Monorail NT5100G-16M BD User manual

SERVICE & MAINTENANCE
MANUAL
October 1997

The information in this document is
subject to change without notice.
Monorail Inc. makes no warranty of any
kind with regard to this material.
Monorail shall not be liable for technical
or editorial errors or omissions contained
herein; nor for incidental or consequential
damages resulting from the furnishing,
performance, or use of this material.
This document contains information that is
protected by copyright. No part of this
document may be photocopied,
reproduced, or translated to another
language without the prior written con-
sent of Monorail Inc.
Product names mentioned herein may be
trademarks and/or registered trademarks
of their respective companies.
Printing History
Edition 2
October 1997
Copyright 1997 by Monorail Inc.
Monorail Inc.
1395 South Marietta Parkway
Building 900, Suite 900
Marietta, GA 30067
SERVICE MANUAL
2

Table of Contents
Preface, Recommended Materials, and Safety Warning ............................................................................4
A. Overall System Detail ..............................................................................................................5
B. Tightening the Computer Stand ..............................................................................................9
C. Removing Upper Housing........................................................................................................9
D. Removing/Replacing/Reinstalling: ......................................................................................11
D.1 LCD Panel ..............................................................................................................................11
D.2 Inverter Board ........................................................................................................................12
D.3 Button Board ..........................................................................................................................13
D.4 Speakers ................................................................................................................................14
D.5 Flex Circuit..............................................................................................................................14
E. Accessing the Internal Components ....................................................................................15
E.1 Separating the Base Frame and LCD support.............................................................................15
E.2 Processor Chip ........................................................................................................................16
E.3 Jumper Settings........................................................................................................................17
E.4 Expansion System Memory ......................................................................................................18
E.5 Video Memory ........................................................................................................................19
E.6 Removing the System Board......................................................................................................20
E.7 Hard Drive ..............................................................................................................................21
E.8 ISA Card ................................................................................................................................21
E.9 Power Supply ..........................................................................................................................22
E.10 Floppy Drive..........................................................................................................................23
E.11 CD ROM ..............................................................................................................................24
E.12 Fan ......................................................................................................................................25
E.13 I/O Board ............................................................................................................................25
F. Reconnecting the Base Frame and LCD Support ..............................................................26
G. Reconnecting the Upper Housing ........................................................................................26
H. Accessing System BIOS...........................................................................................................27
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Preface
Monorail has developed this service and maintenance manual for qualified service technicians to use when
servicing Monorail computers. Monorail provides training material and technical documentation to select organizations
under the Monorail Authorized Service Center program.
Services performed by anyone other than Monorail Authorized Service Center personnel may void the Monorail Limited
Warranty. Assistance with problems resulting from unauthorized repairs can be provided by Monorail for a fee.
This manual should be read in its entirety and followed carefully when performing all service operations on the
Monorail computer.
Thank you for your cooperation and thank you for your interest in Monorail!
Recommended Materials
1. Large flat-blade screwdriver
2. T-10, T-15 Torx drivers
3. Pliers or vice
4. Chip-puller
5. Hex driver
6. Wire cutters
7. Nut driver
Safety Warning
The interior of the Monorail computer is not a customer access area (open frame power supply and inverter board) and
poses a serious risk of electrical shock. Before accessing the interior of the unit, you MUST disconnect the power cord
from the A/C plug. See the figure below.
SERVICE MANUAL
4
Figure 13
Inverter
Board
Power
Supply

