Digital Equipment RK07 User manual

R K06/R K07 Disk Drive
Service Manual
EK-RK067-SV-001
digital equipment corporation • maynard, massachusetts

Copyright cD 1978 by Digital Equipment Corporation
The material in this manual is for informational purposes and
is subject
to change without notice.
Digital Equipment Corporation assumes no responsibility for
any errors
which may appear in this manual.
Printed in U.S.A.
This document was set on DIGITAL's DECset-8000 com-
puterized typesetting system.
The following are trademarks of Digital Equipment Corporation.
Maynard. Massachusetts:
DIGITAL DECsystem-10
MASSBUS
DEC
DECSYSTEM-20 OMNIBUS
PDP DIBOL
OS/8
DECUS EDUSYSTEM
RSTS
UNIBUS VAX RSX
VMS
lAS
1st Editon, January 1979
6/82-15

PREFACE
The RK06/ RK07 Disk Drive Service Manual is intended as an aid for maintaining an RK06 or RK07
disk drive. Chapter 1 describes the maintenance philosophy and lists the necessary tools and available
diagnostics.
It also includes a description of the RK06/07 Field Test Box and several different views of
the drive. Preventive maintenance procedures are also outlined here. Chapter 2 contains the removal
and replacement procedures for all the drive field replaceable units (FRUs). Chapter 3 details the
procedures for performing any necessary checks, adjustments,
or alignments that may be necessary on
an
RK06 or an RK07. The appendices contain information on the User Defined Test (UDT) diagnos-
tic
and its use with the Bad Sector File, the procedure for hand-toggling in the bootstrap procedure,
and the installation
and field acceptance procedures for the drive.
There
is a list of supplemental documentation relative to the RK06 or RK07 drive in Chapter 1.
111

CHAPTER 1
1.1
1.2
1.3
1.4
1.5
1.5.1
1.5.2
1.5.3
1.5.4
1.6
1.7
1. 7.1
1.7.2
1.7.3
1.7.4
1.7.5
1.7.6
1.7.7
1.8
1.8.1
1.8.2
1.9
CHAPTER 2
2.1
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
CONTENTS
Page
MAINTAINABILITY
MAINTENANCE PHILOSOPHy ...................................................................... 1-1
RELATED DOCUMENTATION ...................................................................... 1-1
TOOLS AND EQUIPMENT .............................................................................. 1-1
DIAGNOSTICTESTING ................................................................................... 1-2
RK06/RK07 FIELD TEST BOX......................................................................... 1-3
General ........................................................................................................ 1-3
Basic ............................................................................................................ 1-3
Switch Description ....................................................................................... 1-3
Sample Switch Exercises ............................................................................... 1-8
DRIVE ORIENTATION .................................................................................... 1-9
OPERATOR CONTROLS AND INDICATORS ............................................... 1-9
RUN/STOP Switch ..................................................................................... 1-9
UNIT SELECT Switch...............................................................................1-18
FAULT Indicator ....................................................................................... 1-18
WRITE PROTECT Switch.........................................................................1-19
Access
"A" Enable Switch ..........................................................................1-19
Access
"B" Enable Switch ..........................................................................1-19
Dual Access Option ....................................................................................1-19
MAINTENANCE CONTROL AND INDICATORS .......................................1-19
SERVO RELEASE Switch (SWl) ..............................................................1-19
SERVO SAFETY Switch (SW2).................................................................1-19
PREVENTIVE MAINTENANCE ....................................................................1-19
SUBSYSTEM REMOVAL AND REPLACEMENT
INTRODUCTION .............................................................................................. 2-1
FRONT BEZEL AREA ....................................................................................... 2-1
Front Bezel................................................................................................... 2-1
Control Panel Assembly ...............................................................................2-6
Latch Assembly............................................................................................2-6
Blower Assembly ........................................................................................
2-1 0
Capacitor, Spindle Motor and Transformer ................................................ 2-11
Speed Sensor Assembly............................................................................... 2-11
Spindle Ground Spring...............................................................................2-13
FRONT BEZEL AND REAR COVER AREA ..................................................2-14
Front Bezel.................................................................................................2-15
Rear Cover.................................................................................................2-15
Absolute Filter ...........................................................................................2-15
Power Harness Assembly............................................................................2-16
Blower Assembly ........................................................................................
2-20
Speed Sensor Assembly...............................................................................2-20
Spindle Assembly .......................................................................................
2-21
v

