IBM 6360 Installation instructions

IBM 6360 Diskette Unit
IBM - 6580 Display Station

PREFACE
This manual is written for use by experienced US
and World Trade service personnel. Refer to other
product publications if additional information is
needed.
The display formats shown in this manual are
subject
to minor changes due to software improve-
ments.
Future versions of this manual will reflect
any changes.
Where applicable,
component locator drawings,
adjustments, and
other service aids are given by
module. This manual is in seven sections.
Where applicable,
component locator drawings,
adjustments, and
other service aids are given by
module. This manual is in nine sections.
The- 25-Line Display, Large Display, Keyboard,
and Diskette sections contain service information,
adjustments, and removal/replacement
procedures. In
the diskette section, the type 2D
head
is shown only when it is necessary for
adjustments
or removal.
The Display, Keyboard, and Diskette sections
contain service information, adjustments, and
removal/replacement procedures.
The System Electronics/Power Supply section
contains service information and removal/replace-
ment procedures.
The Cables, Connectors,
and Test Points section
helps locate
test points in the system. Point to
point wiring is shown for tracing wires and voltages
through the system.
The Diagnostics section gives a summary
of the
diagnostic package. Charts and flowcharts provide
reference information for operating procedures and
test results.
More detailed descriptions and operating instruc-
tions are provided for
the diagnostic procedures
that are not self-explanatory. The display formats
that require interaction, and are not self-explana-
tory, are described.
The
Intermittent Problem Diagnostic Approach
section is a guide
to help service personnel solve
intermittent system problems. These procedures
should be used only after MAPs have failed
to
isolate the problem.
The Operating Instructions section lists some of
the basic menu sequences available to the operator.
These menus permit the
operator to perform
tasks and functions that are available in the IBM
Licensed Program Textpack I. Since customer
applications, menu sequences, and basic system
operation are a result
of software programs, the
most current Operator Reference Guide should
always be used
as a reference source for system
operation
or function.

