Overland Storage NEO 4000e User manual

Part Number 10400219-101 03/2009 ©2009 Overland Storage, Inc. Page 1 of 6
IMPORTANT: Overland Storage requires that all NEO
Series parts be removed and replaced by an Overland
Storage authorized service provider. Improper installation may
result in damage which voids existing warranties.
This document describes how to remove and replace either
the front or rear Z-Axis assembly in a NEO 4000 or NEO
4000Elibrary from Overland Storage.
You will need wire cutters, Phillips screwdrivers, and a
Torque wrench.
WARNING: The GUI touch screen does not completely
shut off NEO Series system power. To reduce the risk of
electric shock or damage, unplug both power cords.
Unpacking the Spare
Carefully unpack and verify that you have all the parts:
•Front or rear Z-Axis assembly
•Four (4) M3x20mm panhead Phillips screws
•Four (4) M3 cup washers
•Two (2) M3x6mm panhead Phillips screws
•One (1) miniature cable tie (rear assembly only)
•These instructions
Electrostatic Discharge Information
A discharge of static electricity can damage micro-circuitry
or static-sensitive devices. To help prevent Electrostatic
Discharge (ESD), observe standard ESD precautions.
Remove Library from Rack
1. Remove all four tape magazines.
IMPORTANT: If the library is non-operational, the
doors can be manually opened by pushing a stiff
wire through the manual release holes (Figure 1).
Figure 1. Manual Door Release Locations
2. If operating, use the GUI to power down the library.
3. Turn the power supply switches to OFF (O), and
remove the power cords.
4. Remove all external host cables.
5. Also, to reduce weight, we recommend removing the
drive assemblies.
WARNING: To prevent injury, it is recommended
that a mechanical lifter (or at least two people) be
used during rack installation or removal.
6. Using a mechanical lifter (or two people), remove the
unit from the rack and place it on a secure ESD
surface.
Remove Top Covers
1. Remove and retain the two screws securing the front
top cover.
2. Lift and remove the front top cover, and set aside.
3. If replacing the rear Z-Axis assembly, also remove the
fan cover assembly at the top rear:
a. Remove and retain the 11 screws that secure the
fan cover assembly to the library chassis.
b. Carefully lift the inside edge of the fan cover
assembly and disconnect the cooling fan connector.
CAUTION: Lifting the cover too far can cause a
strain on the cables possibly damaging them or
their connectors.
NEO®4000 or 4000E
Spare Z-Axis Assemblies
Remove & Replace Instructions
Overview & Notes
NEO-9189
NEO-9190
Front Rear
Preparing the Library
NEO-0155
Manual Release

Part Number 10400219-101 03/2009 ©2009 Overland Storage, Inc. Page 2 of 6
c. Lift the fan cover assembly off and set aside.
Be sure the fan side is up to prevent damage to the
fan assembly.
Remove Shuttle and Track Plate
1. Remove the shuttle:
a. By hand, turn the motor/track coupler until the
track section is at a 45° or larger angle (Figure 2).
Figure 2. Rotating Track & Removing Shuttle (Top View)
b. With one hand supporting the top of the shuttle,
grasp the shuttle base and carefully slide the
shuttle off the track.
NOTE: On older models, you must release the shuttle
brake latch at the bottom of the shuttle next to the track
plate that secures the large black gear.
c. Without twisting the shuttle flex cable, set the
shuttle assembly (with the PCB side up) on the top
edge of the unit (Figure 3).
Figure 3. Set the Shuttle Aside; PCB Up
2. On the defective Z-Axis, remove the four screws and
washers (Figure 4) securing the Screw Rail to the
track plate.
NOTE: If unscrewing the rear Z-Axis screws, retain the Screw
Rail clamp from the bottom.
Figure 4. Remove the Z-Axis Screw Rail Screws
3. If the track plate is stuck in a raised position, on the
other Z-Axis, remove the four screws and washers
(Figure 4) securing the Screw Rail, and carefully lower
the track plate to the floor.
Continue with either “Replacing the Front Assembly” or
“Replacing the Rear Assembly” on page 3.
Remove Old Front Assembly
1. Remove the two bracket screws located immediately
below the drive motor (Figure 5).
Figure 5. Remove Front Z-Axis Bracket Screws (Inside View)
2. Tilt the assembly inward and remove the 7-pin
connector from the Z-Axis drive motor top (Figure 6).
Figure 6. Remove Front Z-Axis Motor Cable (Inside View)
3. Lift out the old front Z-Axis assembly.
Motor/Track Coupler
Rear Z-Axis Screws
Front Z-Axis Screws
Replacing the Front Assembly
NEO-7003
Front Z-Axis
Drive Motor
Front Z-Axis
Bracket
O-7002
Motor Connector