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5
A. Overall System Detail
Detail # Description
1 cam lock
2 cam lock plastic latch
3 cam lock plastic latch
4 metal lock tab (part of base frame)
5 backlight connector (part of LCD panel)*
6 inverter board
7 LCD panel
8 flex circuit connector *
9 inverter board cable
10 microphone boot
11 button board cable
12 button board
13 LCD support
14 adhesive tape
15 speaker holder
16 speaker connector and connector
17 snap (part of speaker holder)
18 speaker
19 speaker wire hole (part of speaker holder)
20 LCD data flex cable connector
21 LCD data flex cable connector tabs
22 LCD data flex cable
23 tab (part of LCD support)
24 system board
25 I/O board
26 Z-clip
27 ZIF socket
28 ZIF socket lever
29 microprocessor
30 processor heat sink
31 processor thermal pad
32 SIMM memory modules connector
33 SIMM memory modules connector
34 hard drive power cable and connector
35 hard drive IDE data cable and connector
36 microphone cable and connector
(part of button board cable)
37 connector for button board cable and connector
* Active Matrix (TFT) and 12.1” Panels use
a flex circuit adapter board
Detail # Description
38 inverter board cable and connector
(part of system board)
39 hard drive
40 shoulder screw (hard drive mounting screw)
41 ISA cover plate
42 floppy disk drive
43 fan
44 ISA card connector (part of I/O board)
45 screw
46 ISA mounting tab
47 ISA plate
48 screw, ISA mounting tab
49 screw, power supply
50 power switch connector
(part of power supply)
51 A/C plug
52 grounding wire (part of power supply)
53 CD ROM power connector
54 floppy drive power connector
55 floppy drive data cable and connector
56 CD ROM
57 CD ROM audio cable and connector
58 CD ROM data cable and connector
59 CD ROM mounting plate
60 I/O cover plate and connectors
61 system board DC power cable and connector
62 adjustment screw, stand
63 upper housing
64 I/O connector (part of system board)
65 power supply
66 power switch
67 power cable management clip
68 lower housing
69 video memory
70 floppy drive plate

SERVICE MANUAL
6
63
47
7
68
66
42
68
62
63
60
3
1
2
4
Diagram 1
Diagram 2 lock tab
cover

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7
7
18
15
8
23
13
25
58
37
34
61
55 35 6932, 33
12
(14 not shown)
56
9
11
10
3838 29 64 57 36 16 20
J22
J25
J4
J15J3
J23
Diagram 3
Diagram 4

SERVICE MANUAL
8
65
56
58
35
34
32, 33
22
20
66
16
36
57
38 26– 31 System
Board
24
37
61
41
42
55
53
67
39
43
51, 52
60 25, 44
Diagram 5

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B. Tightening the
Computer Stand
See Figure 1. If the computer stand is
loose, use a screwdriver to turn the
screw (Detail 62) on each side of the
stand a quarter turn. If the display still
seems too loose, repeat this procedure
until desired friction is achieved.
C. Removing the
Upper Housing
To perform any operations on this unit,
you must remove the upper housing
(Detail 63).
Step 1
Place the unit face down on a protective
foam surface to prevent scratching.
Step 2
See Figure 2. Insert a large, flat-blade
screwdriver into the plastic cross-shaped
opening of the cam lock (Detail 1). Push
down on the plastic latch (Detail 2) while
rotating the cam lock (Detail 1) counter-
clockwise 90 degrees.
Once you’ve finished, the CD ROM and
floppy drives will have moved toward
the center of the machine (about .1
inch), and the plastic latch will have
moved from position (Detail 2) to posi-
tion (Detail 3). This action recesses the
floppy disk drive and CD ROM drive
from the upper housing (Detail 63),
enabling the computer to
be disassembled.
Figure 1
Figure 2
2
3
63
1
63
62

SERVICE MANUAL
10
Step 3
Remove the 6 black pan-head torx screws
with a T-15 driver, as shown in Figure 2a.
Step 4
See Figure 3. Carefully position the unit so
that the LCD panel (Detail 7) is face up.
Avoid bending the metal lock tab (Detail 4)
on the back of the unit.
NOTE: Elevating the unit on two boards
will prevent damage to the metal lock tab.
Lift the upper housing (Detail 63) from the
computer assembly to access the interior.
Slightly rotate the stand higher than the top
of the LCD panel to release the upper hous-
ing (Detail 63) from the computer. (The
upper housing fits tightly, so slight rota-
tions, as depicted by the arrow heads in
Figure 3, might be required to remove the
upper housing completely.
Figure 3
Figure 2a
3
63
4
21
7
lock tab
cover

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D. Removing/
Replacing/Reinstalling:
Warning: Before accessing the interior
of the unit, you must disconnect the
power cord from the A/C plug.
D.1 LCD Panel
Step 1
See Figure 4. Remove the dual pin
connector(s) (Detail 5) from the inverter
board (Detail 6).
Step 2
Refer to Figure 4a. Remove the 4
shoulder screws in the corners of the
LCD panel (Detail 7), using a flat-blade
screwdriver.
Step 3
Lift the screen and gently detach the flex
circuit connector (Detail 8) from the
bottom of the LCD panel (Detail 7) or
the LCD adapter board.
NOTE: The flex circuit connector is
delicate! Handle with care.
To reinstall: reverse steps 1–3.
Figure 4
Figure 4a
5
6
7
7
8