25-LlNEDISPLA Y
Page
Service Information
Service
Aid . .......................... 1
Operator Controls . .. ' .................... I
Fonts .
.............................. 2
Removals/Replacements
Display .
............................. 3
LARGE DISPLAY
Safety
Safety Instructions
...................... 6
CRT Anode Discharge Procedure . ............ 7
Service Information
Locator .
............................ 8
Service Aids, Operator Control . ........... . 10
Display Indicators . ..................... 11
Data Flow . .......................... 12
PowerDistribution ..................... 13
Signal Distribution . . . . . . . . . . . . . . . . . . . . . 14
GroundingPoint Locator .
................ 15
Adjustments
Image Size .
.......................... 16
Image Centering . ...................... 17
Removals/Replacements
Large Display Module .
.................. 18
Rear Cover .......................... 19
Display Analog Card . ................... 19
Low Voltage Power Supply ............... 20
High Voltage Power Supply ............... 20
Mainframe Assembly and Front Cover ........ 21
KEYBOARD
Service Information
Locator .
........................... 24
Key Module Operation .................. 25
Shift-Lock Mechanism . .................. 25
BasicAssurance Test (BAT) ............... 25
Matrix Chart ......................... 26
TABLE OF CONTENTS
Data Flow . .......................... 27
Keybutton Position . .................... 28
Keyboard A"angements ................. 29
Tools and Equipment ................... 29
Cleaning Procedures .................... 29
Adjustments
Shift Lock Brake Adjustment . . . . . . . . . . . . . . 30
Removal/Replacements
Keyboard Cover .
...................... 31
Pad Card ............................ 31
Key Module . ......................... 32
Fly Plate Replacement. .................. 33
Shift-LockMechanism . .................. 34
SpacebarMechanism .................... 34
SYSTEM ELECTRONICSPOWER SUPPLY
Service Information
Locator .
........................... 36
DC Voltage Distribution ................. 37
LEDs
.............................. 37
System Grounding Path Schematic .
........... 38
AC Voltages ......................... 39
DC Voltages ......................... 39
Fuses . ............................. 39
C:u"ents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PrInter Sharing ConFrguration .............. 39
Removals/Replacements
Cover .
............................ . 40
Electronic Cards. . . . . . . . . . . . . . . . . . . . . . . 40
Distribution Board ..................... 41
Power Supply ........................ 42
D1SKETTE UNIT
Service Information
Locator .
........................... 44
Service Aid .......................... 44
Diskette Handling . ..................... 45
Data Flow . .......................... 46
Power/SignalDistribution ................ 47
Read/Write Flowchart . .................. 48
Service Aid .......................... 49
Special Tools ......................... 49
Adjustments
Operator Handle
Adjustment, Collet/Flat
Spring
Adjustment Check . ............... . 50
Solenoid and Bail Adjustment . ............. 5)
StepperDrive Band Adjustment ............ 53
Head Carnage Adjustment ................ 54
Removals/Replacements
Cover .
............................. 55
Right DisketteDrive .................... 55
Head Load Bail ....................... 55
Diskette Guide Assembly . ................ 56
Collet/Flat Spring .
........................ 57
Head Load Arm Pad Replacement ........... 58
Bail Solenoid and Idler .................. 59
LED and PTX/File Control Card . ........... 60
Diskette Adapter Card ................... 61
Head/Carnage Assembly ................. 61
Pulley and Drive Band . .................. 62
StepperMotor ........................ 62
Drive BandReplacement .......•......... 62
AC Drive Motor . ...................... 64
Capacitor ........................... 66
CABLES, CONNECTORS & TEST POINTS
Locator Chart (For
Use With MAPs) . ............ 68
AC Voltage Wiring Diagram .................. 75
AC Voltage GroundingPath Schematic . .......... 78
Locator Chart (Point To Point Wiring Checks) ...... 82
DIAGNOSTICS
BasicAssurance Test (BAT) ................. 114
Display Format . ..................... 115
BAT Progress E"or Codes ............... 115
ResidentNon-Automatic (RNA) Diagnostics . ..... 116
Display Format
........... , .......... 117
Diagnostic Tests . ..................... 118

