Apple PowerBook 180 Service Manual

K

Service Source

PowerBook 160/165/180

Series

PowerBook 160, PowerBook 165,

PowerBook 180

K

Service Source

Basics

PowerBook 160/165/180

Basics Overview - 1

Overview

This manual includes
complete repair procedures
for the PowerBook 160,
PowerBook 165, and
PowerBook 180.

Figure: PowerBook 160, 165, 180

Basics Repair Strategy - 2

Repair Strategy

Service the PowerBook 160, 165, and 180 through module
exchange and parts replacement. Customers can request on­site service from an Apple Authorized Service Provider Plus
(AASP+) Apple Assurance (US only), or request a courier
through the Apple Canada Technical Answerline (Canada
only). They can also choose carry-in service from an AASP.

Ordering

Apple Service Providers planning to support the computer
systems covered in this manual may purchase Service
modules and parts to develop servicing capability. To order
parts, use the AppleOrder (US only) or ARIS (Canada only)
system and refer to “Service Price Pages.”

Basics Repair Strategy - 3

Large businesses, universities, and K-12 accounts must
provide a purchase order on all transactions, including
orders placed through the AppleOrder (US only) or ARIS
(Canada only) system.

USA Ordering

US Service Providers not enrolled in AppleOrder may fax
their orders to Service Provider Support (512-908-

8125) or mail them to

Apple Computer, Inc.
Service Provider Support
MS 212-SPS
Austin, TX 78714-9125

For US inquiries, please call Service Provider Support at
800-919-2775 and select option #1.

Basics Repair Strategy - 4

Canadian Ordering

Canadian Service Providers not enrolled in ARIS may fax
their orders to Service Provider Support in Canada
(1-800-903-5284). For Canadian inquiries, please call
Service Provider Support at 905-513-5782 and select
option #3.

Basics Warranty/AppleCare/ARIS - 5

Warranty/AppleCare/ARIS

US Only

The PowerBook 160, 165, and 180 are covered under the
Apple One-Year Limited Warranty. The AppleCare Service
Plan is also available for these products. Service Providers
are reimbursed for warranty and AppleCare repairs made to
these computers. For pricing information, refer to “Service
Price Pages.”

Canada Only

The PowerBook 160, 165, and 180 are covered under
first-year AppleCare. The Extended AppleCare Service Plan
is also available for these products. Service Providers are
reimbursed for first-year warranty and Extended
AppleCare repairs made to these computers. For pricing
information, refer to “Service Price Pages.”

Basics Display Compatibility Matrix - 6

Display Compatibility Matrix

Active Matrix
PB 180
661-0748

Inverter 922-0024 922-0025

Display Cable 630-6273 922-0820

Inverter Cable 936-0106 936-0106

Important

displays—an active matrix and an FSTN display. Each of
these displays requires a compatible inverter and display
cable; the inverters, display cables, and displays are not
interchangeable. Before ordering one of these parts, refer to
the display matrix shown above.

: PowerBook 160/165/180 family includes two

FSTN, Rev. A
PB 160/165
661-0745

K

Service Source

Specifications

PowerBook 160/165/180

Specifications Introduction - 1

Introduction

You can also find specifications information for this product in the

Spec Database, which you can access in one of three ways:

— Launch it directly by double-clicking the Apple Spec Database

runtime alias at the top level of the Main Service Source CD.

— Select "Apple Spec Database" from the Service Source drop-

down main menu.

— Click the Acrobat toolbar icon for the database, which is near

the right end of the toolbar with the letters "SP."

Specifications Processor - 2

Processor

160 CPU

165 CPU

180 CPU

Coprocessor (180
Only)

Motorola 68030 microprocessor
25 MHz

Motorola 68030 microprocessor
33 MHz

Motorola 68030 microprocessor
33 MHz

Motorola 68882 floating-point math coprocessor
33 MHz

Specifications Processor - 3

Addressing

32-bit internal registers
32-bit address bus
32-bit data bus

Specifications Memory - 4

Memory

RAM

ROM

PRAM

VRAM

Clock/Calendar

4 MB pseudostatic RAM (PSRAM) installed on the daughterboard
Expandable to 8 MB with 4 MB expansion card
Expandable to 14 MB with third-party PSRAM expansion cards

1 MB

256 bytes of parameter memory

128K of static video display memory

CMOS custom chip with long-life lithium battery

Specifications Disk Storage - 5

Disk Storage

Floppy Drive

Hard Drive

19 mm high, internal, 1.4 MB Apple SuperDrive

2.5 in. hard drives (many capacities)

Specifications I/O Interfaces - 6

I/O Interfaces

Floppy Drive

SCSI

Apple Desktop Bus

DB-19 serial port for connecting external floppy drives

HDI-30 SCSI port with 1.5 MB/sec. transfer rate
Supports up to five external SCSI devices
Does not provide termination power
Connect SCSI device to computer with HDI-30 SCSI system cable.