SERVICE MANUAL
12
D.2 Inverter Board
Warning: Before accessing the interior
of the unit, you must disconnect the
power cord from the A/C plug.
Step 1
Refer to Figure 5. Disconnect the dual
pin connector(s) (Detail 5) and the
inverter board cable (Detail 9).
Step 2
Refer to Figure 6. Remove the 2 screws
at the opposite ends of the inverter
board using a T-10 driver.
To reinstall: reverse steps 1 and 2. DO
NOT route the inverter board cable
(Detail 9) under the inverter board.
Replace the tape as originally installed.
Figure 5
Figure 6
6
Tape
9
5
6
9

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13
D.3 Button Board*
Step 1
Refer to Figure 7. Remove the micro-
phone boot (Detail 10) at the top of
the button board (Detail 12).
Step 2
Disconnect the button board cable
(Detail 11) in the corner of the button
board (Detail 12).
Step 3
See Figure 7a. Pull on the button
board (Detail 12) to release the
adhesive (Detail 14) from the LCD
support (Detail 13).
NOTE: This action can be difficult.
Pry as gently as possible with a flat-
blade screwdriver at the location
shown.
To reinstall: reverse steps 1–3. Add
new adhesive (3M adhesive number
4921, .016” elastomeric foam) prior
to installing the new button board.
* Not required for PCs with speakers
located in the base.
Figure 7
Figure 7a
12
11
10
12
Prying Location
14
13

SERVICE MANUAL
14
D.4 Speakers*
Step 1
Refer to Figure 8. Press the top snap on each speaker holder
(Detail 15) and remove the speaker holders from the LCD
support (Detail 13).
Step 2
To access the system board, see Section E.
Step 3
Refer to Figures 9 and 10. To remove the speaker (Detail 18)
from the speaker holder (Detail 15), depress the snaps (Detail
17) on each speaker holder.
To Reinstall: reverse steps 1-3. Be sure to route the cable
through the mouse hole (Detail 19). See Figures 10 and 11.
*Not required for PCs with speakers located in the base.
D.5 Flex Circuit*
NOTE: Refer to Section D.1 of this manual (Removing the LCD
panel) to perform this function.
Step 1
Remove the LCD Panel (Detail 7) as shown in Section D.1.
NOTE: First perform Section E.1 ( Separating the Base Frame
and LCD Support
) before proceeding.
Step 3
Locate the system board flex connector (Detail 20) and gently
apply force to the connector tabs, horizontal to the system
board, (Detail 21) on either side of the flex circuit cable
(Detail 22).
NOTE: The connector is easily damaged. Apply force gently!
Step 4
Remove the flex circuit cable (Detail 22) as shown. The
connector is a ZIF connector. The flex circiut should diengage
with minimal effort.
To Reinstall: reverse steps 1-3.
* Active Matrix (TFT) and 12.1” Panels use a flex circuit
adapter board
Figure 8 (speakers facing up)
Figure 9
Figure 10
Figure 11
15 13
15
18
17
18
19
19
15
(speakers facing down)
(speakers facing down)

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E. Accessing the Internal
Components
E.1 Separating the LCD
Support and Base Frame
Step 1 Remove the four T-15 screws from the LCD support
(Detail 13) using a T-15 driver.
Step 2 Refer to Figures 13 and 13a. Separate the LCD
support (Detail 13) from the unit by applying pressure at
the point (Detail 23) shown. This action will disconnect the
system board connector (Detail 64) from the I/O board
(Detail 25).
Note : Before removing any cables or connections, note all
cable routing for re-assembly.
Step 3 See Figure 15. Partialy opening the unit, remove the
CD-ROM audio cable
(Detail 16) from the system board
(Detail 24) connector.
Step 4 See Figure 15. Open the unit by hinging it away
from you, as shown. Disconnect the floppy disk drive data
cable, CD-ROM data cable and DC power cable from the
system board. Lay the LCD subassembly, LCD screen down,
onto a soft scratch resistant, ESD safe surface.
Figure 12
Figure 12a
Figure 13
Figure 13a
Figure 15
22
21
20
21
22
23
Floppy
Removal CD-
ROM
Removal
13
18
64
25