The drawings and 'specifications contained herein
shall
not be reproduced in whole or in part without
written pennission.
IBM has prepared this maintenance manual for the
use of IBM Customer Engineers in the installation,
maintenance
and repair of the specific machines
indicated.
IBM makes no representations that it is
suitable for any other purpose.
Information contained in this manual is subject to
change from time to time. Any such change will be
reported in subsequent revisions or distributed
through Customer Engineering Memorandums
(CEMs)
to all subscribers.
Requests for copies
of IBM publications should be
made
to your IBM representative or to the IBM
Branch Office servicing your locality.
Comments about the publications may be addressed
to (IBM Corporation, 740 New Circle Road N.W.,
Publications
Department 901, Lexington, Ky.
40511). IBM may use or distribute any of the
infonnation you supply in any way it believes
appropriate
without incurring any obligation what-
ever.
You may, of course, continue to use the
infonnation you supply.
"It is possible that this material may contain
reference to,
or information about, IBM products
(machines
and programs), programming, or services
that are not announced in your country. Such
references
or information must not be construed to
mean
that IBM intends to announce such IBM
products,programming, or services in your country."
"IBM," "Executive," "IBM EXECUTARY," and
"Selectric" are registered trademarks of the IBM
Corporation.
©Copyright International Business Machines
Corporation 1980, 1981, 1982
SAFETY PRECAUTIONS
All IBM Customer Engineers are expected to take every safety precaution possible and observe the following
safety practices when servicing IBM equipment.
Mechanical Safety:
1. Safety glasses must be worn.
2. All safety devices, such as guards, shields, signs.
ground wires, etc.,
must be restored after main-
tenance. When a guard or shield
is removed to
observe ormake
an adjustment. that shield must
be replaced when work in the area is completed.
3. Watches. rings, necklaces, ID bracelets, etc.,
must be removed when servicing the machine.
4. Care must be used when working near moving
parts. Keep hair away from moving parts. A void
wearing loose clothing that might be caught
in
the machine. Shirt sleeves must be kept but-
toned or rolled above the elbows. Ties
must be
tucked
in the shirt or have a tie clasp approxi-
mately three inches from the end. Tie chains
are
not recommended.
Electrical Safety:
1. The equipment referenced in this manual may
use high voltages. Check voltage labels!
2. Safety glasses must be worn when checking
energized circuits.
3. If a circuit is disconnected for servicing or parts
replacement,
it must be reconnected and tested
before allowing the use
of the machine.
4. Power should be removedfrom the machine for
servicing whenever possible. Remember, when
checking voltages, avoid contacting ground
potential, such
as metal floor strips, machine
frame, etc.
5. Meter continuity checks should be used instead
of voltage checks whenever possible.
6. Do not apply power to any part, component.
or subassembly when
it is not physically
mounted in the machine, or its approved ser-
vice position.
General Safety:
1. Each Customer Engineer is responsible to be
certain no action on his/her part makes the
product unsafe
or exposes customer personnel
to hazards.
2. Store the removed machine covers in a safe,
out of the way place where no one can trip
over them.
3. If you must leave the machine in a down condi-
tion, always install the covers and disconnect
the power before leaving the customer's office.
4. Always place CE tool kit away from walk areas
where no
one can trip over it.
5. Maintain safe conditions in the area of the
machine while performing and after completing
maintenance.
6. Before s'tarting the equipment, make surefellow
CEs andcustomerpersonnel are not in a hazard-
ous position.
7. All the machine covers must be in place before
the machine
is returned to the customer.
Note:
Refer to the Safety CEMs relating to this
product(s) for further safety precautions.

DIAGNOSTICS (Continued)
Customer Engineer (CE) Loadable Diagnostics
..... 120
Display Format ...................... 124
Keyboard Function . ................... 125
MDI Run Time Options . ................ 125
MDI Run Time Options MenU-Stop On Options . 125
MDI Test Unit Numbering . .............. 125
MDI Prompt Responses ................. 126
MDI Prompts . ....................... 127
MDI Display Typing Area or Menu Area ...... 129
MDI Trace Display .................... 130
CE Ufllities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Error Log Utility Group . ................ 131
System Error Log . .................... 131
Error Log Dump Procedure .............. 132
System Exerciser ........................ 133
Load Program Function . ................... 134
Diskette Unit (6360) Head
Alignment Compatability Check . ............. 134
Field Engineering Service Number/Release
Modification (FESN/RVM)
................. 134
LicensedProgram Guidelines ................ 134
Memory Card Configuration . ................ 134
INTERMITTENT PROBLEM DIAGNOSTICAPPROACH
Introduction ........................... 136
Data Collection ......................... 137
Instructions . ........................ 137
Problem Isolation . ....................... 137
Section 1 Keyboard Isolation ................ 138
Section 2 Display Isolation . ................. 139
Section 3 ElectronicModule Isolation .......... 139
Section 4 Diskette Unit Isolation . ............. 140
Section 55215 Printer Isolation .. 141
Section 65218 Printer Isolation .............. 142
Section 7Printer Sharing Isolation . ............ 142
Section 8 Power Supply Isolation ............. 143
Section 9 Isolation Undetermined ............. 143
Section 10Software/Operator Procedures ........ 144
Section 11 Environment ................... 144
Questions .......................... 144
Recommendation . .................... 144
Section 12 History Build ................... 145
Section 13 Service RequestNumbers ........... 145
Section 14 BAT Failures ............ 146
Pre-CRT Initialization BAT Failures . .... _ ... 146
Post-CRTInitialization BAT Failures ........ 146
Section 15 Diskette RNA Test Failure Codes . ..... 146
Drive Set Ready Test (L) ................ 146
StepperMotorPhase Test (M) ............. 146
Track Step Test (T) . ................... 147
Section 16 Guidelines for Error Log Interpretation .. 147
Section 17 Trace Table Usage ................ 148
OPERATING INSTRUCTIONS
Menu Sequences
Typing Tasks .
...................... . 150
Work Diskette Tasks . .................. 151
Program Diskette Tasks . ................ 152
Spelling Tasks ....................... 153
Change Format Key ................... 154
Request Key . ....................... 155
Instructions . ........................ 156

