IBM 6580 Installation instructions

IBM 6360 Diskette Unit
IBM 6580 Display Station

The drawings and specifications contained herein
shall
not be reproduced in whole or in part without
written permission.
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.
Commentsabout
the publicationsmay 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
information you supply in any way it believes
appropriate
without incurring any obligation what-
ever. You may,
of course, continue to use the
information 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
SAFETY PRECAUTIONS
All IBM Customer Engineersare expected to take every safety precaution possible and observe the following
safety practices when servicing IBM equipment.
Mechanical Sa!ety:
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
or make 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 disconnec ted for servicing or parts
replacement,
it must be reconnected and tested
before allowing the use
of the machine.
4. Power should be removed f;'Om 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
rIO 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 walkareas
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 starting the eqUipment, makesurefellow
CEs andcustomerpersonnel are not in a hazard-
ous position.
7. A II 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.

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.
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 1. 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.

DISPLAY
Page
Service Information
Service
Aid. . . . . . . . . . . . . . . . . . . . 1
Operator Controls ................... 1
Fonts . .......................... 2
Removals/Replacements
Display
...... .................... 3
KEYBOARD
Service Information
Locator
.................. .
Key Module Operation . ......... .
Shift-Lock Mechanism
... .
6
7
Basic Assurance Test (BAT) ............. . 7
7
8
Matrix Chart . . . . . . . . . . . . . . . . . . . . . . .
Data Flow .
................ . 9
Keybutton Position. . . . . . . . . ... . ·
.... . 10
Keyboard Arrangements
......... . ·
..... 11
Tools and Equipment . . . . ...... . ·
..... 11
Qeaning Procedures. . . . . . . . . . . . . ·
..... 11
Adjustments
Shift Lock Brake Adjustment . . . . . . . . . .... 12
Removal/Replacements
Keyboard Cover . . . . . . . . . . . . . . .
.. 13
PI11;i Card . ........................ 13
Key Module ....................... 14
Fly Plate Replacement ................. 15
Shift-Lock Mechanism . . . . . ..... 16
Spacebar Mechanism . . . . . . ..... 16
SYSTEM ELECTRONICS POWER SUPPLY
Service Information
Locator. . . . . . . . . . . . . . . . . ...... 18
DC Voltage Distribution ................ 19
LEDs " ......................... 19
AC Voltages ....................... 20
DC Voltages ....................... 20
Fuses . ......................... . 20
Currents .... . . . . . . . . . . . . . . . . ..... 20
TABLE OF CONTENTS
Printer Sharing Configuration . . . . . . . . . .20
Removals/Replacements
Cover .
.......................... 21
Electronic Cards. . . . . . . . . . . . . . . . . . . . . 21
Distribution Board . . . . . ..... 22
Power Supply . . . . . . . . . . . .... 23
DISKETTE UNIT
Service Information
~~~ .......................... U
Service Aid. . . .............. 26
Diskette Handling . ................... 27
Data Flow . . . . . . . . . . . . . . . . . . . . . . . . 28
Power/Signal Distribution ............... 29
Read/Write Flowchart . . . . . . . . . . ....... 30
Service Aid . . . . . . . . . . . . . . . . . . . . . . . . 31
Special Tools ...................... 31
Adjustments
Operator Handle Adjustment, Collet/Flat
Spring
Adjustment Check . . . . . . . .
Solenoid and Bail
Adjustment ..... .
StepperDrive Band
Adjustment . ... .
Head Carriage
Adjustment ....... .
Removals/Replacements
... 32
... 33
...35
...36
Cover . .......................... 37
Right Diskette Drive ....... . . . . . . . . . .. 37
Head LoadBail
..................... 37
Diskette Guide
Assembly. '.' . . . . . . . . . . ... 38
Head Load Arm Pad Replacement. . . . . . . . . .. 39
Bail Solenoid and Idler . . . . . . . . . . ...... 40
LED and PTX/File Control Card ........... 41
Diskette Adapter Card .......... ...... 42
Head/Carriage Assembly ................ 42
Pulley and Drive Band .............. .. 43
StepperMotor . . . • . . . . . . . . . . . . . . . . . . 43
Drive Band Replacement . . . . . . . . . . . . . . .. 43
CABLES, CONNECTORS & TEST POINTS
Locator Chart (For
Use With MAPs) .... . ·
.... 46
AC Voltage Wiring Diagram . ........ . ·
.... 53
AC Voltage Grounding Path Schematic .. . ·
.... 56
Locator Chart (Point To Point Wiring Checks) . ·
... . 60
DIAGNOSTICS
Basic Assurance Test (BAT)
.......... .
