8/3/12 6:30 AM 01/W Disassembly

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01/W Disassembly
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Topics
Dis-assembly
01/Wpro
01/WproX
Re-assembly
Photos of process and insides of the 01
It's possible to work on stuff inside the 01 yourself. Typical repairs are:
1. Replacing the battery
2. Fixing sticky or broken keys
3. Fixing the LCD backlight. To remove the display from non-ProX models you must remove the CPU card
and keyboard. Those who have done it say it's not that complicated, but it is tedious and requires time and
organization.
For details on those specific repairs, see the appropriate pages (click on the links above). Depending on what
you're trying to get at, you may have to deal with lots of screws and connectors. This job requires
organization and patience.
I have not yet had to go through this procedure myself, so I can't report clearly on the detailed steps. What
I've done is compiled this procedure by scanning years of e-mails, and by reading the service manual (which
isn't very clear).
Since I've never done this, THIS PROCEDURE MAY CONTAIN ERRORS! This procedure is a guide for
those strong-hearted enough (or poor enough) to want to try this themselves. I encourage you to let me know
how to improve these procedures. Click here to e-mail questions/comments to Ken Westover.
SPECIAL NOTE: Photos Available
There are some excellent photographs of the disassembly process and the inside of the 01 at Hajo's web site:
http://www.hajo.kessener.net/01w/. It includes a good description of the process from someone who has gone
through the process and includes valuable lessons only experience can teach. I highly recommend a visit. (the
site was up and running on 01Nov11).
Required Tools
All Models: Screwdriver (electric preferred) Philips, size(s) unknown
ProX: A stick of wood to hold open the top panel.
Recommended Supplies
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Something to hold small parts. Trays, jars, or a cupcake baking tin. Disposable bathroom cups can be
labeled with where the screws came from ("bottom plate", "main board", etc.).
Korg 01/W service manual
Permanent pen to mark connectors. It is very important that Pin 1 of a connector connects to Pin 1 on
the PC board. Before removing a connector, put a black dot on the connector and a black dot on the PC
board next to each other so you can see how to re-plug them. Another technique is to draw a
continuous line across the connector and PC board before they are unplugged. When they are re-
plugged together properly, you will see one continuous line.
Pencil and paper - to make notes and diagrams about where everything goes for re-assembly.
Tips
1. Go slow. Everything should come out with only a little encouragement. If anything resists, STOP, and look
at what might be holding it. Do not yank. Do not force. Be Patient!
2. STATIC CAUTION! Static can be a Korg-Killer! A small dose of static (so small you can't feel it) in the
wrong place can damage electronic parts. It is important to take precautions against generating and/or
discharging static. Precautions include:
Don't wear static-generating shoes or clothes. Certain sneakers on certain carpets generate huge sparks
with only a few steps. Try not to work on carpeting, especially cheap nylon.
Always touch some large piece of metal on the chassis before touching anything inside the 01.
Touching metal plates helps drain off damaging static.
If you have access to anti-static pads and/or grounding straps, use them.
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Dis-assembly
Most of these instructions come from the 01/Wpro and proX service manual. They are probably more
complicated than what you must do with a 61-key 01 (01/W or 01/Wfd). For example, the number of screws
used in the different 01s may vary, and there is no disk drive in a non-fd model.
If you don't have a pro model, these instructions may still work as a guide. One non-pro owner said you just
keep removing stuff until you get where you want to go. Just be extremely careful to keep track of where all
the screws and connectors go (pencil, paper, cups, etc.).
If you're using a cupcake tin or disposable bathroom cups to hold the screws, you might label each cup with
the dis-assembly step number. This can reduce questions about where each screw came from during re-
assembly.
It is unclear if you must turn your 01 upside down to work on it. (It may depend on the model.) You may be
able to open the 01 on a keyboard stand. If ever turn your 01 upside down, WATCH OUT FOR YOUR
JOYSTICK! You may need to place something under your 01 (packing foam or pillows, for example) so the
joystick doesn't get broken. Either that or make sure the joystick hangs over the edge of your workbench or
keyboard stand.
Key Repair Note
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I'm not sure if you have to go through all these steps to get at the keys. Some 01 users have reported they had
to remove the disk drive, diode matrix board, and a small circuit board (with pots for adjusting aftertouch). It
may depend on which model of 01 you have. The following is the order things are removed in the service
manual. If it looks like you don't have to remove something, then don't remove it and see if you can still get
at the keys.
01/Wpro Disassembly
1.Open the lower case
1.1 Remove (21) 4x10screws, 15 of one kind, 6 of another.
2. Remove the Main PCB
2.1 Remove (6) 3x8 screws on rear panel (4 of one type, 2 PLAX types)
2.2 Remove (3) 3x8 screws on the side of the keyboard
2.3 Lift out the Main PCB
3. Remove the Jack PCB
3.1 Remove (4) 3x8 screws on the rear panel.
3.2 Lift out the metal fitting of the power switch
3.3 Remove (3) 3x8 screws
3.4 Life out the Jack PCB
4. Remove the Power Supply and wiring harness
4.1 Remove (6) 3x10 screws on the Power Supply
4.2 Lift out Power Supply
4.3 Loosen 3 spiral clips on the Panel PCB
4.4 Lift out the harness
5. Remove the PCB support plate and ground plate B
5.1 Remove (5) 3x8 screws on the support rail and keyboard
6. Remove the Shield Sheet
6.1 Remove (5) 3x8 screws on the support rail
6.2 Remove (3) 3x8 screws in the keyboard
6.3 Remove (6) 3x8 screws on the Panel PCB
6.4 Lift out the Shield Sheet
7. Remove the Floppy Disk Drive (FDD)
7.1 Remove (2) 3x8 screws on the FDD
7.2 Remove (2) 4x20 screws on the keyboard angle bracket
7.3 Lift out the FDD
7.4 Remove (2) 3x8 screws on the Joystick Panel
8. Remove the Keyboard and Joystick Shield Sheet
8.1 Remove (3) 4x10 screws on the Keyboard
8.2 Remove (7) screws on the Joystick Shield Sheet [(5) 3x8, (2) 4x10]
8.3 Lift out Keyboard and the Joystick Shield Sheet
Apparently there's a flimsy board with metal spring contacts underneath the keys. It looks like "decorative
weather stripping" that "keeps the keys from slipping back and popping out the springs". The contacts on this
board can be easily damaged when re-inserting keys. Several users highly recommend carefully removing
this board when cleaning the keys. Otherwise, it is highly likely you will accidentally damage these contacts.
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If you are disassembling your 01 to work on the keyboard, you can return to that web page now.
THESE STEPS ARE FOR THOSE REMOVING THE LCD
9. Remove the Joystick Panel Support Rail
9.1 Remove (2) screws on the joystick panel support [(1) 3x10 and (1) 3x8]
9.2 Remove (2) 3x8 screws on the joystick panel
9.3 Lift out the Joystick Panel
9.4 Remove (7) 3x8 screws on the support rail
9.5 Lift out the support rail
10. Remove the LCD and Panel PCB
10.1 Remove (19) 3x8 screws on the panel PCB
10.2 Lift out the Panel PCB
10.3 Remove (4) 3x8 screws on the LCD
10.4 Lift out the LCD
(Optional for other repair)
11. Remove LCD hood and side plate
11.1 Remove (3) 3x8 screws on the LCD hood
11.2 Lift out the LCD hood
11.3 Remove (6) 3x8 screws on the side plates
11.4 Remove (2) 3x8 screws on the rear panel
11.5 Lift out the side plates
01/WproX Disassembly
The proX is perhaps the easiest to work on, a small reward for lugging around the heaviest of the 01s. The
first thing to do is identify the various screws on the bottom panel. You might label them with a pencil,
marking the surface lightly with the following letters by the appropriate screws. (Sorry I don't have a picture,
only words.):
.
01/WproX Screws: Bottom Panel
Label Holds Location
D
side
plates
There are four screws, one in each corner. Label each with a "D". As you come forward
from the back two screws, there are two more, one on the left and one on the right. Label
each "D". That is, the four screws most towards the back are "D".
E
upper
case
Coming forward from the back, after the four "D" screws, are three screws in a line from
left to right. Each has a washer. Label each "E".
A keyboard
Jumping to the front, there are 7 screws in a line between the two "D" screws in the
corners. Label all 7 as "A".
B
front bar
spacer
Right behind the middle "A" screw (fourth "A" screw from either end) is a single screw.
Label it "B".
C
joystick On the floppy drive side are the only two screws not yet labeled. One is next to the corner
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panel "D" screw, the other next to the rubber foot. Label each "C"
.
1. To open the upper case
A stick of wood is required to hold the top panel open. Get one first!
1.1 On the bottom panel, remove (3) 4x18 screws labeled "E".
1.2 On the back panel, remove (7) screws, all near the card slots and MIDI jacks. (3) screws near the
card slots (one each side, one under); (1) screw between card slots and MIDI jacks; (2) screws, one
each side of the MIDI jacks; (1) screw closest to MIDI jack screw.
1.3 Open the upper case being CAREFUL not to touch the card slot on the rear panel and both side
plates.
You should now be able to change the battery or do other simple repairs.