Apple Desktop Bus (ADB) port (maximum of three ADB devices is

recommended)

200 mA maximum current draw for all ADB devices

Specifications I/O Interfaces - 7

Serial

Sound

Video

Power Adapter

Security

Modem

Two RS-422 serial ports; mini DIN-8 connectors

Monaural sound-in port
Stereo sound-out headphone jack, which plays CD audio tracks in

stereo and computer-generated sounds in mono

Video-out port; 8 bit, 256 color video support
Supports Macintosh monitors up to 16-in. color and VGA monitors

Power adapter port

Slot for third-party security equipment

Slot for optional internal modem

Specifications I/O Devices - 8

I/O Devices

Keyboard

Trackball

Microphone

Built-in keyboard with standard Macintosh layout
63 keys domestic; 64 keys ISO
Two-level tilt adjustment

30 mm diameter, dual button
ADB interface

Electret, omnidirectional
Output voltage of 4 mV, peak to peak

Specifications Sound and Video - 9

Sound and Video

Sound Generator

160/165 Video
Display

180 Video Display

Apple sound chip provides 8-bit sound capable of driving stereo
headphones or other stereo equipment through the sound jack
8-bit sound input, sampled at 11 or 22 kHz

10 in. (254 mm) diagonal screen
Flat-panel, film-compensated supertwist nematic (FSTN) liquid

crystal display
CCFL on-demand backlight
16 shades of gray; 640 by 400 pixels

10 in. (254 mm) diagonal screen
Flat-panel, active-matrix liquid crystal display
CCFL on-demand backlight
16 shades of gray; 640 by 400 pixels

Specifications Electrical - 10

Electrical

Main Battery

PRAM Battery

Power Adapter

Nickel cadmium (NiCad), 2.5 Ah
Provides 2-3 hours of usage before recharging
Recharge time: 3 hours
500 power cycles capacity

3 V lithium

110–220 VAC line voltage
17 W, 50–60 Hz
US, Japanese, United Kingdom, Australian, and European versions

Specifications Physical - 11

Physical

Dimensions

Weight

Height: 2.25 in. (5.7 cm)
Width: 11.25 in. (28.6 cm)
Depth: 9.3 in. (23.6 cm)

6.8 lb. (3.1 kg) with battery

Specifications Environmental - 12

Environmental

Operating
Temperature

Storage
Temperature

Relative Humidity

Altitude

Operational Altitude

50–104° F (10-40° C)

-13 to 140° F (-25 to 60° C)

20–80% noncondensing

0–15,000 ft. (0–4722 m)

0–10,000 ft. (0–3048 m)

Specifications Other - 13

Other

Fax/Data Modem

Internal 2400-baud modem with fax send at 9600 baud (includes

fax send software)
300/1200/2400 bps transmission rates
Serial binary and asynchronous protocols
Error correction and data compression: MNP 4, 5 and V.42,

V.42bis

Specifications Other - 14

Express Modem

SCSI Adapter

Internal 14,400-baud modem with fax send/receive at 9600

baud
300-14,400 bps data transmission rates
2400/4800/7200/9600 bps transmission rates
Full duplex operation; asynchronous or framed modes
Error correction: V.42 compliance (MNP 2-4)
Data compression: V.42bis (4 to 1 compression) and MNP-5 (2

to 1 compression)
Requires 300K of system RAM

Enables connection between PowerBook computer and desktop

Macintosh (PowerBook appears as a hard drive on the desktop

K

Service Source

Troubleshooting

PowerBook 160/165/180

Troubleshooting General/ - 1

General

The Symptom Charts included in this chapter will help you
diagnose specific symptoms related to your product. Because cures
are listed on the charts in the order of most likely solution, try
the first cure first. Verify whether or not the product continues to
exhibit the symptom. If the symptom persists, try the next cure.
(Note: If you have replaced a module, reinstall the original module
before you proceed to the next cure.)

If you are not sure what the problem is, or if the Symptom Charts
do not resolve the problem, refer to the Flowchart for the product
family.

For additional assistance, contact Apple Technical Support.