Display Format
....
BA T Progress Error Codes . . . . . . ...
. . . . 88
.. .. 89
.... 89
Resident Non·Automatic (RNA) Diagnostics . ...... 90
Display Format. . . . . ....... 91
Diagnostic Tests . ................... 92
Customer Engineer (CE) Loadable Diagnostics . . . . . . 93
Display Format .................... 94
Keyboard Function . ................. 95
MDT Run Time Options ............... 95
MDT Run Time Options Menu· Stop On Options. 95
MDI Test Unit Numbering . . . . . . . . . . . . . . 95
MDIPrompt Responses ............... 96
MDI Prompts ..... . .............. 97
MDI Display Typing Area orMenu Area ...... 99
MDI Trace Display. . . . . . . ... 100
CE Utilities . ......... .
Error Log
Utili~y Group
System Error Log . . . .
Error Log
Dump Procedure
System Exerciser. . . . . . . . . .
LoadProgram Function
..
Diskette Unit (6360) Head
Alignment Compatabiliry Check
....
Field Engineering Service Number/Release
Version Modification (FESN/RVM)
DIAGNOSTICS (Continued)
· .. . 101
·
... 101
.101
.102
.103
· .. . 104
.... . 104
.... . 104

DIAGNOSTICS (Continued)
Licensed Program Guidelines
... . .... . 104
Memory Card Configuration ................ . 104
INTERMITTENT PROBLEMDIAGNOSTICAPPROACH
Introduction
..... . . . . . . . . . . . . . . . . . . . .. 106
Data Coliection . . . . . . . . . . . . . . . . . . . . . . . . . 1U7
Instructions
...................... . 107
Problem Isolation ...................... . 107
Section 1 Keyboard Isolation ............... . 108
Section 2 Display Isolation. . . . . . . . . . . . . . . ... 109
Section 3 ElectronicModule Isolation ... . ....... 109
Section 4 Diskette Unitlsolation ....... . 110
Section 5 5215 Printer Isolation .............. 111
Section 6 5218 Printer Isolation .............. 112
Section 7 Printer Sharing Isolation . . . . . . . . . . . .. 112
Section 8 Power Supply Isolation . . . . . . . . . . . . . . 113
Section 9 Isolation Undetermined ........... .. 113
Section 10 Software/OperatorProcedures . ........ 114
Section 11 Environment . . . . . . . . . . . ........ 114
Questions. . . . . . . . . . . . . . . . . . . . . . . .. 114
Recommendation _ ................... 114
Section 12 History Build . . . . . . . . . . . . . . . . . . .115
Section 13 Service Request Numbers . . . . . . . . . . . .115
Section 14
BAT Failures . . . . . . . . . . . . . . . . ... 116
Pre-CRTInitialization BAT Failures. ......... 116
Post-CRTInitialization BAT Failures . ........ 116
Section 15 Diskette RNA Test Failure Codes ....... 116
Drive Set Ready Test (L) . ............... 116
StepperMotor Phase Test (M) ............. 116
Track Step Test (T) .................. 117
Section 16 Guidelines for Error Log Interpretation .... 117
Section 17 Trace Table Usage . . . . . . . . . . . ..... 118
OPERATING INSTRUCTIONS
Menu Sequences
Typing Tasks. . . . . . . . . . . . . . . . . . . . . .
120
Work Diskette Tasks. ................. 121
Program Diskette Tasks. . . . . . . . . . . . . . . . 122
Spelling Tasks. . . . . . . . . . . . .... 123
Change Format Key. . . . . . . . . . . . . . . . . . 124
Request Key . ..................... 125
Instructions ...................... 126

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 Illodule is a field replaceable unit (FRU) 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 (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 a loss of the input signals.
NOTE: When a displayed character
is changed an "after·
image" will remain for a short time.
I!irO-;;--+----Brightness
Display Raster
DISPLAY -Service Aids, Operator Controls
-1-

-2- DISPLAY - Fonts
1 2
0 1 2 3
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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.
DISPLAY - Removals/Replacements ·3·
Interlock

TABLE OF CONTENTS
KEYBOARD
Service Information
Page
Locator. .............................. 6
Key Module Operation . .................... 7
Shift-Lock Mechanism . .................... 7
Basic Assurance Test (BAT). ................. 7
Matrix Chart. ........................... 8
DataFlow ............................. 9
Keybutton Position . ..................... 10
Keyboard Arrangements. .................. 11
Tools andEquipment. .................... 11
Cleaning Procedures. ..................... 11
Adjustments
Shift Lock Brake Adjustment ............... 12
Removals/Replacements
Keyboard Cover .