SERVICE MANUAL
16
E.2 Processor Chip
NOTE: First perform Section E.1
(
Separating the Base Frame and LCD
Support
) before proceeding.
Step 1
See Figure 16. Unhook one edge of the
heat sink clip (Detail 26) from the ZIF
socket (Detail 27) and remove it.
NOTE: One type of clip/heat sink is
shown; several types are available.
Step 2
Raise the lever (Detail 28) of the ZIF sock-
et (Detail 27) in the direction shown and
remove the processor chip (Detail 29)
and heat sink (Detail 30).
Step 3
Refer to Figure 16a. Install the new
processor chip, paying close attention to
the component keying. Be sure to align
pin 1.
Step 4
After the processor (Detail 29) is seated
flush, lower the lever (Detail 28) of the ZIF
socket.
Step 5
Before reinstalling the heat sink (Detail 30),
replace the thermal pad (Detail 31) and
heat sink (Detail 30).
NOTE: ZIF stands for Zero Insertion
Force. It should take no force to seat the
processor properly. If the processor does
not seat properly, re-check the pins and
key alignment.
Figure 16a
Figure 16
28
30
29 27 26
31
29
28
30

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17
E.3 Jumper Settings
NOTE: First perform Section E.1 ( Separating the Base Frame and LCD Support ) before proceeding.
See Diagram 6.
Erasing CMOS (J38)
1) To clear the CMOS, remove the jumper from pins 1 and 2 of J38, and install it on pins 2 and 3 for 10
seconds. Reinstall the jumper on pins 1 and 2 for normal operation.
BIOS Programming Voltage (J36)
The programming voltage for the ROM BIOS is set from the factory and is dependent on the make of the ROM
chip.
Changing the Processor (J1, J6, J7, J8, J16 & J37)
Jumpers J1, J6, J7, J8, J16 and J37 should be verified against the following tables if the processor is replaced
with one of a different speed, make or MMX capable.
NOTE: MMX processors require a MMX compatible system board. The MMX system board is identified by a
VRM (Voltage Regulator Module) adapter board located to the left of the microprocessor.
Monorail System Board Jumper Settings Model: NT5100G-16M BD
Rockwell
R6749
Microprocessor
MMX
VRM
SiS
5513
J21
SiS
5511
SiS
5512
CHIPS
65548
J38
1-2 SHORT
2-3 SHORT
CMOS Disposition
Maintain
Destroy Vpp
+5
+12
J36
3-2 SHORT
2-1 SHORT
Supplier
ROM Programming Voltage
CMOS MEMORY
MXIC
SelfOPEN SST, Atmel
PROC
P55/K6
P54C
J1
1-2 SHORT
1-2 SHORT
Processor I/O Voltage
K5
CPU VCC
3.3V
3.3V
3.5V2-3 SHORT
Output
3.3V
3.2V
J2
CLOSE
OPEN
CPU
Processor Core Volatage Settings
––
––
2.9VCLOSE
J3
CLOSE
CLOSE
Supported System Boards Revisions: 3C - 4B Updated: 11/4/97
OPEN
J7
OPEN
CLOSE
CLOSE
J8
OPEN
CLOSE
CLOSE
AMD K6-166/200
2.8VOPENOPEN INTEL P55C
Pentium
150/166
133/120
3-4
CLOSE
OPEN
J16 CPU SPEED
200CLOSE
1-2
CLOSE
CLOSE
OPEN
75/90
P55/K6
166
133
200
233
uP
75
90/120/150
133/166/200
K5
PR166
PR133/150
PR75OPENOPEN
3-4
OPEN
OPEN
J26 FLAT PANEL SETTING
CLOSE
1-2
OPEN
OPEN
CLOSE
CLOSE
CLOSE
CLOSE
OPEN
OPEN
CLOSE
CLOSE
OPEN
CLOSE
5-6
OPEN
CLOSE
OPEN
OPEN
CLOSE
OPEN
CLOSE
CLOSE
PANEL
SANYO EH53-22NTK
Hitachi TX31D21VC1CBE
SANYO JK53-22NTV
12.1" DSTN ALTERNATE
SHARP LM64C381OPEN
PANEL TYPE
10.4" DSTN
12.1" TFT
12.1" DSTN
12.1" DSTN
10.4" DSTN
2-1
CLOSE
OPEN
J37 Frequency Setting
CLOSE
4-3
CLOSE
CLOSE
OPEN
OPENOPEN
CPU
50
60
66.6
40
PCI
25
30
33.3
20
1
2
3
1
3
5
2
4
6
J38
J7
J8
321
J36
321
J35
J26
321
J1
4321
J37
34
12
J16
J2
J3
SHORT 3-2
J35 L2 TYPE
3 2 1TYPE
SYNC
ASYNC SHORT 1-2
Diagram 6