CAUTION
Do not remove the display covers. Operating voltages
np to 14,000 volts are present inside the display.
No bleeder
resistor
is provided.
SERVICE AIDS
The display module is a field replaceable unit (FRUI which
is not field serviceable.
The raster is a normal background image on the display
screen which is visible when the brightness control is turned
up (clockwisel all the way.
A blank screen or blank area of the screen may not be a
problem in the display module. The problem may be a
change in or a loss of the input signals.
NOTE: When a displayed character is changed an '"after
image" will remain for a short time.
"if-+--- Brightness
Display Raster
25-LlNE DISPLAY -Service Aids, Operator Controls -1-

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Display Fonts

DISPLAY
1. Turn the system power off.
2. Disconnect the system AC power cord.
3. Disconnect the display connector from the electronics
module Panel 1.
4. Lift the display module up, releasing
the interlock.
5. Pack the display
in a display packing box.
CAUTION
Do not transport the display module unless it is suitably
packed. The display may burst inward
if broken.
D
25-LlNE DISPLAY -Removals/Replacements -3-
Interlock

Safety
TABLE OF CONTENTS
LARGE DISPLAY
Safety Instructions ...................... 6
CRT Anode Discharge Procedure. . . . . . . . . . . . . 7
Service Information
Locator .
............................ 8
Service Aids, Operator Control ............. 10
Display Indicators . ..................... 11
Data Flow . .......................... 12
PowerDistribution ..................... 13
Signal Distribution ..................... 14
GroundingPoint Locator . ................ 15
Adjustments
Image Size . .......................... 16
[mage Centering . ...................... 17
Removals/Replacements
Large Display Module
................... 18
RearCover .......................... 19
DisplayAnalogCard .................... 19
Low Voltage Power Supply ............... 20
High Voltage Power Supply ............... 20
Mainframe Assembly and Front Cover ........ 21
-5-

-6~ LARGE DISPLAY -Safety Instructions
DANGER
Operating voltages of up to 17,000 volts are present
inside the large display. A bleeder circuit
is provided.
However, you must wait at least 10 seconds after
power
is turned off for the voltages to reach a safe
level (less than 60 volts). Follow all normal safety
precautions.
SAFETY
Whenever the rear cover is removed from the large
display. ALWAYS ensure
that the CRT (Cathode Ray
Tubel ground spring is in place, and that it is connected
to the CRT socket o. Do this before any type of
service
is performed.
Use the CRT Anode Discharge Procedure whenever
continuity checks are made, and during
removal/replacement procedures. This will ensure
that no high voltage is present.

CRT ANODE DISCHARGE PROCEDURE
1. Turn the system power off, and disconnect the
system AC line cord from the wall
outlet.
2. Wait 15 seconds.
3. Perform the rear cover removal.
4. Perform the low voltage power supply removal.
5. Use an alligator clip to connect the plug end of a
Fluke' meter lead to the display mainframe.
6. Push the probe end of the meter lead under the
boot
on the anode O. Visually ensure that the probe tip
touches the metal prongs on the anode lead.
7. Remove the probe from the anode, and ensure that
the boot is securely seated against the surface of the
CRT O.
CAUTION
Even though this safety procedure is used, if the anode
lead
is disconnected from the CRT, the CRT may
slowly recharge.
Make sure you discharge the anode
hole in the CRT:
Every 5 to 10 minutes
Before connecting the anode lead to the CRT
When installing a new mainframe assembly or
high voltage power supply.
* Trademark of John Fluke Manufacturing, Inc.
-7-