....................... 13
Pad Card . ............................ 13
Key Module . .......................... 14
Fly Plate Replacement. ................... 15
Shift-Lock Mechanism . ................... 16
SpacebarMechanism ..................... 16
-5-

-6- KEYBOARD -Locator
Key ModUl~ti
----Speaker
I Speaker Connector
I 30-Pin Edge Connector
I I Pad Card
I
)j
ij'
Keyboard
00-- ___ ' Connector

Flat
Spring
Fly Plate
~]~~3~-; Compression Spring
Spring_;~!~~~~~~~~;;
Fly Plate
Normal
FullyP,BIS8d
Pad Card Capacitor Plate
Stem
Assembly
Key Module Operation
Shift Reset
Bail
Shift-Lock RestoringMechanism
Key Module Operation,
KEYBOARD -Shift Lock Mechanism, BAT -7-
BASIC ASSURANCE TEST (BAT)
A Power on Reset (POR) of the system will automatically
start
the keyboard Basic Assurance Test (BAT) and perform
wrap tests on the keyboard adapter circuits of
the system
card.
The keyboard
BAT will verify the keyboard microproces·
sor, located on the keyboard logic card
is operating cor·
rectly. The keyboard notifies the system processor of the
keyboard status by transmitting a specified sequence of
two bytes of data. Successful completion of the
BAT is
necessary for the keyboard to proceed with normal sys·
tern operation.
A third byte containing the keyboard ID is also transmitted
to provide configuration information.
System Power·On·Reset
BAT Signal to Keyboard Microprocessor
BAT Self·test of Keyboard Microprocessor
BAT Completion Codes Transmitted
System Electronics Accepts Data Byte Codes
Keyboard
ID Transmitted
Keyboard Operational

-8- KEYBOARD -Matrix Chart
Edge
CO ...... 'J~
POIition
(01) A
(02) B
103)C
(04) D
(27) E
(28) F
(29) G
(3O)H
Drive Lines
Keyboard Number 1 Matrix Chart

Key
Pressed
(First)
To System Electronics
KEYBOARD -Data Flow -9-

-10- KEYBOARD -Keybutton Position
KEY POSITION
The key positions are shown in Figure 10. Key positions
marked with a
"T" are typamatic keys, positions marked
"N-A" are non-active, and those marked "M" are make/
break keys. The position
of the typamatic keys are con-
trolled by software and may
be different for World Trade
countries depending on the country layout.
Work Station
Control
Keys
Key
Position
Number
ill NA 101( NUII·Ad;ve Keys
T ypamat;c Key
Make/Break Key
Key Legend
Function Keys
Cursor Control Keys
96-Character Keyboard

STRAP IDs
LANGUAGE SUPPORT
92 96
Australia/New Zealand 1
Austria/Germany
29
Belgium (Flemish) 247
Canada-England 37
Canada-F rance/B ilinguaJ
39
Czech-Czech
83
Czech-Slovak
85
Denmark 57
Finland
248
France/Belgium (AZ)
251
Franee (Qwerty)
252
Greece (Latin)
75
Hong Kong (Latin)
119
Hungary
91
Italy (S.A.)
41
Japan (English)
69
Netherlands
43
Norway 55
Poland 93
Portugal 63
Rumania 87
S. Africa
81
Spain 45
SP Speak/Puerto Rico 25
Sweden 53
SWitzerland-Germanv 51
Switzerland-France
49
Turkey 79
U.K.llsrael 67
U.S. 1
U.S. 249
U.S. Dvorak 250
Yugoslavia (Latin)
95
"X's Indicate Jumper Positions
o
X X X
X X X
X X
X X
X X
X X
X X
X X
X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X X
X X
X X
X X
X X
X X
X X X
X X
KEYBOARD -Keyboard Arrangements, Tools & Equipment, Cleaning Procedures -11-
10 JUMPERS'
3 4 5 6
X X X X
X
X
X X X
X X
X X
X X
X X
X X
X X
X X
X X
X X X
X X X
X X
X X
X
X X X
X X
X X
X X
X X
X X X
X
X X X
X X X X
X X
X
X
X
X
The Keyboard Assembly requires no scheduled preventive
maintenance.
TOOLS AND EQUIPMENT
The following equipment is required to service the key-
board:
Keybutton Puller (PIN 9900373)
Alcohol Pad (PIN 9900679)
Lint-free Cloths (PIN 2108930 or PIN 2123106), or
Disposable Cleaning Cloths
(PIN 1650800)
CLEANING PROCEDURES
Plastic parts and painted covers can be cleaned with IBM
cover cleaner, PIN 450891, or a mild non-abrasive hand
soap. Other solvents or cleaners are not recommended as
damage or discoloration of plastic or painted parts can
result.
