Page 3 - Table of Contents
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 3 of 106 Revision A01 Table of Contents 1 BEFORE YOU BEGIN ..................................................................................................... 6 1.1 R ECOMMENDED T OOLS .........................................................
Page 6 - Before You Begin; Recommended Tools; Before Working Inside Your Computer
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 6 of 106 Revision A01 1 Before You Begin This chapter provides procedures for removing and installing the components in your computer. Unless otherwise noted, each procedure assumes that the following: • You have performed the steps in 91H T...
Page 8 - Screw Chart
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 8 of 106 Revision A01 c. Remove the PC Card or Express Card. d. Then close the protective door. 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...
Page 13 - XBay Devices
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 13 of 106 Revision A01 18815 XFR LCD ASSY TOUCH SCREEN 8 18802 PALMREST ASSY 2 18803 CARD CAGE ON BASE CHASSIS 4 18623 KEYBOARD ASSY 3 18823 MOTHERBOARD ASSY 2 18591 PAN HEAD SCREW M2.5X8 2 18802 PALMREST ASSY 2 18634 JACK SCREW FOR VGA PORT...
Page 14 - Hard Drive
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 14 of 106 Revision A01 1 Optical drive 2 Device Latch release 4. Pull the device out of the XBay. To install a device, push the new device into the XBay until it clicks into place. 3 Hard Drive CAUTION: If you remove the hard drive from the ...
Page 17 - Replacing the Stylus Clip
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 17 of 106 Revision A01 9. Slide the hard drive into the bay until it is fully seated. 10. Replace and secure the hard disk drive compartment cover with the quarter-turn latches. 11. Use the Operating System CD to install the operating system...
Page 19 - Replacing the Stylus; Handle
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 19 of 106 Revision A01 4. Tighten the screw, ensuring the screw head secures the stylus clip in place. NOTE: If you relocate the stylus from one side of the handle to the other, remember to tighten the screw that was loosened in step 1 . NOT...
Page 20 - Removing the Handle
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 20 of 106 Revision A01 1 Main handle assembly 2 Handle cover (2) 5.1 Removing the Handle 1. Remove the 4 screws (2 on each handle cover) that secure the handle covers as shown in the figure above. 2. Remove the 6 screws (3 on each side) on t...
Page 21 - Port Covers; Comms Door; Removing the Comms Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 21 of 106 Revision A01 4. Align each of the handle covers over the main handle assembly ends as shown. 5. If your XFR D630 is equipped with the optional Touch Screen, please refer to 97H Replacing the Stylus Clip for instructions regarding i...
Page 22 - Installing the Comms Door; Docking Door; Removing the Docking Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 22 of 106 Revision A01 6.1.2 Installing the Comms Door 1. Align the Comms 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 ...
Page 24 - Installing the Docking Door
Dell TM XFR D630 Fully Rugged Notebook 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 - VGA Door; Removing the VGA Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 25 of 106 Revision A01 3. Secure the docking door with the 6 screws provided. 6.3 VGA Door The VGA Door is located on the rear panel of the notebook, and protects the serial and video connectors. 6.3.1 Removing the VGA Door NOTE: The VGA Doo...
Page 27 - Installing the VGA Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 27 of 106 Revision A01 6.3.2 Installing the VGA Door 1. Place the 2 screw mounts on 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...
Page 28 - Power Door; Removing the Power Door; Installing the Power Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 28 of 106 Revision A01 6.4 Power Door The Power Door is located on the rear panel of the notebook, 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. ...
Page 29 - XBay Door; Removing the XBay Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 29 of 106 Revision A01 2. Use the 2 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 optic...
Page 30 - Installing the XBay Door
Dell TM XFR D630 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 - Audio Ports/WiFi Door; Removing the Audio Ports/WiFi Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 31 of 106 Revision A01 2. Using the 2 screws provided, secure the XBay Door to the notebook. 6.6 Audio Ports/WiFi Door The Audio Ports/WiFi Door is located on the left side of the notebook, and protects the notebook’s audio connectors, smart...
Page 32 - Installing the Audio Ports/WiFi Door; USB Side Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 32 of 106 Revision A01 6.6.2 Installing the Audio Ports/WiFi Door 1. Place the Audio Ports/Wifi 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 ho...
