Page 1
Thank you for purchasing this Factory Service Manual CD/DVD from servicemanuals4u.com. Please check out our eBay auctions for more great deals on Factory Service Manuals: servicemanuals4u...
Page 2
Reproduction in any manner whatsoever without the written permission of Dell Computer Corporation is strictly forbidden. Trademarks used in this text: Dell, the DELL logo, and Latitude are trademarks of Dell Computer Corporation. Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products.
Page 3
Dell Latitude C540/C640 Service Manual April 2003 Rev. A01 file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/...%20C640/C540%20C640_SERVICE_MANUAL/index.htm (2 of 2)6/21/2004 1:27:07 AM...
System Information Guide. CAUTION: Only a certified service technician should perform repairs on your computer. Damage due to servicing that is not authorized by Dell is not covered by your warranty. NOTICE: To avoid damaging the computer, perform the following steps before you begin working inside the computer.
Before You Begin: Dell Latitude C540/C640 Service Manual 9. Close the display and turn the computer upside down on a flat work surface. NOTICE: To avoid damaging the system board, you must remove the main battery and secondary battery (if present) before you service the computer.
Before You Begin: Dell Latitude C540/C640 Service Manual 1 back 2 right 3 front 4 left Screw Identification When you are removing and replacing components, photocopy the placemat as a tool to lay out and keep track of the screws. The placemat provides the number of screws and their sizes.
Page 7
Before You Begin: Dell Latitude C540/C640 Service Manual NOTICE: When reinstalling a screw, you must use a screw of the correct diameter and length. Ensure that the screw is properly aligned with its corresponding hole, and avoid overtightening. Hard Drive Door:...
Before You Begin: Dell Latitude C540/C640 Service Manual Hybrid Cooling Fan: System Board to Bottom Case: (2 each) (1 each) (10 each) Back to Contents Page file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/...%20C640/C540%20C640_SERVICE_MANUAL/begin.htm (6 of 6)6/21/2004 1:27:08 AM...
NOTICE: Only a certified service technician should perform repairs on your computer. Damage due to servicing that is not authorized by Dell is not covered by your warranty. NOTICE: Unless otherwise noted, each procedure in this document assumes that a part can be replaced by performing the removal procedure in reverse order.
System Components: Dell Latitude C540/C640 Service Manual 1 display assembly 10 bottom case 2 center control cover 11 memory module cover 3 microprocessor thermal cooling 12 module bay device assembly 4 hybrid cooling fan 13 main battery 5 microprocessor 14 hard drive...
Hard Drive: Dell Latitude C540/C640 Service Manual Back to Contents Page Hard Drive Dell™ Latitude™ C540/C640 Service Manual Removing the Hard Drive 1. Save and close any open files, exit any open programs, and then shut down the computer. NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries.
Hard Drive: Dell Latitude C540/C640 Service Manual bottom of computer M3 x 5-mm screw hard drive door 4. Lift the hard drive door until you hear a click. 5. Slide the hard drive out of the computer. Replacing the Hard Drive NOTICE: Use firm and even pressure to slide the hard drive into place.
Page 14
Hard Drive: Dell Latitude C540/C640 Service Manual file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/...40%20C640/C540%20C640_SERVICE_MANUAL/hdd.htm (3 of 3)6/21/2004 1:27:10 AM...
Memory Modules, Mini PCI Card, and Modem: Dell Latitude C540/C640 Service Manual Back to Contents Page Memory Modules, Mini PCI Card, and Modem Dell™ Latitude™ C540/C640 Service Manual Memory Modules Mini PCI Card Modem Memory Modules Removing the Memory Module Cover...
Memory Modules, Mini PCI Card, and Modem: Dell Latitude C540/C640 Service Manual M2.5 x 12-mm screw (1) captive screws (2) Removing the Memory Modules NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries.
Memory Modules, Mini PCI Card, and Modem: Dell Latitude C540/C640 Service Manual JDIM 2 memory socket JDIM 1 memory socket keying tab keying notch inner tabs (2 per socket) 3. Lift the memory module out of its socket. Replacing the Memory Modules 1.
Memory Modules, Mini PCI Card, and Modem: Dell Latitude C540/C640 Service Manual NOTE: Memory modules are keyed, or designed to fit into their sockets, in only one direction. NOTICE: The memory module must be inserted at a 45-degree angle to avoid damaging the connector.