Part Number 10400219-101 03/2009 ©2009 Overland Storage, Inc. Page 3 of 6
Install New Front Assembly
1. Insert the new front Z-Axis assembly into the round
Z-Axis bracket on the chassis floor.
2. Align the Z-Axis bracket over the screw holes on the
front bulkhead and secure it using two new M3x6mm
screws (Figure 7).
Figure 7. Install the New Bracket Screws
3. Attach the 7-pin connector to the drive motor.
4. Attach the Screw Rail bracket to the track plate
assembly (Figure 8) on the chassis floor as follows:
Figure 8. Loosely Install Screw Rail Bracket Screws
a. Align the Screw Rail bracket holes over the track
plate holes.
b. Manually lower the Screw Rail bracket down onto
the track plate by turning the motor coupler
(Figure 9) counterclockwise until resistance is felt.
Figure 9. Turn Front Z-Axis Motor Coupler (Inside View)
c. Install the four new M3x20mm screws and M3
washers until snug, then loosen them one turn.
NOTE: The screws are tighten during the final unit test.
Be sure the cup washer is positioned correctly with
the cup side up against the screwhead (Figure 10).
Figure 10. Screw and Cup Washer Assembly
IMPORTANT: Continue with “Power On and Test the
Library” on page 5.
Remove Old Rear Assembly
1. Remove the shuttle flex cable from the Z-Axis bracket:
a. Remove and retain the clip (Figure 11) holding the
flex cable to the Z-Axis cable bracket.
Figure 11. Remove Clip Holding Flex Cable
b. Pressing the release, lift the cable guide up and off
the Z-Axis guide bracket.
Figure 12. Press Release to Remove Cable Guide
NEO-7007
Coupler Lower
Set Screw
Z-Axis
Bracket
NEO-7006
Loosely
Screw Rail Bracket
Install Screws
NEO-7008
Turn Coupler
Screw head
Cup Washer
(Cup Up)
Replacing the Rear Assembly
Bracket
Clip
Guide
Bracket
Release
Guide

Part Number 10400219-101 03/2009 ©2009 Overland Storage, Inc. Page 4 of 6
c. Carefully stow the flex cable and guide assembly
off to the left in the magazine bay.
2. Release the Z-Axis upper connections:
a. Remove the two mounting screws (Figure 13).
Figure 13. Remove the Upper Z-Axis Items
b. Cut the cable tie from the drive motor.
c. Remove the 7-pin connector from the drive motor.
3. Verify that the Screw Rail bracket clears the track
plate alignment pins (Figure 14).
Figure 14. Rear Z-Axis Alignment Pins on Track Plate
If it does not clear the pins, manually rotate the Z-Axis
motor gear clockwise (Figure 15) to raise the bracket
until it clears the pins.
Figure 15. Turn Rear Z-Axis Pulley Gear
4. Swing the Screw Rail bracket toward the rear, then tilt
and remove the rear Z-Axis assembly.
Installing New Rear Assembly
1. Insert the new rear Z-Axis assembly into the round
Z-Axis bracket on the chassis floor.
2. Insert the 7-pin connector to the bottom of the Z-Axis
drive motor.
3. Using two new M3x6mm screws, secure the Z-Axis
assembly to the two top mounting holes.
4. Install new cable tie to secure the cables to the motor
(Figure 16) observing these points:
•Cables in rear must be clear of the pulleys.
•Locate the Tie ratchet away from the Screw Rail.
•Trim the excess tie leader that extends beyond the
tie ratchet.
Figure 16. Cable Tie and Cable Positions on Drive Motor
5. Attach the Screw Rail bracket to the track plate
assembly (Figure 17) on the chassis floor as follows:
Figure 17. Loosely Install Screw Rail Bracket Screws
a. Align the Screw Rail bracket holes over the Track
Plate holes and alignment pins.
b. Manually lower the Screw Rail bracket down onto
the track plate by turning the motor gear
counterclockwise until resistance is felt.
c. Reinstall the Screw Rail clamp over the rear-left
screw hole on the Screw Rail bracket.
(a) Remove Screws
(b) Cut Cable Tie
(c) Remove Drive
Motor Connector
Alignment Pins
Turn Gear
Front View Rear View
Screw Rail
Tie Ratchet
Avoid
Pulley
Off to Side
NEO-7001
Loosely Screw Rail Bracket
Install Screws
Screw Rail Clamp