Troubleshooting General/ - 2

If this does not reset the power manager,
1 Remove the AC adapter and the battery.
2 Let the unit sit without power hooked up for 3–5 minutes.
3 Using two paper clips, simultaneously hold down the reset

and interrupt buttons for 5–10 seconds.

4 Reinstall the battery and, if necessary, reconnect the AC

adapter.

5 Turn on the computer.

Troubleshooting Symptom Charts/Startup - 3

Symptom Charts

Startup

RAM failure occurs
(eight-tone error
chord sequence sounds
after startup chord)

Hardware failure
occurs (four-tone
error chord sequence
sounds after startup
chord)

1 Reseat PSRAM expansion card and check connection.
2 Replace PSRAM expansion card.
3 Replace daughterboard.
4 Replace motherboard.

1 Disconnect hard drive data cable and restart computer. If

startup sequence is normal, reconnect cable and retest.
2 Replace hard drive.
3 Disconnect floppy drive cable and restart computer. If

startup sequence is normal, reconnect cable and retest.
4 Replace floppy drive.
5 Replace motherboard.

Troubleshooting Symptom Charts/Startup - 4

Startup

Screen displays
checkerboard pattern;
no startup chime

1 Reseat RAM expansion card.
2 Replace RAM expansion card.
3 Replace daughterboard.
4 Reseat display cable.

Troubleshooting Symptom Charts/Power - 5

Power

Screen is blank;
computer doesn’t
respond

1 Restart computer.
2 Connect power adapter and restart computer in 3-4 minutes.
3 Try known–good, charged main battery.
4 Check all interconnect board, daughterboard, and

motherboard connections.
5 Reset the power manager.
6 Replace keyboard.
7 Replace interconnect board.
8 Replace daughterboard.
9 Replace motherboard.

Troubleshooting Symptom Charts/Power - 6

Power

After you remove
main battery, some
Control Panel settings
are different

Power adapter is
plugged in, but
battery DA does not
indicate charger is
connected

1 Check cables.
2 Replace interconnect board.
3 Replace daughterboard.
4 Replace motherboard.

1 This is normal for fully charged battery.
2 Check battery charger connection.
3 Try known-good, charged main battery.
4 Try known-good power adapter.
5 Check battery thermistor cable connection.
6 Replace motherboard.

Troubleshooting Symptom Charts/Power - 7

Power

Low-power warning
appears

Computer runs when
plugged into wall
outlet but not on
battery power;
battery voltage is
within tolerance

1 Recharge battery or attach power adapter.
2 Verify that peripherals are low-power.
3 Remove external devices or connect power adapter.
4 Try known-good, charged main battery.
5 Try known-good power adapter.
6 Replace motherboard.

1 Reseat battery to make sure it is mating with contacts on

motherboard.
2 If motherboard includes removable fuse, replace fuse.
3 Replace motherboard.
4 Return computer to Apple.

Troubleshooting Symptom Charts/Video - 8

Video

Pixel is always white PowerBook 180

If there are more than five voids (pixels that are always white),
or two or more voids within one inch of each other, replace
display (CPRC/international repairers only) or return computer
to Apple.

PowerBooks 160 and 165
Replace display.

Pixel is always black PowerBook 180

Replace display (CPRC/international repairers only) or return
computer to Apple.

PowerBooks 160 and 165
Replace display.

Troubleshooting Symptom Charts/Video - 9

Video

Row or partial row of
pixels never comes on
(white line)

PowerBook 160/165
1 Check cables.
2 Replace display cable.
3 Replace display. If PowerBook has serial number below

FC247xxxxxx or CK247xxxxxx, replace both display and

daughterboard. (Do not replace Rev. B daughterboard.)
4 Replace interconnect board.

PowerBook 180
5 Check cables.
6 Replace display cable.
7 Replace display (CPRC/international repairers only) and

install System Enabler, v. 1.01.
8 Replace interconnect board.
9 Return computer to Apple.

Troubleshooting Symptom Charts/Video - 10

Video

Row or partial row of
pixels is always on
(black line)

PowerBook 160/165
1 Check cables.
2 Replace display cable.
3 Replace display.
4 Replace interconnect board.

PowerBook 180
5 Check cables.
6 Replace display cable.
7 Replace interconnect board.
8 Replace display (CPRC/international only) or return

computer to Apple.

Troubleshooting Symptom Charts/Video - 11

Video

Thin white line is
always on at middle of
screen

PowerBook160/165
Thin white line is normal.

PowerBook 180
Replace display (CPRC/international repairers only) or return
computer to Apple.