Cleanliness
is important when working on the keyboard.
Any particle between
the key module fly plate and the pad
card is a potential problem.
Before any keyboard disassembly, prepare a smooth, clean
work area by wiping contamination away with an alcohol
pad. Gently tap, brush, and shake the keyboard assembly to
remove any loose particles which could get into the pad
card and fly plate area during disassembly and reassembly.
The pad card and key module fly plates are cleaned by
carefully wiping each with an alcohol pad followed by a
lint-free cloth. Care should be taken
not to dislodge or
remove fly plates from key modules.
Some minor liquid spills, such
as soft drinks or coffee with
sugar, can
be removed by first washing the pad card and
affected fly plates with a lint-free cloth dampened with a
mixture of water and a mild hand soap. Rinse with a water-
dampened lint-free cloth, then clean with an alcohol pad
and dry with a lint-free cloth.
NOTE: Sticky key modules must be replaced. A severe
liquid spill may necessitate replacement of the entire
keyboard assembly.

-12- KEYBOARD -Adjustments
Shift Lock Brake Adjustment
1. Adjust the shift lock brake screw so the shift latches and
and locks reliably (clockwise increases brake tension)
.•
Shift Reset Bail /
~
haft Assembly
\ t:", ~
/
/", c%~~
,::/::: / N
~~0
-(:_ ~~/~ d
l ••
Shaft Assembly

KEYBOARD COVER
1. Turn the system power off.
2. Remove the
top cover by loosening the four captive
screws on the bottom of the keyboard assembly
•.
o
\ o
Four Captive Screws
o
PAD CARD
1. Turn the system power off.
2. Remove the
top cover by loosening the four captive
screws on
the bottom of the keyboard assembly (see
Keyboard Cover RemovaL)
3. Remove the two screws holding
the keyboard logic
card. Disconnect the speaker
cable. and the key-
board cable
.• Remove the logic card.
KEYBOARD -Removals/Replacements -13-
4. If a key module is to be removed, locate the position
of
the key before the keyboard is inverted and remove
the keybutton.
5. Remove two mounting screws on each side of the
keyboard under the contamination shield .•
6. Lift the keyboard out of the keyboard frame.
7. Invert the keyboard and install it on the frame using a
screw on each side
to hold the assembly in place.
1/ II \
.. ,,' ~
::=---=a-=------~v= _
~\--~~--------------------------------/~

-14- KEYBOARD -Removals/Replacements
Warning: Removing the pad card with a key
pressed may cause
the fly plate to spring out of the
key module.
8. Ensure there is no pressure on any keys.
9. Remove
the screws from the pad card .•
10. Lift the pad card from the keyboard assembly.
• •
Pad Card Screws
11. To assemble, reverse the above procedure. Before
inserting the logic card, the pad card should be
cleaned and lubricated
as follows:
A. Carefully wipe the pad card with
an alcohol pad
followed by a lint-free cloth.
B. Use a light abrasive (PIN 9900089) or a .pencil
eraser
to clean the top and bottom copper con·
tacts
of the 30'pin edge connector.
C. After cleaning the contacts, apply a thin layer of
I
BM No. 10 oil to the edge connector (top and
bottom) of the pad card. Coverage of about
50% of the tab area (as measured from the edge of
the tab) will ensure the desired protection of the
contacts.
Warning: Do not over-lubricate the edge
connector, as permanent damage
to the key
modules may occur
if lubricant gets on the
pad card.
Pad Card Copper Contacts
KEY MODULE
Removal
1. Use the keybutton removal tool (PIN 9900373) to lift
the keybutton from
the key module to be removed.
2. Disassemble the keyboaru
(see Pad Card Removai).
3. Reach under the key assembly and push the failing key
module up until it
is free .•
Warning: To prevent loosening a fly plate, ensure no
keys are accidentally pressed while the pad card is
removed.
NOr
h •
Spacebar Edge I. Retaining Ear
<:!lil!/nW/i!i~/<%
NOTE: The module retaining ears must clear the frame.
Installation
1. Insert the key module. Match the opening
in the key
module with the aligning
lug in the mounting hole. The
key stem notch must be positioned toward the space·
bar edge
of the keyboard .•
2. Reinstall the pad card.
3. Turn
the key assembly over and, if necessary, reposi·
tion
the contamination shield.
4. Put the keybutton on the key module.
5. Reinstall
the logic card cables and covers.