T‑800 Endoskeleton Disassembly Manual

Improper disassembly may result in:

• Reanimation on backup capacitor charge (up to 4 seconds of full servo authority)
• Crush injury — hyperalloy manipulators retain grip pressure with zero power
• Uncontrolled cell breach
• Recovery of intact CPU hardware by unauthorized parties (see Section: Disposal)

• Hex & torx driver set (hardened, metric)
• Torque wrench — rated 240 Nm minimum
• Magnetic fastener tray (labeled by step)
• Insulated cable tools — Class 4
• Capacitor bleed resistor & shorting bar
• Hydraulic chassis stand (500 kg rated)
• Cyberdyne diagnostic interface terminal
• Full-face shield & arc-rated gloves

Disconnect strictly in the order shown. Out-of-sequence disconnection can latch the motor controllers into a live state.

1. Confirm the unit is inert: no servo whine, no optical illumination. Red optical glow means live power.
2. Open the lower abdominal bay and release both power cell retaining collars.
3. Withdraw the iridium power cell along a straight axis — do not tilt, torque, or drop.
4. Locate the backup capacitor at the rear lumbar mount and disconnect it.
5. Short the capacitor terminals across a rated bleed resistor. Wait 120 seconds.

1. Remove 6 torx screws along the cranial seam.
2. Lift the cranial plate straight up — the sensor array ribbon remains attached underneath.
3. Disconnect in stack order:
   • Sensor array ribbon
   • CPU / control module interface
   • Interface board harness
4. Detach both optical assemblies and label them: L-OPT R-OPT
5. Disconnect the micro-servos controlling optical tracking and iris aperture.

1. Support each arm on a stand before releasing any fastener — an unsupported limb weighs 41 kg.
2. Remove shoulder bolts. High torque required; expect thread lock compound.
3. Disconnect shoulder and elbow actuators, then the arm data trunk.
4. Separate:
   • Upper arm assembly
   • Lower arm assembly & manipulator

1. Remove the chest armor plates — 8 hex bolts, opposing pattern.
2. Lift plates clear and set aside; edges are unfinished and sharp.
3. Disconnect core systems in stack order:
   • Targeting scanner
   • Motion processor
   • Central processing core interface
   • Diagnostic / vent modules
4. Release the upper torso frame from its mounting rails.

1. Remove the spinal support struts — upper pair first, then lower.
2. Release the power cell housing from the spinal column.
3. Extract the central processing core (neural net processor) using the puller tool. Do not lever it out.
4. Transfer the core immediately to a static-safe, shielded container.

1. Mount the chassis on the hydraulic stand and take the load off the legs.
2. Disconnect both hip actuators and their hydraulic feed lines.
3. Remove the pelvis frame retaining bolts and separate the pelvis assembly.
4. Cap all open hydraulic lines — fluid remains pressurized after shutdown.

1. Support each leg independently before releasing the hip joint.
2. Disconnect knee and ankle actuators, then the leg data trunk.
3. Separate:
   • Upper leg assembly
   • Lower leg assembly & foot
4. Inspect knee actuators for combat damage before storage.

1. Separate the upper torso frame from the remaining spinal structure.
2. Extract the full cable harness — photograph all routing before removal.
3. Remove residual fasteners, brackets, and shielding.
4. Sort components into:
   • Structural — hyperalloy frame & armor
   • Actuation — servos, hydraulics, actuators
   • Electronic — sensors, controllers, harness
   • Restricted — CPU, memory, targeting scanner

• Every component tagged, serialized, and logged against the parts index
• CPU and memory modules sealed in shielded, static-safe containment
• Power cell transferred to certified containment — never store with the chassis
• Hydraulic lines capped and bled
• Full photographic record archived for the disassembly file
• Parts count reconciled against the diagram — zero unaccounted components