Memory Modules, Mini PCI Card, and Modem: Dell Latitude C540/C640 Service Manual 1 antenna connectors on card 2 antenna cables (2) Replacing the Mini PCI Card 1. Align the Mini PCI card with the socket at a 45-degree angle, and press the Mini PCI card into the socket.
Memory Modules, Mini PCI Card, and Modem: Dell Latitude C540/C640 Service Manual Modem Removing the Modem NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries. NOTICE: To avoid ESD, ground yourself by using a wrist grounding strap or by touching an unpainted metal surface on the computer.
Memory Modules, Mini PCI Card, and Modem: Dell Latitude C540/C640 Service Manual M2 x 3-mm screws (2) modem connector modem cable pull-tab Replacing the Modem 1. Connect the modem cable to the modem. NOTICE: The connectors are keyed for correct insertion; do not force the connections.
Page 22
Memory Modules, Mini PCI Card, and Modem: Dell Latitude C540/C640 Service Manual 3. Install the two M2 x 3-mm screws that secure the modem to the system board. 4. Replace the memory module cover and tighten the two captive screws.
Keyboard: Dell Latitude C540/C640 Service Manual Back to Contents Page Keyboard Dell™ Latitude™ C540/C640 Service Manual Removing the Keyboard NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries. NOTICE: To avoid ESD, ground yourself by using a wrist grounding strap or by touching an unpainted metal surface on the computer.
Page 24
Keyboard: Dell Latitude C540/C640 Service Manual 3. Turn the computer over and open the display. NOTICE: The keycaps on the keyboard are fragile, easily dislodged, and time- consuming to replace. Be careful when removing and handling the keyboard. 4. Remove the center control cover: a.
Page 25
Keyboard: Dell Latitude C540/C640 Service Manual keyboard track stick blank key palm rest 6. Lift the keyboard straight up about an inch and then rotate it forward toward the front of the computer, until the key face is resting on the palm rest.
Keyboard: Dell Latitude C540/C640 Service Manual 1 boss supports (5) 2 track stick cable 3 keyboard flex cable 4 keyboard interface connector 5 orientation label 8. Remove the keyboard from the bottom case. Replacing the Keyboard 1. Place the keyboard on the palm rest at the front of the computer with the keys face down and the connector toward the back of the computer.
Page 27
Keyboard: Dell Latitude C540/C640 Service Manual 3. Carefully turn the keyboard over. Align the keyboard boss supports, fit the left side of the keyboard into place, and then snap the right side of the keyboard into place. NOTICE: Position the keyboard flex and track stick cables so that they are not pinched when you replace the keyboard in the bottom case.
Display Assembly, Display Latch, and Hinge Covers: Dell Latitude C540/C640 Service Manual Back to Contents Page Display Assembly, Display Latch, and Hinge Covers Dell™ Latitude™ C540/C640 Service Manual Display Assembly Display Latch Hinge Covers Display Assembly NOTICE: You must remove the display assembly before you remove the palm rest.
Page 29
Display Assembly, Display Latch, and Hinge Covers: Dell Latitude C540/C640 Service Manual M2 x 3-mm screws (2) top cover center control cover M2.5 x 5-mm screws (5) bottom case display-feed flex cable EMI shield bracket 8. Remove the two M2 x 3-mm screws that secure the display-feed flex cable to the system board.
Page 30
Display Assembly, Display Latch, and Hinge Covers: Dell Latitude C540/C640 Service Manual 1 M2 x 3-mm screws (2) 2 pull-tab 3 display-feed cable connector 4 interface connector 9. Pull up on the pull-tab that is attached to the display-feed flex cable connector to remove it from the interface connector on the system board.
Carefully separate the bezel from the top cover to avoid damage to the bezel. 5. Starting at the bottom of the display panel (by the Dell™ logo), use your fingers to separate the bezel from the top cover by lifting the inside of the bezel while pushing in on the outside.
Page 33
Display Assembly, Display Latch, and Hinge Covers: Dell Latitude C540/C640 Service Manual NOTE: If you have a Hitachi display panel, remove the two M2 x 4-mm screws from the center of the left side of the display panel. 6. Remove the M2 x 4-mm screw that secures the display-feed flex cable through the black plastic flex- cable retention bracket.
Display Assembly, Display Latch, and Hinge Covers: Dell Latitude C540/C640 Service Manual 9. Remove the tape that secures the display panel connector and the tape that secures the middle of the display-feed flex cable to the display panel. 10. Pull the top flex cable connector down and away to remove it from the display panel connector.