Part Number 10400219-101 03/2009 ©2009 Overland Storage, Inc. Page 5 of 6
d. Using a new M3x20mm screw and M3 washer,
secure the clamp to the Screw Rail, tightening the
screw until snug and then loosening it one turn.
Be sure the cup washer is positioned correctly with
the cup side up against the screwhead (Figure 18).
Figure 18. Screw and Cup Washer Assembly
e. Install the remaining three new M3x20mm
screws and M3 washers, tightening the screws
until snug and then loosening them one turn.
NOTE: The screws are tighten during the final unit test.
6. Insert the cable guide onto the new Z-Axis bracket:
a. Positioning the flex cable and guide assembly
over the Z-Axis bracket, verify that there are NO
twists in the flex cable between the chassis wall
and the bracket (Figure 19).
Figure 19. Flex Cable Position Around Shuttle Spooler
b. Slide the clip end of the cable guide onto the Z-Axis
bracket (Figure 20).
Figure 20. Insert Cable Guide onto Z-Axis Bracket
c. Attach the retained clip onto the bracket to secure
the flex cable (Figure 21).
Verify that the flex cable is in the appropriate slot
and that the clip is positioned in the notches.
Figure 21. Retaining Clip Notches & Flex Cable Slot
7. Reinstall the Fan Cover:
a. Carefully reposition the Fan Cover assembly over
the opening and move it slightly toward the front to
permit the deflector to enter the cavity.
b. Reconnect the fan cable to the backplane cable.
c. Align the cover in place.
NOTE: Verify that all the cables are clear before closing.
d. Using the retained screws, reattach the cover.
Reinstall the Shuttle
1. Carefully lift the shuttle and position it at the open
end of the track, checking that there are NO twists in
the flex cable (Figure 22).
NOTE: The open side of the shuttle should be on the left.
2. Slide the shuttle onto the track making sure the
shuttle flex cable wraps around the spooler correctly.
3. Turn the motor/track coupler until the track sections
are realigned.
Figure 22. Flex Cable Position Around Shuttle Spooler
Screw head
Cup Washer
(Cup Up)
No Twists Guide
Bracket
Bracket
Guide
Bracket
Guide
Notches
Slot
Power On and Test the Library
Guide Bracket
Spooler

Part Number 10400219-101 03/2009 ©2009 Overland Storage, Inc. Page 6 of 6
Power On Library
Before returning the unit to the rack, verify that it works.
1. For SCSI systems, verify the terminators are still in
place.
2. Plug in the power cords.
3. Turn the power supply switch to ON (|).
4. Tap the GUI to power on the library.
5. Observe the POST process to verify the installation of
the Z-Axis assemblies:
•Watch the shuttle assembly and track movement.
•Make sure that nothing interferes with the track
plate assembly through its full range of motion.
NOTE: If problems occur, contact Overland Storage
Technical Support.
Run Friction Test (Loose Screws)
Test the Z-Axis assemblies to make sure that they operate
properly.
1. From the touch-screen GUI, press Menu >
Diagnostics > Vertical Calibration.
2. Press Initial Calibration.
The library runs 10 cycles and displays the results.
3. Verify that all the demand results are less than 100.
IMPORTANT: If any results are over 100, repeat
Steps 2–3. If acceptable results are still not
attained, contact Overland Technical Support.
4. Press Back three times.
5. Power off the library, turn off the power supplies, and
remove the power cords.
Run Friction Test (Tightened Screws)
1. In the order shown in Figure 23, tighten the screws
until just snug.
Figure 23. Tighten the Z-Axis Screws in This Order
2. Next, in the same order, tighten the screws to around
6lbstorque.
3. Reconnect the power cords, turn on the power
supplies, and tap the GUI to power on the library.
4. Press Menu > Diagnostics > Vertical Calibration >
Initial Calibration.
5. Verify that all the demand results are less than 100.
6. Press Final Calibration.
7. Verify that all the demand results are less than 100.
IMPORTANT: If any results are over 100, power off
the unit, loosen the screws, and repeat Steps 1–7.
If acceptable results are still not attained after several
attempts, contact Overland Technical Support.
8. Press Back three times.
9. Power off the library, turn off the power supplies, and
remove the power cords.
1. Reinstall the front top cover by inserting the tabs into
their slots and gently setting the cover into place.
2. Reinstall the two retained top cover screws.
3. Using a mechanical lifter (or two people), reinstall the
library into the rack.
4. Manually open the doors and reinstall the magazines.
5. Reinstall any removed drive assemblies.
6. Reattach all external host cables.
7. Reconnect the power cords, turn on the power
supplies, and tap the GUI to power on the library.
8. Place the removed parts in the replacement part
box for returning to Overland Storage.
Tighten Screws
Tighten Screws
1
3
2
4
1
3
4
2
Reinstall the Library
Additional Help
You can get additional technical support on the Internet at http://support.overlandstorage.com, or call
1-877-654-3429 (toll-free U.S. & Canada), [phone] (Europe), or [phone] Option 5 (International).