2. To remove the keyboard
2.1 Remove seven (7) 5x20 screws on the bottom plate labeled "A".
2.2 Remove eleven (11) screws on the keyboard, (3) 3x10 and (8) 4x14
2.3 Lift out the keyboard, being careful not to hit right side plate.
One user says there's a flimsy board with metal spring contacts underneath the keys, and the contacts can be
easily damaged when re-inserting keys. He suggests carefully removing this board so you can clean the keys
and not accidentally damage these contacts.
(Optional for other repair)
4. Remove the main circuit board
4.1 Disconnect all wiring harnesses
4.2 Remove seven (7) 3x8 screws on the main circuit board.
4.3 Remove the main circuit board.

5. Remove the Panel circuit board.
5.1 Remove eleven (11) 3x8 screws on the ground plates.
5.2 Remove two (2) 3x8 screws on the circuit board support.
5.3 Remove five (5) 3x8 screws on the shield sheet.
5.4 Remove fourteen (14) 3x8 screws on the Panel circuit board
5.5 Remove five (5) 3x8 PLAX screws on the Panel circuit board.
5.6 Remove the joints of the LCD hood.
5.7 Lift out the Panel circuit board.

6. Remove the LCD
6.1 Remove (4) 3x8 PLAX screws.

7. Remove the LCD hood
7.1 Remove (3) 3x8 screws.
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Re-assembly
When putting screws back into holes in plastic, BE VERY CAREFUL not to start new threads (which may
strip out old material, and the screw won't hold). The way to do this is to place the screw in the hole, then
turn it counter-clockwise (like unscrewing it) until you feel the screw pop - it just found the start of the old
thread. You should now be able to screw the screw in smoothly and easily. If you meet any resistance during
the early screwing-in, stop, unscrew it and start over.
Follow the Dis-assembly Procedure, but in reverse order. Consult any notes you made earlier.
Be sure to reconnect all connectors, especially the LCD connector to the motherboard.
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Copyright 1998-2003 by Ken Westover at Cliff Canyon Publishing Co. All rights reserved.
This material may not be distributed without the written permission of the author.
E-mail questions or comments to cliffcan@indra.com.

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