Troubleshooting Symptom Charts/Video - 12

Video

Display is very light
or totally white

1 Adjust screen contrast.
2 Check display cable, inverter board, interconnect board,

daughterboard, and motherboard connections.
3 Replace inverter board.
4 Replace interconnect board.
5 Replace display cable.
6 PowerBook 160/165: Replace display.
7 Replace daughterboard.
8 Replace motherboard.
9 PowerBook 180: Replace display (CPRC/international

repairers only) or return computer to Apple.

Troubleshooting Symptom Charts/Video - 13

Video

Rainbow colors
visible from extreme
viewing angles

Screen brightness is
not uniform

PowerBook 160/165
Such colors are normal for FSTN screens.

PowerBook 160/165
Irregularity in screen brightness is normal. Adjust contrast and
brightness to diminish effect.

PowerBook 180:
Replace display (CPRC/international repairers only) or return
computer to Apple.

Troubleshooting Symptom Charts/Video - 14

Video

Display stopped
working or dimmed
but is fine now

PowerBook 160/165
If temperature is in the approximate range of under 5 or over 40
degrees centigrade, this reaction is normal.

Troubleshooting Symptom Charts/Video - 15

Video

Backlight doesn’t
operate

1 Verify that cables are not pinched or severed.
2 Check display cable, inverter board, interconnect board,

daughterboard, and motherboard connections.
3 Replace inverter board.
4 Replace inverter display cable.
5 Replace interconnect board.
6 Replace display cable.
7 PowerBook 160/165: Replace display.
8 Replace daughterboard.
9 Replace motherboard.
10 PowerBook 180: Replace display (CPRC/international

repairers only) or return computer to Apple.

Troubleshooting Symptom Charts/Video - 16

Video

Screen goes blank 1 Press any key to wake computer from system sleep.

2 Check display cable connection.
3 Reseat daughterboard.
4 Replace daughterboard.

Troubleshooting Symptom Charts/Video - 17

Video

No display, but
computer appears to
operate correctly

1 Adjust screen contrast.
2 Check display cable, inverter board, interconnect board,

daughterboard, and motherboard connections.
3 Connect power adapter.
4 Replace inverter board.
5 Replace interconnect board.
6 Replace display cable.
7 PowerBook 160/165: Replace display.
8 Replace daughterboard.
9 Replace motherboard.
10 PowerBook 180: Replace display (CPRC/international

repairers only) or return computer to Apple.

Troubleshooting Symptom Charts/Video - 18

Video

Audio and video
present, but internal
floppy drive does not
operate

1 Try known-good floppy disk.
2 Check floppy drive cable connection.
3 Replace floppy drive cable.
4 Replace floppy drive.
5 Replace daughterboard.
6 Replace motherboard.

Troubleshooting Symptom Charts/Hard Drive - 19

Hard Drive

Internal hard drive
does not operate

1 Disconnect external SCSI devices.
2 Check internal hard drive cable connection.
3 Use HD SC Setup to reinitialize drive.
4 Replace internal hard drive cable.
5 Replace internal hard drive.
6 Replace motherboard.

Troubleshooting Symptom Charts/Floppy Drive - 20

Floppy Drive

Audio and video
present, but internal
floppy drive does not
operate

Disk ejects while
booting; display
shows Mac icon with
blinking X

1 Try known-good floppy disk.
2 Check floppy drive cable connection.
3 Replace floppy drive cable.
4 Replace floppy drive.
5 Replace daughterboard.
6 Replace motherboard.

1 Try known-good system disk.
2 Verify that trackball or mouse button is not stuck.
3 Check floppy drive cable connection.
4 Replace floppy drive cable.
5 Replace floppy drive.
6 Replace motherboard.

Troubleshooting Symptom Charts/Floppy Drive - 21

Floppy Drive

Disk does not eject 1 Switch off system and hold mouse button down while you

switch system on.
2 Insert opened paper clip into hole beside drive.
3 Check floppy drive cable connection.
4 Replace floppy drive cable.
5 Replace floppy drive.
6 Replace daughterboard.
7 Replace motherboard.

Disk initialization
fails

1 Try known-good floppy disk.
2 Install inverter shield (if absent).
3 Check floppy drive cable connection.
4 Replace floppy drive cable.
5 Replace floppy drive.

Troubleshooting Symptom Charts/Floppy Drive - 22

Floppy Drive

Read/write/copy
error

1 Try known-good floppy disk.
2 Install inverter shield if absent.
3 Check floppy drive cable connection.
4 Replace floppy drive cable.
5 Replace floppy drive.