SERVICE MANUAL
18
E.4 Expansion System
Memory
Warning: Before accessing the interior of the unit,
you must disconnect the power cord from the A/C
plug.
NOTE: First perform Section E.1 ( Separating the
Base Frame and LCD Support
) before proceeding.
Installing
See Figures 17, 18, and 18a.
The system memory
must be upgraded with two SIMM modules (Detail
32) of the same type. System memory should be
upgraded with 72 pin, nonparity, +5.0 volt, 60ns,
EDO SIMMs.
Install the upper module (J22) first. See Section E.4.
Step 1
Insert the SIMM module (Detail 32) into the socket, with
the key to the left, and verify that the SIMM is seated
properly in the socket.
Step 2
Lightly press on the SIMM in the direction indicated
by the arrow and allow it to pivot back into the
socket. Stop applying pressure after the lock
mechanisms (Detail 33) on both sides of the socket
have engaged.
Step 3
Repeat steps 1 and 2 for J23. See Section E.4.
Removing
To remove expanded system memory (Detail 32),
lightly apply horizontal pressure to both lock mech-
anisms (Detail 33) away from the SIMM.
The SIMM is unlocked when it pivots upward from
its locked position. The SIMM can be removed at
this point.
Remove the SIMM in J23 first. See Section E.4.
NOTE: To save system memory changes to CMOS
enter BIOS setup and perform a “Save and Exit”
from the BIOS setup screen. See Section H
(Accessing System BIOS)
Figure 17
Figure 18
Figure 18a
33
32
33
J22
J23
32
32
33
33

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19
E.5 Video Memory
Step 1
See Figure 19. Visually inspect the video memory chip
(Detail 69) so that you can orient it with pin 1 of the
socket
(identified by a bevel in the corner).
Step 2
Align the pins and press into place with thumb
pressure until seated.
NOTE: To remove the video memory upgrade, use a
chip-pulling device. See Figure 19a.
NOTE: Some models do not have socketed video
memory.
Figure 19
Figure 19a
69
69

SERVICE MANUAL
20
E.6 Removing the
System Board from the
LCD Support Assembly
Warning: Before accessing the interior of
the unit, you must disconnect the power
cord from the A/C plug.
NOTE: Refer to Section E (Separating
the Base Frame and LCD support) before
proceeding.
Note: When replacing the system board,
remove the microprocessor, modem chip,
and video ram chip for reuse.
Step 1
Refer to Figure 20. Disconnect the hard
drive power cable (Detail 34) and the
hard drive data cable (Detail 35).
Step 2
Disconnect the internal speaker cable (Detail 16) and the LCD flex cable (Detail 22).
Step 3
Disconnect the microphone cable (Detail 36). Not required on some models.
Step 4
Disconnect the button board cable (Detail 37) and the inverter board cable (Detail 38).
NOTE: The following is a list of the cables that should already be removed at this point. See Diagram 4 on page 7.
• CD audio cable (J25) (Detail 57) • Main power cable (J4) (Detail 61)
• Floppy drive cable (J3) (Detail 55) • CD ROM data cable (J15) (Detail 58)
Step 5
See Figure 20. Remove the five M-3 screws using a T-10 driver. Lift the system board from the LCD support.
To Reinstall: Reverse steps 1-5.
Figure 20
Figure 21
Figure 21a
22
13
36
35
34
24
38
16
37
13
39
39
13
40