Display Assembly, Display Latch, and Hinge Covers: Dell Latitude C540/C640 Service Manual M1.7 x 3.5-mm screws (2) M2.5 x 5-mm screws (2) display latch bracket Replacing the Display Latch 1. On XGA panels, place the display latch on top of its screw holes, and then place the bracket on top of the display latch, aligning the bracket and display latch screw holes.
Display Assembly, Display Latch, and Hinge Covers: Dell Latitude C540/C640 Service Manual Removing the Hinge Covers 1. Remove the display assembly. 2. Rotate the hinges forward at an angle of approximately 90 degrees to the front of the display assembly.
Display Assembly, Display Latch, and Hinge Covers: Dell Latitude C540/C640 Service Manual right hinge cover left hinge cover Back to Contents Page file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/...0C640/C540%20C640_SERVICE_MANUAL/display.htm (10 of 11)6/21/2004 1:27:14 AM...
Page 38
Display Assembly, Display Latch, and Hinge Covers: Dell Latitude C540/C640 Service Manual file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/...0C640/C540%20C640_SERVICE_MANUAL/display.htm (11 of 11)6/21/2004 1:27:14 AM...
Palm Rest: Dell Latitude C540/C640 Service Manual Back to Contents Page Palm Rest Dell™ Latitude™ C540/C640 Service Manual Removing the Palm Rest NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries. NOTICE: To avoid ESD, ground yourself by using a wrist grounding strap or by touching an unpainted metal surface on the computer.
Page 40
Palm Rest: Dell Latitude C540/C640 Service Manual M2.5 x 12-mm screws (3) M2 x 3-mm screws (2) hard-drive bay door 5. Remove the two M2 x 3-mm screws that are located in the hard-drive bay door labeled "circle P." 6. Turn the computer over, and remove the three M2 x 3-mm screws that secure the palm rest to the bottom case: a.
Page 41
Palm Rest: Dell Latitude C540/C640 Service Manual 1 M2 x 3-mm screws (3) 2 palm rest 3 palm-rest flex cable 4 bottom case 5 interface connector for palm- rest flex cable 6 back center of the palm rest NOTICE: Carefully separate the palm rest from the bottom case to avoid damage to the palm rest.
Page 42
Palm Rest: Dell Latitude C540/C640 Service Manual Back to Contents Page file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...0C640/C540%20C640_SERVICE_MANUAL/palmrest.htm (4 of 4)6/21/2004 1:27:15 AM...
Microprocessor Thermal Cooling Assembly: Dell Latitude C540/C640 Service Manual Back to Contents Page Microprocessor Thermal Cooling Assembly Dell™ Latitude™ C540/C640 Service Manual Removing the Microprocessor Thermal Cooling Assembly NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries.
Page 44
Microprocessor Thermal Cooling Assembly: Dell Latitude C540/C640 Service Manual 1 microprocessor thermal cooling assembly 2 captive screws (4) 3 right side of thermal cooling assembly 4 recess in EMI shield (prying location) 4. Insert a screwdriver into the recess in the EMI shield under the front left corner of the thermal cooling assembly, and pry the assembly up and out of the system board.
Page 45
Microprocessor Thermal Cooling Assembly: Dell Latitude C540/C640 Service Manual lower the assembly onto the system board. 2. Tighten the four captive screws, labeled 1 through 4, in consecutive order. Back to Contents Page file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...20C640/C540%20C640_SERVICE_MANUAL/thermal.htm (3 of 3)6/21/2004 1:27:16 AM...
Microprocessor Module: Dell Latitude C540/C640 Service Manual Back to Contents Page Microprocessor Module Dell™ Latitude™ C540/C640 Service Manual Removing the Microprocessor Module NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries. NOTICE: To avoid ESD, ground yourself by using a wrist grounding strap or by touching an unpainted metal surface on the computer.
Page 47
Microprocessor Module: Dell Latitude C540/C640 Service Manual 1 screwdriver (perpendicular to microprocessor) 2 pin-1 corner 3 processor die (do not touch) 4 ZIF socket 5 ZIF-socket cam screw 1. Remove the hard drive. 2. Remove the keyboard. NOTICE: To ensure maximum cooling for the microprocessor, do not touch the heat transfer areas on the microprocessor thermal cooling assembly.