Troubleshooting Symptom Charts/Peripherals - 23

Peripherals

After you connect
external SCSI device,
computer does not
boot

Cursor does not move
when you are using
trackball

1 Switch on external SCSI device before starting computer.
2 Check cable connections.
3 Verify that standard Apple terminator terminates SCSI chain

at beginning and end.
4 Verify that SCSI select switch setting on external device is

unique.
5 Verify operation of internal hard drive.
6 Try known-good external SCSI device.
7 Replace motherboard.

1 Restart computer.
2 Check cables.
3 Check interconnect board, daughterboard, and motherboard

connections.
4 Try low-power mouse. If cursor moves, replace trackball or

keyboard.

Troubleshooting Symptom Charts/Peripherals - 24

Peripherals

1 Replace interconnect board.
2 Replace daughterboard.
3 Replace motherboard.

Cursor intermittently
does not move or
moves erratically

1 Restart computer.
2 Clean ball and rollers of trackball.
3 Check cables.
4 Replace trackball.
5 Replace keyboard.
6 Replace interconnect board.
7 Replace motherboard.

Troubleshooting Symptom Charts/Peripherals - 25

Peripherals

Cursor moves, but
clicking trackball
button has no effect

Cursor does not move
when you are using
mouse

1 Restart computer.
2 Check interconnect board, daughterboard, and motherboard

connections.
3 Replace trackball.
4 Replace keyboard.
5 Replace interconnect board.
6 Replace daughterboard.
7 Replace motherboard.

1 Check mouse connection to ADB port.
2 Restart computer.
3 Clean mouse ball and inside mouse.
4 Replace mouse.
5 Replace motherboard.

Troubleshooting Symptom Charts/Peripherals - 26

Peripherals

No response to any
key on keyboard

Known-good direct­connect printer does
not print

1 Reset power manager.
2 Check connections of keyboard to interconnect board, and

interconnect board to daughterboard.
3 Replace keyboard.
4 Replace interconnect board.
5 Replace daughterboard.

1 Verify that System is 7.1 or later.
2 Verify that Chooser and Control Panel settings are correct.
3 Check cables.
4 Replace printer interface cable.
5 Try known-good printer.
6 Replace daughterboard.
7 Replace motherboard.

Troubleshooting Symptom Charts/Peripherals - 27

Peripherals

Known-good network
printer does not print

Device connected to
external modem port
doesn’t work

1 Verify that System is 7.1 or later.
2 Verify that Chooser and Control Panel settings are correct.
3 Check cables.
4 Replace printer interface cable.
5 Try known-good printer. If printer works, troubleshoot

network. Refer to Networks manual.
6 Replace daughterboard.
7 Replace motherboard.

1 Verify that External Modem is selected in CDEV.
2 Verify that System is 7.1 or later.
3 Check cables.
4 Test device with known-good computer.
5 Replace daughterboard.
6 Replace motherboard.

Troubleshooting Symptom Charts/Peripherals - 28

Peripherals

I/O devices are
unrecognized or
garbage is
transmitted or
received

1 Verify that System is 7.1 or later.
2 Check cables.
3 Verify that SCSI device has standard Apple terminator.
4 Verify that SCSI select switch setting on external device is

unique.
5 Test device with known-good computer.
6 Replace daughterboard.
7 Replace motherboard.

Troubleshooting Symptom Charts/Internal Modem - 29

Internal Modem

Internal modem
options do not appear
in CDEV

Modem does not
respond properly to
AT command set
instructions

1 Remove and reseat modem card.
2 Verify that System is 7.1 or later.
3 Replace modem card.
4 Replace motherboard.

1 Verify that baud rate and data format settings of

communications application are compatible with internal

modem and remote modem.
2 Check phone cord connection and operation.
3 Remove and reseat modem card.
4 Verify that System is 7.1 or later.
5 Replace modem card.

Troubleshooting Symptom Charts/Internal Modem - 30

Internal Modem

Strange mix of
characters appears on
screen

Modem interferes
with system sound

1 Verify that baud rate and data format settings of

communications application are compatible with internal

modem and remote modem.
2 Check phone cord connection and operation.
3 Remove and reseat modem card.
4 Verify that System is 7.1 or later.
5 Replace modem card.
6 Replace daughterboard.
7 Replace motherboard.

