber floor mats that
contain small conductive fibers to decrease electrostatic discharges. Do
not use this type of mat to protect yourself from an electric shock.
vFind the room emergency power-off (EPO) switch, disconnecting switch, or
electrical outlet. If an electrical accident occurs, you can then operate the switch
or unplug the power cord quickly.
vDo not work alone under hazardous conditions or near equipment that has
hazardous voltages.
vDisconnect all power before:
– Performing a mechanical inspection
– Working near power supplies
– Removing or installing Field Replaceable Units (FRUs)
vBefore you start to work on the machine, unplug the power cord. If you cannot
unplug it, ask the customer to power-off the wall box that supplies power to the
machine and to lock the wall box in the off position.
vIf you need to work on a machine that has exposed electrical circuits, observe
the following precautions:
– Ensure that another person, familiar with the power-off controls, is near you.
Remember: Another person must be there to switch off the power, if
necessary.
– Use only one hand when working with powered-on electrical equipment;
keep the other hand in your pocket or behind your back.
Remember: There must be a complete circuit to cause an electric shock. By
observing the above rule, you may prevent a current from passing through
your body.
– When using a tester, set the controls correctly and use the approved probe
leads and accessories for that tester.
– Stand on suitable rubber mats (obtained locally, if necessary) to insulate you
from grounds such as metal floor strips and machine frames.
Observe the special safety precautions when you work with very high voltages;
these instructions are in the safety sections of maintenance information. Use
extreme care when measuring high voltages.
vRegularly inspect and maintain your electrical hand tools for safe operational
condition.
vDo not use worn or broken tools and testers.
vNever assume that power has been disconnected from a circuit. First, check that it
has been powered-off.
4Hardware Maintenance Manual

vAlways look carefully for possible hazards in your work area. Examples of these
hazards are moist floors, nongrounded power extension cables, power surges,
and missing safety grounds.
vDo not touch live electrical circuits with the reflective surface of a plastic dental
mirror. The surface is conductive; such touching can cause personal injury and
machine damage.
vDo not service the following parts with the power on when they are removed
from their normal operating places in a machine:
– Power supply units
– Pumps
– Blowers and fans
– Motor generators
and similar units. (This practice ensures correct grounding of the units.)
vIf an electrical accident occurs:
– Use caution; do not become a victim yourself.
– Switch off power.
– Send another person to get medical aid.
Voltage-selection switch
Some computers are equipped with a voltage-selection switch located near the
power-cord connection point on the computer. If your computer has a
voltage-selection switch, ensure that you set the switch to match the voltage
available at your electrical outlet. Setting the voltage-selection switch incorrectly
can cause permanent damage to the computer.
If your computer does not have a voltage-selection switch, your computer is
designed to operate only at the voltage provided in the country or region where
the computer was originally purchased.
If you relocate your computer to another country, be aware of the following:
vIf your computer does not have a voltage-selection switch, do not connect the
computer to an electrical outlet until you have verified that the voltage provided
is the same as it was in the country or region where the computer was originally
purchased.
vIf your computer has a voltage selection switch, do not connect the computer to
an electrical outlet until you have verified that the voltage-selection switch is set
to match the voltage provided in that country or region.
If you are not sure of the voltage provided at your electrical outlet, contact your
local electric company or refer to official Web sites or other literature for travelers
to the country or region where you are located.
Safety inspection guide
The intent of this inspection guide is to assist you in identifying potentially unsafe
conditions on these products. Each machine, as it was designed and built, had
required safety items installed to protect users and service personnel from injury.
This guide addresses only those items. However, good judgment should be used to
identify potential safety hazards due to attachment of features or options not
covered by this inspection guide.
Chapter 2. Safety information 5

If any unsafe conditions are present, you must determine how serious the apparent
hazard could be and whether you can continue without first correcting the
problem.
Consider these conditions and the safety hazards they present:
vElectrical hazards, especially primary power (primary voltage on the frame can
cause serious or fatal electrical shock).
vExplosive hazards, such as a damaged CRT face or bulging capacitor
vMechanical hazards, such as loose or missing hardware
The guide consists of a series of steps presented in a checklist. Begin the checks
with the power off, and the power cord disconnected.
Checklist:
1. Check exterior covers for damage (loose, broken, or sharp edges).
2. Power-off the computer. Disconnect the power cord.
3. Check the power cord for:
a. A third-wire ground connector in good condition. Use a meter to measure
third-wire ground continuity for 0.1 ohm or less between the external
ground pin and frame ground.
b. The power cord should be the appropriate type as specified in the parts
listings.
c. Insulation must not be frayed or worn.
4. Remove the cover.
5. Check for any obvious alterations. Use good judgment as to the safety of any
alterations.
6. Check inside the unit for any obvious unsafe conditions, such as metal filings,
contamination, water or other liquids, or signs of fire or smoke damage.
7. Check for worn, frayed, or pinched cables.
8. Check that the power-supply cover fasteners (screws or rivets) have not been
removed or tampered with.
Handling electrostatic discharge-sensitive devices
Any computer part containing transistors or integrated circuits (ICs) should be
considered sensitive to electrostatic discharge (ESD). ESD damage can occur when
there is a difference in charge between objects. Protect against ESD damage by
equalizing the charge so that the machine, the part, the work mat, and the person
handling the part are all at the same charge.
Notes:
1. Use product-specific ESD procedures when they exceed the requirements noted
here.
2. Make sure that the ESD protective devices you use have been certified (ISO
9000) as fully effective.
When handling ESD-sensitive parts:
vKeep the parts in protective packages until they are inserted into the product.
vAvoid contact with other people while handling the part.
vWear a grounded wrist strap against your skin to eliminate static on your body.
6Hardware Maintenance Manual