Microprocessor Module: Dell Latitude C540/C640 Service Manual 4. To loosen the ZIF socket, use a small, flat-blade screwdriver and rotate the ZIF-socket cam screw counter-clockwise until it reaches the cam stop. The ZIF-socket cam screw secures the microprocessor to the system board. Take note of the arrow on the ZIF-socket cam screw.
Page 49
Microprocessor Module: Dell Latitude C540/C640 Service Manual Back to Contents Page file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/...40%20C640/C540%20C640_SERVICE_MANUAL/cpu.htm (4 of 4)6/21/2004 1:27:16 AM...
Hybrid Cooling Fan: Dell Latitude C540/C640 Service Manual Back to Contents Page Hybrid Cooling Fan Dell™ Latitude™ C540/C640 Service Manual Removing the Hybrid Cooling Fan NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries.
Page 51
Hybrid Cooling Fan: Dell Latitude C540/C640 Service Manual 1 system-board interface connector 5 M2 x 3-mm screw (1) 2 fan power cable 6 M2.5 x 5-mm screws (2) 3 spring fingers 7 hybrid cooling fan 4 keyboard screw hole 7. Disconnect the fan power cable from the system-board interface connector and remove the hybrid cooling fan.
Reserve Battery: Dell Latitude C540/C640 Service Manual Back to Contents Page Reserve Battery Dell™ Latitude™ C540/C640 Service Manual Removing the Reserve Battery NOTICE: The reserve battery provides power to the computer's RTC and NVRAM when the computer is turned off. Removing the battery causes the computer to lose the date and time information as well as all user-specified parameters in the BIOS.
Reserve Battery: Dell Latitude C540/C640 Service Manual 1 reserve battery 2 reserve battery tray 3 reserve battery cable 4 reserve battery connector on system board 5 speaker cables 6 opening for reserve battery cable Replacing the Reserve Battery 1. Connect the reserve battery cable to the reserve battery connector on the system board and then route the battery cable through the opening in the EMI shield to the battery tray.
Page 54
Reserve Battery: Dell Latitude C540/C640 Service Manual 3. Update the BIOS using a flash BIOS update floppy disk or CD. For instructions on how to flash the BIOS, see "Flashing the BIOS." Back to Contents Page file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...0C640/C540%20C640_SERVICE_MANUAL/rsrvbatt.htm (3 of 3)6/21/2004 1:27:18 AM...
Flashing the BIOS: Dell Latitude C540/C640 Service Manual Back to Contents Page Flashing the BIOS Dell™ Latitude™ C540/C640 Service Manual To update the basic input/output system (BIOS): 1. Ensure that the AC adapter is plugged in and that the main battery is installed properly.
Speaker Assemblies: Dell Latitude C540/C640 Service Manual Back to Contents Page Speaker Assemblies Dell™ Latitude™ C540/C640 Service Manual Removing the Speaker Assemblies NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries. NOTICE: To avoid ESD, ground yourself by using a wrist grounding strap or by touching an unpainted metal surface on the computer.
Speaker Assemblies: Dell Latitude C540/C640 Service Manual right speaker palm-rest screw posts (2) bottom case holders (2) left speaker file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...0C640/C540%20C640_SERVICE_MANUAL/speakers.htm (2 of 5)6/21/2004 1:27:19 AM...
Page 58
Speaker Assemblies: Dell Latitude C540/C640 Service Manual antenna cable antenna cable file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...0C640/C540%20C640_SERVICE_MANUAL/speakers.htm (3 of 5)6/21/2004 1:27:19 AM...
Page 59
Speaker Assemblies: Dell Latitude C540/C640 Service Manual speaker interface cable right speaker holder in-line connector mounting ring left speaker right speaker mounting ring speaker interface cable left speaker holder 1. Remove the hard drive. 2. Remove the keyboard. 3. Remove the display assembly.
Page 60
Speaker Assemblies: Dell Latitude C540/C640 Service Manual Back to Contents Page file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...0C640/C540%20C640_SERVICE_MANUAL/speakers.htm (5 of 5)6/21/2004 1:27:19 AM...
System Board: Dell Latitude C540/C640 Service Manual Back to Contents Page System Board Dell™ Latitude™ C540/C640 Service Manual Removing the System Board The system board's BIOS chip contains the service tag sequence, which is also visible on a bar code label on the bottom of the computer.