1 Remove and reseat modem card.
2 Replace modem board.
3 Replace interconnect card.
4 Replace motherboard.

Troubleshooting Symptom Charts/Internal Modem - 31

Internal Modem

Modem does not
respond to incoming
call

Modem has no sound
output

Modem connects but
does not communicate
with remote modem

1 If computer is in sleep mode, verify that Wake On Ring option

in CDEV is selected.
2 Check phone cord connection and operation.
3 Replace modem card.
4 Replace motherboard.

1 Verify that Control Panel volume setting is above 0.
2 Replace modem card.
3 Replace interconnect card.
4 Replace motherboard.

1 Verify that remote modem needs error correction (error

correction is internal modem default).
2 Type “AT &Q0” to disable error correction.

Troubleshooting Symptom Charts/Miscellaneous - 32

Miscellaneous

Screen goes blank and
computer shuts down
every few minutes

Application seems to
run slower after few
seconds

Hard drive is slow to
respond, or screen
goes blank too often

Adjust sleep delays in Control Panel or connect power adapter.

1 Disable System Rest. (See owner’s manual.)
2 Connect power adapter.

Adjust sleep delays in Control Panel or connect power adapter.

Troubleshooting Symptom Charts/Miscellaneous - 33

Miscellaneous

No sound from
speaker

1 Verify that volume setting in Control Panel is above 0.
2 Verify that no external speaker is plugged in.
3 Check connections of speaker to interconnect board,

interconnect board to daughterboard, and daughterboard to

motherboard.
4 Replace interconnect board.
5 Replace daughterboard.
6 Replace motherboard.

Troubleshooting Startup Problems Flowchart/Miscellaneous - 34

Startup Problems Flowchart

START

Reset the power

manager.

Press the power button to
begin the startup sequence.

Do the

startup tones

sound?

Yes

Is the

startup tone

normal?

Yes

Does a

gray pattern

appear?

Yes

1

No

No

No

Does any

video

appear?

Yes

1. Check the cables.

2. Replace the interconnect board.

3. Replace the daughterboard.

4. Replace the motherboard.

See Startup Problems in
the Symptom/Cure Chart.

1. Check the cables.

2. Replace the inverter board.

3. Replace the interconnect board.

4. Replace the display cable.
PowerBook 520, 520c, 540,
540c: Replace the interconnect­ to-display cable.

5. Replace the display.
PowerBook 170, 180, 180c:
Replace the display
(international only) or
return the computer to Apple.

6. Replace the daughterboard.

7. Replace the motherboard.

No

1. Replace the daughterboard.

2. Replace the motherboard.

Troubleshooting Startup Problems Flowchart/Startup Problems Flowchart

Startup Problems Flowchart (continued)

1

Does

the desktop

appear?

Yes

Do the

trackball and

keyboard
function?

Yes

Does

No

No

the disk icon with

the flashing question

mark remain on the

screen?

Yes

1. Reset parameter RAM.

2. Use HD SC Setup to update the SCSI driver.

3. Reinstall System Software.

4. Replace the internal hard drive cable.

5. Replace the hard drive.

6. Replace the motherboard.

7. Replace the daughterboard.

1. Reset the power manager.

2. Check the cables.

3. Replace the trackball (or track­ pad).

4. Replace the keyboard.

5. Replace the interconnect board.

6. Replace the daughterboard.

7. Replace the motherboard.

1. Replace the

No

daughterboard.

2. Replace the
motherboard.

Go to

Start

Insert a known-good disk
into the floppy disk drive

and try to initialize it.

Does the

disk

initialize?

Yes

END

No

1. Replace the floppy drive cable.

2. Replace the floppy drive.

K

Service Source

T ak e Apart

PowerBook 160/165/180

Take Apart Main Battery - 1

Main Battery

Before you begin,
disconnect the power
adapter.

Note:

This procedure also
covers removal of the main
battery door.

Main Battery

Important:

the main battery, use the
Macintosh Shut Down
command. Otherwise, all
RAM contents will be lost.

Before removing

Take Apart Main Battery - 2

±

Warning:

battery contains toxic
materials. Review
battery-handling and
disposal instructions in
Bulletins/Safety.

1 Slide open the battery

door.

2 Using the battery door as

a handle, pull out the
main battery.

The main

Take Apart Main Battery - 3

3 Slide the battery door

completely open.

4 Pull the end tab until it

releases and remove the
door from the battery.

End Tab

Take Apart I/O Door - 4

I/O Door

No preliminary steps are
required before you begin
this procedure.

I/O Door

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart I/O Door - 5

1 Open the I/O door.

2 Carefully bend the door

so that the middle bows

Right Door
Peg

downward and unhinge
the two bottom door pegs.