Page 33 - Removing the USB Side Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 33 of 106 Revision A01 6.7.1 Removing the USB Side 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 t...
Page 34 - USB Rear Door; Removing USB Rear Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 34 of 106 Revision A01 6.8 USB Rear Door The 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 ...
Page 35 - Installing USB Rear Door; PC Card Slot Door; Removing the PC Card Slot Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 35 of 106 Revision A01 6.8.2 Installing USB Rear Door 1. Position the USB Rear Door onto the notebook, aligning it with the 2 screw mount holes on the notebook. Then align the gasket with the screw holes on the USB Rear Door. 2. Using the 2 ...
Page 36 - Installing the PC Card Slot Door
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 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 ...
Page 37 - Hinge Cover; Removing the Hinge Cover
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 37 of 106 Revision A01 7 Hinge Cover 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 y...
Page 39 - Installing the Hinge Cover; Keyboards; Standard Keyboard; Removing the Standard Keyboard
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 39 of 106 Revision A01 5. Starting on the right side of the notebook, use a plastic scribe inserted in the hinge area to pry up the hinge cover. Lift the right side of the hinge cover away from the notebook. Then go to the left side, and sim...
Page 41 - Installing the Standard Keyboard; Rugged Keyboard; Removing the Rugged Keyboard
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 41 of 106 Revision A01 8.1.2 Installing the Standard Keyboard 1. Attach the keyboard cable to the motherboard. 2. Lay the keyboard tray in position and tighten down the 15 captive screws. 3. Replace the hinge cover (see 101H Installing the H...
Page 44 - Installing the Rugged Keyboard
Dell TM XFR D630 Fully Rugged Notebook 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 51 - Memory; DIMM A
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 51 of 106 Revision A01 12. Fasten the 2 M2x6 screws shown in the image below to complete the installation of the top metal bracket. 13. Replace the hinge cover (see 104H Installing the Hinge Cover). 9 Memory CAUTION: Before you begin any of ...
Page 53 - DIMM B
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 53 of 106 Revision A01 1 tab 2 notch 6. Replace the keyboard (see 108H Keyboards). 7. Replace the hinge cover (see 109H Installing the Hinge Cover). 9.2 DIMM B NOTICE: If you need to install memory modules in two connectors, install a memory...
Page 55 - Display Assembly
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 55 of 106 Revision A01 b. Slide the module firmly into the slot at a 45-degree angle, and rotate the module down until it clicks into place. If you do not feel the click, remove the module and reinstall it. NOTE: If the memory module is not ...
Page 56 - Removing the Display Assembly
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 56 of 106 Revision A01 10.1 Removing the Display Assembly 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 electrostati...
Page 60 - Installing the Display Assembly
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 60 of 106 Revision A01 10.2 Installing the Display Assembly NOTICE: To avoid damage to your computer, when replacing the display assembly be careful to reroute the cables in the appropriate cable channels. NOTE: If the display assembly was d...
Page 62 - Removing the Display Bezel
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 62 of 106 Revision A01 Grommets 8. Install the keyboard (see 118H Keyboards). 9. Install the hinge cover (see 119H Installing the Hinge Cover). 10.3 Removing the Display Bezel CAUTION: Before working inside your computer, follow the safety i...
Page 63 - Installing the Display Bezel
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 63 of 106 Revision A01 1 display bezel overlay 2 display bezel 3 display panel 4 display back cover PART NUMBER SCREW TYPE QUANTITY 18428 CSK SCREW M2 X 8-BLACK 2 18417 PAN HEAD SCREW M2 X 12-BLACK 7 18114 SHOULDER SCREW M2.5 6 4. Remove the...
Page 65 - Installing the Display Panel
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 65 of 106 Revision A01 6. For the optional Touch Screen displays, pull the touch controller cable through the rubber grommet in the antenna cable assembly on the left side hinge. These antenna cables are part of the back cover assembly and m...
Page 66 - Removing the Display Top Cover; Installing the Display Top Cover
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 66 of 106 Revision A01 Location of left and right display grommets 6. Install hinge on each side, on top of display panel brackets. Secure each hinge to top cover with 3 M2.5 X 5-mm screws. NOTE: Hinges are labeled R (right) and L (left) and...