System Board: Dell Latitude C540/C640 Service Manual fan guard M2.5 x 5-mm screws (9) 10. Turn the computer over and remove the M2.5 x 5-mm screw, which is labeled "circle B" with an arrow on the front center of the system board by the battery connector.
System Board: Dell Latitude C540/C640 Service Manual 1 M2.5 x. 5-mm screw (1) 2 audio connector locations; pull outward here 11. Remove the speaker assemblies from the bottom case. 12. Pull the right side of the bottom case, next to the audio connectors, away from the system board as you simultaneously lift the front of the system board out and away from the bottom case.
Page 64
System Board: Dell Latitude C540/C640 Service Manual c. Replace the fan guard, inserting the tab into the bottom case, and replace the three M2.5 x 5-mm screws. Replacing the screw opposite the tab first makes it easier to insert and replace the other two screws.
Page 65
Battery and Module Bay Latches: Dell Latitude C540/C640 Service Manual Back to Contents Page Battery and Module Bay Latches Dell™ Latitude™ C540/C640 Service Manual Removing the Battery and Module Bay Latches NOTICE: Disconnect the computer and any attached devices from electrical outlets, and remove any installed batteries.
Page 66
Battery and Module Bay Latches: Dell Latitude C540/C640 Service Manual bumps (2 per latch) latch release buttons (2) slider snap tabs (2 per latch assembly) spring upper latch assemblies (2) bottom case wear rib Replacing the Battery and Module Bay Latches 1.
Page 67
Battery and Module Bay Latches: Dell Latitude C540/C640 Service Manual NOTE: The latch will not function properly if the slider is oriented incorrectly. 2. Hold down the upper latch assembly and snap in the new latch release button through the bottom case, ensuring that the snap tabs are fully engaged in the upper latch assembly.
Pin Assignments for I/O Connectors: Dell Latitude C540/C640 Service Manual Back to Contents Page Pin Assignments for I/O Connectors Dell™ Latitude™ C540/640 Service Manual USB Connector Signal –Data +Data Ground Serial Connector file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...20C640/C540%20C640_SERVICE_MANUAL/pinouts.htm (1 of 9)6/21/2004 1:27:22 AM...
Page 69
Pin Assignments for I/O Connectors: Dell Latitude C540/C640 Service Manual Signal Signal RXDA TXDA Parallel Connector Signal Signal STRB#/5V BUSY/MTR# file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...20C640/C540%20C640_SERVICE_MANUAL/pinouts.htm (2 of 9)6/21/2004 1:27:22 AM...
Pin Assignments for I/O Connectors: Dell Latitude C540/C640 Service Manual PD0/INDEX# PE/WDATA# PD1/TRK0# SLCT/WGATE# PD2/WP# AFDF# PD3/RDATA# ERROR#HDSEL# PD4/DSKCHG# INIT#/DIR# PD5F SLCT_IN#STEP# PD6F 18–23 PD7F DFDD/LPT# ACK#/DRV# Video Connector Signal Signal CRT_VCC GREEN BLUE MSEN# DAT_DDC2 HSYNC VSYNC CLK_DDC2 file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...20C640/C540%20C640_SERVICE_MANUAL/pinouts.htm (3 of 9)6/21/2004 1:27:22 AM...
Page 71
Pin Assignments for I/O Connectors: Dell Latitude C540/C640 Service Manual PS/2 Connector Signal DAT_KBD DAT_SM1 PS2VCC CLK_KBD CLK_SM1 S-Video TV-Out Connector file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...20C640/C540%20C640_SERVICE_MANUAL/pinouts.htm (4 of 9)6/21/2004 1:27:22 AM...
Pin Assignments for I/O Connectors: Dell Latitude C540/C640 Service Manual S-Video Signal DLUMA-L DCRMA-L Composite Video Signal DCMPS-L Docking Connector Signal Signal STRB#/5V VGA_GRN file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...20C640/C540%20C640_SERVICE_MANUAL/pinouts.htm (5 of 9)6/21/2004 1:27:22 AM...
Page 76
Pin Assignments for I/O Connectors: Dell Latitude C540/C640 Service Manual DCD0 +5VSUS Back to Contents Page file:///I|/SERVICE%20MANUALS/DELL%20MANUALS/L...20C640/C540%20C640_SERVICE_MANUAL/pinouts.htm (9 of 9)6/21/2004 1:27:22 AM...