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SECTION FOUR
DISASSEMBLY/ASSEMBLY


4.1 FALCON030 DISASSEMBLY

Use the following procedure to disassemble the FALCON030. Refer to Assembly Drawings, Section 7.


4.1.1 Top Cover/Keyboard Removal

1.	Turn unit upside down.

2.	Remove the 4 screws, item 220, from the square holes. Remove the 3 screws, item 240, from the round holes. These fasten the top case to the bottom.

3.	Turn the unit upright and remove the top case, item 210.

4.	Remove the keyboard, item 200, by unplugging the keyboard harness connector located in the right front corner.


4.1.2 Shield and Speaker Removal

1.	Remove the 9 screws, item 80, holding the shield, item 160, and speaker assembly, items 170, 180, 1nd 190, in place.

2.	Remove the shield.


4.1.3 Floppy Disk Removal


1.	Turn the unit upside down.

2.	Remove the 3 screws, item 150, in the round holes.

3.	While holding the drive in place turn the unit back over.

4.	Lift the disk drive, item 120, slightly and unplug the power harness connector and the ribbon cable.

5.	Remove the drive, item 120, and standoffs, item 130.

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4.1.4 Power Supply Removal


1.	Unplug the wire harness connector in the right front corner of the power supply, item 90.

2.	Remove the 4 screws, item 80, at corners of power supply.

3.	Lift the power supply up out of the main assembly.


4.1.5 Memory Board Removal

1.	Lift the memory board, item 110, out of the unit.


4.1.6 Removal of Main Assembly from Bottom Case

1.	Remove three screws, item 80, from the front of the shield/printed circuit board assembly.

2.	If power supply has not already been removed, remove the power supply.

3.	Lift the assembly up from the front and pull forward.


4.1.7 Removal of Upper Shield from Printed Circuit Board

1.	Remove the 6 screws, item 50, from the upper shield, item 40.

2.	Remove the upper shield, item 40.

Note: Now that the major components are exposed, this is a convenient configuration for troubleshooting. The keyboard and disk drive may be re-connected and placed off to the side if those components are needed.

3.	Lift printed circuit assembly, item 30, away from the PCB insulator, item 20, and bottom shield, item 10.


4.2 FALCON030 RE-ASSEMBLY

1.	Place insulation panel, item 20, on Bottom Shield, item 10.

2.	Place Main Board, item 30, on top of Bottom Shield, item  10, over insulator panel item 20.

3.	Replace the 6 screws, item 50, in the upper shield, item 40.

4.	Place assembly in lower plastic case.

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5.	Replace the three screws, item 80, in the front of the shield/printed circuit board assembly.

6.	Replace the memory board, item 110, in the unit.

7.	Replace the power supply in the main assembly.

8.	Replace the 4 screws, item 80, at corners of power supply.

9.	Plug the wire harness connector in the right front corner of the power supply, item 90, into the main PCB.

10.	Replace the drive, item 120, and standoffs, item 130.

11.	Lift the disk drive, item 120, slightly and plug in the power harness connector and the ribbon cable.

12.	While holding the drive in place turn the unit over.

13.	Replace the 3 screws, item 150, in the round holes.

14.	Turn the unit back over.

15.	Replace the shield.

16.	Replace the 9 screws, item 80, holding the shield, item 160, and speaker assembly, items 170, 180, 1nd 190, in place.

17.	Replace the keyboard, item 200, and plug the keyboard harness connector located in the right front corner.

18.	Turn the unit upright and replace the top case, item 210.

19.	Replace the 4 screws, item 220, in the square holes. Replace the 3 screws, item 240, in the round holes. These fasten the top case to the bottom.

20.	Turn unit upside down.


Warning: It is strongly recommended that the computer be retested once in plastic to make sure that the reassembly was done correctly and there are no shorts to the shield.