-8-
LARGE DISPLAY
Brightness
Control Knob
-Locator
Rear
Cover
Display AC Cable
Front
Cover
Connector 2
Display Signal
Cable
Bezel
High Voltage
Power Supply
Low Voltage
Power Supply
,,~LVl
Display Indicator ~
LV2 (DC out)
LV3 (AC in)
prong
ZL--lIlII~~~~--- CRT Ground S .
CRT Socket

LARGE DISPLAY -Locator (continued) -9-
CRT Anode Lead
Yoke
• Sealed Pots (Do Not Adjust)

-10- LARGE DISPLAY -Service Aids, Operator Control
DANGER
Operating voltages of up to 17,000 volts are present
inside the large display, A bleeder circuit
is provided,
However, you must wait
at least
10 seconds after power is turned off for the voltages to
reach a safe level (less than 60 volts),
SERVICE AIDS
The raster on the display screen is a normal display
which
is usually visible when the brightness control is
turned up (clockwise) all the way.
A blank screen or blank area of the screen may
not be
a problem
in the display module. The problem may be
a change
in or loss of the input signals.
NOTE: When a displayed character is changed, an
"after image" remains for a short time·,

DISPLAY INDICATORS
There are three display indicators on the back of the
display module. They are:
0= Low Voltage Power Supply (LED)
1 =High Voltage Power
Supply (Neon)
2 =Horizontal Beam Deflection Circuit (Neon)
These indicators show the operating condition of the
two power supplies and the circuit.
If an indicator is ON (glowing), it indicates correct
operation.
If an indicator is OFF, it indicates a problem.
The problem may be caused by one or more of the
following:
Loose or defective indicator lamp
Loose or defective cable or plug
Defective Low Voltage or High Voltage
Power Supply
Defective Analog Card
NOTE: Loss of horizontal beam deflection causes
both indicators 1 and 2 to be OFF.
LARGE DISPLAY -Display Indicators -11-
Display
Indicators
2

-12- LARGE DISPLAY -Data Flow
Electronics Module
Large Display
Display
Analog
Adapter
Bright
Card
Microprocessor
Card
on the System
Video
K'"
Card moves
-t
Display
data from the
Buffer
Vertical Sync
Memory Card (RAM)
Horizontal Sync
(Controls logic and
character generator)

LARGE DISPLAY -Power Distribution -13-
--Panel 1 Electronics
Module
____ J
Keyboard Keyboard Cable -I
0
A 1 I
I I Electronics
Logic Card Package I
2
f---
I
Large Display Module 3
~
I
4 0
III
I
Internal Distribution Cable c
Low 5 0
~
."
::>
I
Voltage Large Display
.D
Power
6A
'§
LV3 AC Cable a I
Supply
ILV2
68 I
7
CRT Anode
-----l I--
f{ :
8
Lead Display
4~
Analog I
LED ~
I High ~
8 Assembly '--,-
____ J
Voltage Card
Power
J
Supply
System Power Cable
Diskette Unit
L12--.r
P2
P1
Power Supply
I AC Motor I
--%
Diskette Unit
AC Cable 12
Left Drive J 12
AC Line
rr_C::;~
Cord 9
AC Motor
9
I L
_-1
I
Diskette Unit
-
DC Cable 10
I I
82
U
Diskette 10
I Right
Drive
I Q
I (Optional) Adapter
I Card
11
I
~
11
L
----
Power Supply Distribution Schematic
(System with Large Display)

-14- LARGE DISPLAY -Signal Distribution
Large Display Module
Display Cable
2
Electronics ModulE'
-- Panel 1
o Internal
3
4
6A
68
Distribution Cable
Signal Distribution Schematic
Electronics I
Package I
I
I
I
I
I
I
I
I
I
____ J
I