Take Apart Top Case - 6

Top Case

Before you begin, remove
the following:

• Main battery

• I/O door

Top Case

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart Top Case - 7

Note:

Use a T-8 torx driver
to remove the small screw
from the rear connector
panel and a T-10 torx
driver to remove the other
case screws.

1 Remove the five torx

screws from the bottom
case.

Take Apart Top Case - 8

2 Lift the back of the top

case and disconnect the
interconnect cable.

3 Lift off the top case and

unhook the two tab

Interconnect

Cable

fasteners from the front
of the bottom case.

Replacement Caution:

When connecting the display
cable connector, fold the
cable as shown. If it is not
folded correctly, the cable
could short.

Tab Fastener

Take Apart Trackball Assembly - 9

Trackball Assembly

Before you begin, remove
the following:

• Main battery

Trackball
Assembly

• I/O door

• Top case

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart Trackball Assembly - 10

Trackball

Ribbon Cable Locking

Tab

Caution:

The trackball
ribbon cable is fragile and
should be handled with care.

1 Pull out the locking tab

on the trackball
connector and remove
the trackball ribbon
cable.

Take Apart Trackball Assembly - 11

2 Using a T-8 torx driver,

remove the two mounting
screws and lift the
trackball assembly
from the top case.

Take Apart Keyboard - 12

Keyboard

Before you begin, remove
the following:

• Main battery

• I/O door

Keyboard

• Top case

• Trackball assembly

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart Keyboard - 13

Keyboard
Ribbon Cables

Caution:

The keyboard
ribbon cables are fragile and
should be handled with care.

1 Lift the locking tabs on

the two keyboard
connectors and remove
the keyboard ribbon
cables.

Take Apart Keyboard - 14

2 Using a T-8 torx driver,

remove the seven
mounting screws and
lift the keyboard from
the top case.

Take Apart Inverter Board - 15

Inverter Board

Before you begin, remove
the following:

• Main battery

• I/O door

• Top case

Inverter Board

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart Inverter Board - 16

Important:

160/165 and PowerBook
180 displays require
different inverter boards.
Refer to the Service Source
parts database for the
correct part number for
each board.

The PowerBook

Take Apart Inverter Board - 17

1 Remove the two

mounting screws.

Note:

Do not remove the

Inverter

Shield

Inverter
Cable

Inverter

Board

inverter shield from the
inverter board.

2 Pull the inverter board

and attached shield
straight up and off the
connector on the
interconnect board.

3 Disconnect the inverter

cable.

Take Apart Inverter Board - 18

Contrast PotBrightness Pot

Actuator Actuator

Inverter

Board

Replacement Note:

Be sure
to align the brightness and
contrast pots on the inverter
board with the plastic
actuators on the top case. It
is easiest to align the pots
and actuators if you set both
to their extreme outer
positions.

Take Apart Inverter Board - 19

Inverter Shield

Inverter
Board

Replacement Note:

If you
are replacing the inverter
board, order both the
inverter board and the
inverter shield. Install the
new shield on the board
before replacing it. Do not
reuse the original inverter
shield.

Take Apart Interconnect Board - 20

Interconnect Board

Before you begin, remove
the following:

• Main battery

• I/O door

• Top case

• Inverter board

Interconnect Board

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart Interconnect Board - 21

±

J5 Connector

Warning:

interconnect board contains
hazardous materials.
Return bad interconnect
boards to Apple for proper
disposal.

The

J3 Connector

Caution:

display cables are fragile
and should be handled with
care.

1 Lift the locking tabs on

The keyboard and

connectors J5 and J3 and
remove the keyboard
ribbon cables.

Take Apart Interconnect Board - 22

Note:

The display cable will
not come entirely out of the
connector until you remove
the interconnect board from
the top case.

2 Pull out the locking tab

on connector J2 and ease
the display cable out of
the connector as far as
the cable will go.

J2 Connector

Replacement Note:

Connect
the display cable before
replacing the interconnect
board.

Take Apart Interconnect Board - 23

3 Using a T-8 torx driver,

remove the two mounting
screws and lift the
interconnect board from
the top case.

Take Apart Actuators - 24

Actuators

Before you begin, remove
the following:

• Main battery

• I/O door

• Top case

• Inverter board

Actuators

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart Actuators - 25

1 Pull up the contrast

actuator, rotate it
toward the display, and
remove the actuator
from the top case.

2 Repeat for the

brightness actuator.