vPrevent the part from touching your clothing. Most clothing is insulative and
retains a charge even when you are wearing a wrist strap.
vUse the black side of a grounded work mat to provide a static-free work surface.
The mat is especially useful when handling ESD-sensitive devices.
vSelect a grounding system, such as those listed below, to provide protection that
meets the specific service requirement.
Note: The use of a grounding system is desirable but not required to protect
against ESD damage.
– Attach the ESD ground clip to any frame ground, ground braid, or green-wire
ground.
– Use an ESD common ground or reference point when working on a
double-insulated or battery-operated system. You can use coax or
connector-outside shells on these systems.
– Use the round ground-prong of the ac plug on ac-operated computers.
Grounding requirements
Electrical grounding of the computer is required for operator safety and correct
system function. Proper grounding of the electrical outlet can be verified by a
certified electrician.
Safety notices (multi-lingual translations)
The caution and danger safety notices in this section are provided in the following
languages:
vEnglish
vArabic
vBrazilian/Portuguese
vChinese (simplified)
vChinese (traditional)
vFrench
vGerman
vHebrew
vItalian
vKorean
vSpanish
DANGER
Electrical current from power, telephone and communication cables is hazardous.
To avoid a shock hazard:
vDo not connect or disconnect any cables or perform installation, maintenance,
or reconfiguration of this product during an electrical storm.
vConnect all power cords to a properly wired and grounded electrical outlet.
Chapter 2. Safety information 7

vConnect to properly wired outlets any equipment that will be attached to this
product.
vWhen possible, use one hand only to connect or disconnect signal cables.
vNever turn on any equipment when there is evidence of fire, water, or
structural damage.
vDisconnect the attached power cords, telecommunications systems, networks,
and modems before you open the device covers, unless instructed otherwise
in the installation and configuration procedures.
vConnect and disconnect cables as described in the following tables when
installing, moving, or opening covers on this product or attached devices.
To Connect To Disconnect
1. Turn everything OFF.
2. First, attach all cables to devices.
3. Attach signal cables to connectors.
4. Attach power cords to outlet.
5. Turn device ON.
1. Turn everything OFF.
2. First, remove power cords from outlet.
3. Remove signal cables from connectors.
4. Remove all cables from devices.
8Hardware Maintenance Manual

CAUTION:
When replacing the lithium battery, use only Part Number 45C1566 or an
equivalent type battery recommended by the manufacturer. If your system has a
module containing a lithium battery, replace it only with the same module type
made by the same manufacturer. The battery contains lithium and can explode if
not properly used, handled, or disposed of.
Do not:
vThrow or immerse into water
vHeat to more than 100°C (212°F)
vRepair or disassemble
Dispose of the battery as required by local ordinances or regulations.
CAUTION:
When laser products (such as CD-ROMs, DVD-ROM drives, fiber optic devices,
or transmitters) are installed, note the following:
vDo not remove the covers. Removing the covers of the laser product could
result in exposure to hazardous laser radiation. There are no serviceable parts
inside the device.
vUse of controls or adjustments or performance of procedures other than those
specified herein might result in hazardous radiation exposure.
DANGER: Some laser products contain an embedded Class 3A or Class 3B laser
diode. Note the following:
Laser radiation when open. Do not stare into the beam, do not view
directly with optical instruments, and avoid direct exposure to the
beam.
≥18 kg (37 lbs) ≥32 kg (70.5 lbs) ≥55 kg (121.2 lbs)
CAUTION:
Use safe practices when lifting.
Chapter 2. Safety information 9

CAUTION:
The power control button on the device and the power switch on the power
supply do not turn off the electrical current supplied to the device. The device
also might have more than one power cord. To remove all electrical current from
the device, ensure that all power cords are disconnected from the power source.
1
2
10 Hardware Maintenance Manual

Chapter 2. Safety information 11

12 Hardware Maintenance Manual

≥18 kg (37 lbs) ≥32 kg (70.5 lbs) ≥55 kg (121.2 lbs)
1
2
Chapter 2. Safety information 13

PERIGO
A corrente elétrica proveniente de cabos de alimentação, de telefone e de
comunicações é perigosa.
Para evitar risco de choque elétrico:
vNão conecte nem desconecte nenhum cabo ou execute instalação, manutenção
ou reconfiguração deste produto durante uma tempestade com raios.
vConecte todos os cabos de alimentação a tomadas elétricas corretamente
instaladas e aterradas.
vTodo equipamento que for conectado a este produto deve ser conectado a
tomadas corretamente instaladas.
vQuando possível, utilize apenas uma das mãos para conectar ou desconectar
cabos de sinal.
vNunca ligue nenhum equipamento quando houver evidência de fogo, água ou
danos estruturais.
vAntes de abrir tampas de dispositivos, desconecte cabos de alimentação,
sistemas de telecomunicação, redes e modems conectados, a menos que
especificado de maneira diferente nos procedimentos de instalação e
configuração.
vConecte e desconecte os cabos conforme descrito na tabela apresentada a seguir
ao instalar, mover ou abrir tampas deste produto ou de dispositivos conectados.
Para Conectar: Para Desconectar:
1. DESLIGUE Tudo.
2. Primeiramente, conecte todos os cabos
aos dispositivos.
3. Conecte os cabos de sinal aos
conectores.
4. Conecte os cabos de alimentação às
tomadas.
5. LIGUE os dispositivos.
1. DESLIGUE Tudo.
2. Primeiramente, remova os cabos de
alimentação das tomadas.
3. Remova os cabos de sinal dos conectores.
4. Remova todos os cabos dos dispositivos.
14 Hardware Maintenance Manual