Page 67 - Removing the Display Latch
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 67 of 106 Revision A01 1. Follow the instructions in 133H Before You Begin. 2. Install the display panel (see 134H Installing the Display Panel). 3. Install the display bezel (see 135H Installing the Display Bezel). 4. Install the display as...
Page 68 - Installing the Display Latch; Internal Card with Bluetooth® Wireless; Removing the Bluetooth® Wireless Card
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 68 of 106 Revision A01 5. Remove the latch spring from the top cover and slide the latch out of the top cover. 10.10 Installing the Display Latch 1. Install the latch and secure with the 2 screws and washers. Do not fully tighten screws at t...
Page 69 - Installing the Bluetooth® Wireless Card
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 69 of 106 Revision A01 5. Lift the card from the compartment, ensuring that you do not pull on 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 comp...
Page 73 - Flash Cache Module; Removing the Flash Cache Module
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 73 of 106 Revision A01 7. Install the keyboard (see 150H Keyboards). 8. Install the hinge cover (see 151H Installing the Hinge Cover). 12.2 Flash Cache Module CAUTION: Before you begin any of the procedures in this section, follow the safety...
Page 74 - Installing the Flash Cache Module
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 74 of 106 Revision A01 NOTE: If you leave the area, ground yourself again when you return to the computer. 4. Release the FCM by pushing the metal securing brackets away from the card until the card pops up slightly. 5. Remove the FCM. 1 FCM...
Page 76 - Removing the Coin-Cell Battery
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 76 of 106 Revision A01 1 SIM card 2 metal brackets (2) NOTICE: To prevent electrostatic discharge (ESD), hold the card in your hand before you insert or remove the card. Do not touch the SIM card connectors. 2. Turn the computer upside-down ...
Page 77 - Installing the Coin-Cell Battery
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 77 of 106 Revision A01 4. Remove the battery cable connector from the connector on the system board. 5. Being careful not to break the plastic, lift the battery slightly and slide the battery out from under the plastic tab until it has been ...
Page 78 - Palm Rest; Removing the Palm Rest
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 78 of 106 Revision A01 14 Palm Rest 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 yo...
Page 80 - Installing the Palm Rest
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 80 of 106 Revision A01 1 touch pad connector 14.2 Installing the Palm Rest NOTICE: When reinstalling the palm rest, ensure that you reconnect the USB cable to the IO dash board, and then reconnect the touch pad cable connector to the system ...
Page 81 - Cards; Removing the WLAN Card
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 81 of 106 Revision A01 5. Replace the display assembly (see 173H Installing the Display Assembly). 6. Replace the keyboard (see 174H Keyboards). 7. Replace the XBay device (see 175H XBay Devices). 8. Replace the hinge cover (see 176H Install...
Page 83 - Installing the WLAN Card
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 83 of 106 Revision A01 15.2 Installing the WLAN Card 1. Move any antenna cables out of the way to make space for the WLAN card. 2. Insert the WLAN card into the system board connector at a 45-degree angle, and press the card into the metal s...
Page 84 - Modem; Removing the Modem
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 84 of 106 Revision A01 4. Replace the palm rest (see 182H Installing the Palm Rest). 5. Replace the display assembly (see 183H Installing the Display Assembly). 6. Replace the keyboard (see 184H Keyboards). 7. Replace the hinge cover (see 18...
Page 85 - Installing the Modem; Processor Thermal-Cooling Assembly
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 85 of 106 Revision A01 1 modem pull-tab 2 M2 x 3-mm screw 3 modem cable 4 system board connector NOTICE: Do not disconnect the modem cable from the system board. 9. Disconnect the modem cable from the modem. 16.2 Installing the Modem NOTE: W...
Page 86 - Removing the Processor Thermal-Cooling
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 86 of 106 Revision A01 17.1 Removing the Processor Thermal-Cooling Assembly 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 ...
Page 87 - Installing the Processor Thermal-Cooling
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 87 of 106 Revision A01 9. Lift the processor thermal-cooling assembly out of the computer. 17.2 Installing the Processor Thermal-Cooling Assembly CAUTION: Before working inside your computer, follow the safety instructions in the XFR D630 Pr...