Take Apart Elevation Feet - 26

Elevation Feet

Before you begin, remove
the following:

• Main battery

• I/O door

• Top case

Elevation Foot

Elevation Foot

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart Elevation Feet - 27

1 Using a T-8 torx driver,

remove the torx screw,
washer, and spring clip
from the inside of the
elevation foot.

2 Pull off the elevation

foot.

Spring
Clip

Elevation
Foot

Take Apart Daughterboard - 28

Daughterboard

Before you begin, remove
the following:

• Main battery

• I/O door

• Top case

• PSRAM expansion card

(if present)

Daughterboard

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart Daughterboard - 29

Logic Board
Take-Apart

Tool

Daughterboard

Motherboard

1 Using a T-8 torx driver,

remove the four
daughterboard mounting
screws.

Caution:

Always use the
logic board take-apart tool
to separate the
daughterboard connector
from the motherboard
connector. Trying to
disconnect the
daughterboard from the
motherboard by rocking or
peeling the boards apart
damages the connectors.

Take Apart Daughterboard - 30

2 Using the Apple logic

board take-apart tool,
disconnect the
daughterboard from the
motherboard.

U27

Replacement Note:

If you
are replacing a defective
daughterboard, be aware
that the PowerBook 160/
165/180 daughterboards
are very similar. To
differentiate
daughterboards, check the
underside of the board.
PowerBook 180
daughterboards have an FPU
chip soldered at location

Take Apart Daughterboard - 31

U27; PowerBook 160/165
boards do not.

To further differentiate
PowerBook 160 and 165
daughterboards, check the
underside for the following
resistors:

• PowerBook 160

daughterboard

R38 resistor: installed

R39 resistor: not
installed

• PowerBook 165

daughterboard

R38 resistor: not
installed

Take Apart Daughterboard - 32

R39 resistor: installed

Heat Sinks

Daughterboard

Heat Sink

For daughterboard part
numbers, refer to the
Service Source parts
database.

Replacement Note:

The
green heat sinks attached to
the daughterboard are made
of delicate heat-conducting
material. If they are missing
or damaged, they must be
replaced.

Replacement Note:

To
replace a damaged heat sink,
carefully peel it from the
daughterboard. Select the

Take Apart Daughterboard - 33

appropriately sized heat
sink from the heat sink kit
(part number 076-0069),
and gently press the part
into place.

Replacement Caution:

sure the heat sink is placed
exactly as shown in the
illustration. The heat sink
should not hang over the side
of the component it is
covering, or it may short
the component leads.

Make

Take Apart Daughterboard - 34

Motherboard

Sound Jack Insulator

Sound Jack
Assembly

Replacement Note:

If you
are replacing a defective
daughterboard in a
PowerBook 160/180
within the serial number
range FC233xxxxxx
through FC241xxxxxx, you
must also replace the sound
jack insulator on the
motherboard.

Take Apart Daughterboard - 35

Replacement Note:

replace the sound jack
insulator, carefully peel off
the original insulator.
Remove the paper backing on
the revised insulator (part
number 922-0591), and
gently press it into place.

Replacement Caution:

sure the new insulator sits
in exactly the same position
as the original insulator.

To

Make

Take Apart Motherboard - 36

Motherboard

Before you begin, remove
the following:

• Main battery

• I/O door

• Top case

• PSRAM expansion card

(if present)

• Daughterboard

• Modem card (if present)

Motherboard

Caution:

160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

The PowerBook

Take Apart Motherboard - 37

Floppy Drive Cable

Thermistor Cable

Locking Tab

Locking

Tab

Hard Drive

Cable

Caution:

The hard drive,
floppy drive, and thermistor
cables are fragile and
should be handled with care.

1 Lift the locking tabs and

remove the floppy drive
and thermistor cables.

2 Remove the hard drive

cable.

Take Apart Motherboard - 38

Hex-Head Screw

Motherboard

3 Remove the two hex-

head screws and lift the
motherboard from the
bottom case.

Take Apart Hard Drive - 39

Hard Drive

Before you begin, remove
the following:

• Main battery

• I/O door

• Top case

• Modem card (if present)

• Daughterboard

Caution: The PowerBook
160/165/180 contains
CMOS devices that are very
susceptible to ESD damage.
Review the ESD precautions
in Bulletins/Safety.

Hard Drive

Take Apart Hard Drive - 40

Caution: The hard drive
cable is fragile and should be
handled with care.

Hard Drive
Cable

1 Disconnect the hard

drive cable from the
motherboard.