2.3.8
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
2.4.8
2.4.9
2.4.10
2.4.11
2.4.12
2.4.13
2.4.14
2.4.15
2.5
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
2.5.7
2.5.8
2.5.9
2.5.10
2.5.11
2.5.12
2.5.13
2.5.14
2.5.15
2.5.16
2.5.17
2.5.18
2.5.19
2.5.20
2.5.21
2.5.22
2.6
2.6.1
2.6.2
2.6.3
CONTENTS (Coot)
Page
Spindle Drive Belt.......................................................................................2-23
REAR C()VER AREA ......................................................................................2-24
Rear Cover .................................................................................................2-26
Battery Pack Assembly ...............................................................................2-26
Servo
Pre-Amp Board .................................................................................2-28
Circuit Breaker Assembly ...........................................................................2-29
Power Supply Assembly..............................................................................2-34
Spin(lle
Brake Assembly .............................................................................2-38
Read/Write Heads ..................................................................................... 2-41
Servo Head .................................................................................................2-42
Read/Write Board ......................................................................................2-46
Home Lock Solenoid Assembly .................................................................'.2-46
Tachometer Magnet Assembly....................................................................2-50
Flexstrip Assembly ..................................................................................... 2-51
Glass Shutter Assembly ..............................................................................2-54
Velocity
Transducer Assembly, Two Dowel Version ...................................2-58
Magnet Housing Assembly.........................................................................2-65
LID ASSI~MBL Y AREA ...................................................................................2-68
Front Bezel.................................................................................................2-68
Rear Cover .................................................................................................2-68
Lid Assembly..............................................................................................
2-70
Pack-In-Place Switch ..................................................................................2-70
Motor and Bracket Assembly .....................................................................2-72
Shrolld Assembly........................................................................................2-74
Brush
Arm ..................................................................................................2-76
Brush Switch ..............................................................................................2-76
Brush
and Motor Assembly ........................................................................2-78
Brush
Motor ...............................................................................................2-79
Fixed
Way ..................................................................................................2-80
Read/Write Heads .....................................................................................2-80
Servo Head .................................................................................................2-82
Cam Guide .................................................................................................2-83
Universal Bracket Assembly .......................................................................2-84
Cam Tower Assembly.................................................................................2-86
Spring
Way Assembly.................................................................................2-86
Circuit Breaker Assembly ...........................................................................2-87
Magnet Housing Assembly.........................................................................2-88
Tachometer Magnet Assembly....................................................................2-89
Carriage and Coil Assembly........................................................................2-90
Guide Rod ..................................................................................................2-98
BASEPLATE ASSEMBLY AREA ..................................................................2-100
Front Bezel ............................................................................................... 2-1 00
Rear Cover ............................................................................................... 2-1 02
Lid Assembly............................................................................................2-102
VI

2.6.4
2.6.5
2.6.6
2.6.7
2.6.8
2.6.9
CHAPTER 3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.5
3.6
3.7
3.8
3.9
3.10
3.1 ]
3.12
3.13
3.14
CONTENTS (Cont)
Page
Shroud Assembly...................................................................................... 2-1 03
Blower Assembly ...................................................................................... 2-1 04
Circuit Breaker Assembly ......................................................................... 2-1 04
Baseplate Assembly .................................................................................. 2-1 06
Magnet Housing Assembly .......................................................................2-109
Power
Transformer ................................................................................... 2-11 0
ADJUSTMENT PROCEDURES
LATCH ASSEMBLY ADJUSTMENT ............................................................... 3-1
SPEED SENSOR ASSEMBLY ADJUSTMENTS ..............................................3-3
BELT
TENSION ADJUSTMENT ......................................................................3-4
HEAD ALIGNMENT CHECKS AND CARTRIDGE CARE ...........................3-8
Head Alignment Using Program Control......................................................3-5
Head Alignment Using the Field Test Box .................................................. 3-11
HOME LOCK SOLENOID ASSEMBLY ADJUSTMENTS ............................3-15
TACHOMETER MAGNET ASSEMBLY ADJUSTMENTS ...........................3-16
GLASS SHUTTER ASSEMBLY ALIGNMENT ..............................................3-19
TRANSDUCER HOUSING ALIGNMENT .................................................... 3-21
TRANSDUCER PRE-AMP ADJUSTMENTS .................................................3-22
VELOCITY ADJUSTMENT ............................................................................3-24
PACK-IN PLACE SWITCH ADJUSTMENT ..................................................3-25
CARRIAGE ROLL ALIGNMENT ..................................................................3-27
POWER SUPPLY ±5 VOLTS........................................................................... 3-31
VCO ADJUSTMENT ........................................................................................3-33
APPENDIX A BAD SECTOR FILE
APPENDIX B TOGGLE BOOTSTRAP
APPENDIX C SUBSYSTEM INSTALLATION AND CHECKOUT
C.1
C.Ll
C.1.2
C.2
C.2.1
C.2
.. 2
C.2.3
C.2A
C.2.5
C.2.6
C.2.7
C.3
SITE CONSIDERATIONS AND PREPARATIONS ........................................ C-l
Environmental Considerations .................................................................... C-l
Site Preparation ...........................................................................................C-5
INSTALLATION ...............................................................................................C-5
Unpacking
and Inspection ...........................................................................C-6
Safety Precautions .....................................................................................
C-l 0
Installation Procedures .............................................................................. C-l1
Installation Checks and Adjustments .........................................................C-19
Power Conversion......................................................................................C-27
Dual Access Drive Installation...................................................................C-27
Dual Access Acceptance Procedure............................................................C-28
FIELD ACCEPTANCE TEST PROCEDURE .................................................C-28
Vll