Page 88 - Processor; Removing the Processor
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 88 of 106 Revision A01 processor thermal-cooling assembly. The new processor thermal-cooling assembly has new pads already installed. 5. Install the heat sink. Place the processor thermal-cooling assembly on the system board. 6. Tighten in c...
Page 89 - Installing the Processor
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 89 of 106 Revision A01 7. Remove the processor thermal-cooling assembly (see 215H Removing the Processor Thermal- Cooling Assembly). NOTICE: When removing the processor, pull it straight up. Be careful not to bend the pins on the processor. ...
Page 90 - PC Card Reader
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 90 of 106 Revision A01 NOTICE: To prevent intermittent contact between the ZIF-socket cam screw and the processor when removing or replacing the processor, press to apply slight pressure to the center of the processor while turning the cam s...
Page 91 - Removing the PC Card Cage
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 91 of 106 Revision A01 periodically touching an unpainted metal surface (such as a connector on the back of the computer). 19.1 Removing the PC Card Cage 1. Follow the instructions in 224H Before You Begin. 2. Remove the hinge cover (see 225...
Page 92 - Installing the PC Card Cage; Speaker; Removing the Speaker
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 92 of 106 Revision A01 NOTICE: If you are servicing the system board, RF Passthru board or bottom chassis, continue with next steps to remove the PC Card interface board. 10. Remove the screw and then disconnect the interface board connector...
Page 93 - Installing the Speaker; Fan; Removing the Fan
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 93 of 106 Revision A01 6. Remove the palm rest (see 241H Removing the Palm Rest). 7. Disconnect the speaker connector from the system board. 1 Speaker 2 Speaker connector NOTICE: Handle the speakers with care to avoid damaging them. 8. Pull ...
Page 94 - Installing the Fan
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 94 of 106 Revision A01 1. Follow the instructions in 248H Before You Begin. 2. Remove the hinge cover (see 249H Removing the Hinge Cover). 3. Remove any installed media bay device (see 250H XBay Devices). 4. Remove the keyboard (see 251H Key...
Page 95 - System Board; Removing the System Board
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 95 of 106 Revision A01 5. Replace the display assembly (see 258H Installing the Display Assembly). 6. Replace the keyboard (see 259H Keyboards). 7. Replace the media bay device (see 260H XBay Devices). 8. Replace the hinge cover (see 261H In...
Page 98 - Installing the System Board
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 98 of 106 Revision A01 22.2 Installing the System Board NOTE: If a new system board is installed, the kit includes a new system board and separate new IO dash board, with instructions. 1. If you are installing a new system board, follow thes...
Page 101 - Flashing the BIOS; Flashing the BIOS From a CD; Flashing the BIOS From the Hard Drive
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 101 of 106 Revision A01 18. Insert the battery into the battery bay (see 291H Before Working Inside Your Computer). 19. Connect the AC adapter to the computer and to an electrical outlet. NOTICE: Before turning on the computer, replace all s...
Page 102 - RF Passthru Board; Removing the RF Passthru Board
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 102 of 106 Revision A01 3. Locate the latest BIOS update file for your computer at support.dell.com . 4. Click Download Now to download the file. 5. If the Export Compliance Disclaimer window appears, click Yes, I Accept this Agreement . The...
Page 103 - Installing the RF Passthru Board
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 103 of 106 Revision A01 3. Remove the 2 screws from the base and lift the RF Passthru Board from the base. If the gasket is not attached to the bottom of the RF Passthru Board, remove the gasket from the base. 24.2 Installing the RF Passthru...
Page 104 - Bottom Chassis; Removing the Bottom Chassis
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 104 of 106 Revision A01 3. Attach the 2 antenna cables. Refer to the antenna cable wiring diagram to ensure the antenna cables are properly attached. 4. Install the system board (see 295H Installing the System Board). 25 Bottom Chassis 25.1 ...
Page 105 - Installing the Bottom Chassis; Installing the Modem Cable
Dell TM XFR D630 Fully Rugged Notebook Service Manual Page 105 of 106 Revision A01 6. If your XFR D630 is equipped with the optional Touch Screen, remove the stylus, tether and clip (see 301H Stylus, Tether and Clip). 25.2 Installing the Bottom Chassis NOTE: The replacement assembly will include the...