C.3.l
C.3.2
CONTENTS (Cont)
Page
Error Definitions/Rates .............................................................................C-28
Diagnostic Testing.....................................................................................C-32
APPENDIX D TRANSDlJCER HOUSING ASSEMBLY SINGLE DOWEL VERSION
Figure No.
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-1 1
1-12
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
2-15
2-16
FIGURES
Title
Page
Field Test Box ......................................................................................................1-4
RK06/RK07 Drive Front View ..........................................................................1-10
RK06= RK07 Drive Rear View (Early Model) .................................................... 1-11
RK06/RK07 Drive Rear View (Late Model) ......................................................1-12
Card Nest (Early Model) ....................................................................................1-13
Card Nest (Late Model) ......................................................................................1-14
Read/Write Board Area .....................................................................................1-15
Velocity Transducer Assembly............................................................................1-16
Chassis Assembly ...............................................................................................1-17
Operator C:ontrol Panel......................................................................................1-18
RK06 Maintenance Controls and Indicators .......................................................1-20
RK07 Maintenance Controls and Indicators ....................................................... 1-21
Removal and Replacement Procedures Block Diagram ........................................2-2
Front Bezel Area Removal Replacement Procedures Block Diagram ....................2-4
Bezel Lid
and Cover .............................................................................................2-5
Chassis Assembly
(Front) .....................................................................................2-7
Base Plate Assembly..............................................................................................2-8
Latch Assembly....................................................................................................2-9
Speed Sensor Adjustment ...................................................................................2-12
Spindle Ground Spring.......................................................................................2-13
Front Bezel and Rear Cover Area Removal and Replacement
Procedures Block Diagram .................................................................................2-14
Chassis Assembly ...............................................................................................2-17
Power Supply .....................................................................................................2-19
Spindle Drive .....................................................................................................2-22
Rear Cover Area Removal and Replacement Procedures
Block Diagram ...................................................................................................2-25
Chassis Assembly
(Rear) ................. "." ..............................................................2-27
Servo Pre-;\mp Assembly ...................................................................................2-28
Circuit Breaker Assembly ...................................................................................2-30
Vlll

Figure No.
2-17
2-18
2-19
2-20
2-21
2-22
2-23
2-24
2-25
2-26
2-27
2-28
2-29
2-30
2-31
2-32
2-33
2-34
2-35
2-36
2-37
2-38
2-39
2-40
2-41
2-42
2-43
2-44
2-45
2-46
2-47
2-48
2-49
2-50
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
FIGURES (Cont)
Title Page
Spindle Break Assembly .....................................................................................2-39
Read/Write Head Connectors ............................................................................ 2-41
Insertion Tool Position Up Data Heads ..............................................................2-43
Insertion
Tool Position Down Data Heads ., .......................................................2-43
Servo
Head Position...........................................................................................2-44
Insertion
Tool Position Servo (Down) Head .......................................................2-45
Read/Write Board Area .....................................................................................2-47
Homelock Assembly...........................................................................................2-48
Head Separator Tool ..........................................................................................2-49
Tachometer Magnet Assembly ...........................................................................2-52
Flexstrip Assembly.............................................................................................2-53
Glass
Shutter Assembly......................................................................................2-54
Glass
Shutter Alignment Fixtures.......................................................................2-56
Transducer Block Alignment..............................................................................2-58
Velocity
Transducer Assembly............................................................................2-59
Transducer Pre-Amp Adjustments ......................................................................2-60
RK06 Maintenance Controls and Indicators....................................................... 2-61
RK07 Maintenance Controls and Indicators.......................................................2-62
RK06/RK07 Field Test Box...............................................................................2-66
magnet Housing Assembly.................................................................................2-67
Lid Assembly
Area Removal and Replacement Procedures Block Diagram ........2-69
Pack-In Place Switch .......................................................................................... 2-71
Motor and Bracket Assembly .............................................................................2-72
Shroud Assembly ...............................................................................................2-75
Brush
and Motor Assembly................................................................................2-77
Spring Plate Assembly........................................................................................
2-81
Velocity Tranducer Pre-Amp Board ...................................................................2-85
Carriage and Coil Assembly ............................................................................... 2-91
Tee Bar Assembly...............................................................................................2-93
Carriage Alignment Fixture ................................................................................2-94
Indicator Comparator Gauge .............................................................................2-95
Eccentric Bearing
Adjustment ............................................................................2-99
Guide Rod ........................................................................................................ 2-1 00
Baseplate Assembly Area Removal and Replacement
Procedures Block Diagram ............................................................................... 2-1 01
Latch Assembly....................................................................................................3-2
Speed Sensor
Adjustment .....................................................................................3-3
Spring Plunger
Adjustment ..................................................................................3-4
RK06 Maintenance Controls and Indicators ........................................................3-6
RK07 Maintenance Controls and Indicators ........................................................3-7
Servo
Head and Board Area .................................................................................3-9
Head Alignment Tool ...:.....................................................................................3-10
Servo Head and Board Area ...............................................................................3-12
RK06/RK07 Field Test Box...............................................................................3-13
IX