Y-E Data YD-380 User manual

VY·E DATA
MAINTENANCE MANUAL
YD-380
HALF HEIGHT, HIGH DENSITY, DOUBLE SIDED
5.25 INCH FLEXIBLE DISK DRIVE
Contents of this manual may be changed without notice.
Check the revision number when placing an order.
September 1983
FDL-523006
REV. A

---
Date
..
~ptember
--
--
-
.-
-
--
-
~ote: I~"
('21
Revisions
Rev.
Description
Revised Pages
83 A First Edition
publication
----~e YD-380 may be referred to as simply a "drive".
~=~e 5.25 inch flexible disk may be referred to as simply
~ -. disk.

YD-380 Maintenance Manual
TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 MAINTENANCE TOOLS AND TEST EQUIPMENT
2.1 Maintenance Tool List
2.2 Maintenance Supplies List
2.3 Test Equipment
2.4 Exerciser
3.0 PREVENTIVE MAINTENANCE
3.1 General
3.2 Visual Check
3.3 Cleaning
4.0
SERVICE CHECKS,
REPLACEMENT AND ADJUSTMENT
Maintenance
Level 1
4.1
PWB
4.2 Index Sensor Assembly
4.3
Track 00
Sensor Assembly
4.4
Write
Protect Sensor Assembly
4.5 Media Sensor Assembly
4.6 In Use
Lamp
Assembly
Page
1
1
1
2
2
2
3
3
3
3
4
5
6
9
11
12
14

TABLE OF CONTENTS
~Aintenance Level. 2
4.7 Carrier Assembly
4.8 Index Lamp Assembly (on Motor Control PWB)
4.9 Drive Motor Assembly (on Motor Control PWB)
4.10 Head Load Solenoid
4.11. Front Lever
4.12 Front Bezel
4.13 Stepper Assembly
4.14 Head/Carriage Assembly
5.0 PARTS/ASSEMBLIES PHYSICAL LOCATIONS
6.0 TEST POINT/CONNECTOR PIN ASSIGNMENTS
7.0 SPARE PARTS LIST
8.0 SCHEMATIC DIAGRAMS
9.0 EXPLODED VIEW
10.0 USING A CLEANING DISK
Page
15
16
17
18
21
U
23
24
30
35 .
38
39
42
43

1.0 INTRODUCTION
This manual describes the maintenance and operation of the Y-E
DATA YD-380 two sided, high density, 5.25 inch Floppy Disk Drive.
Included is information on service checks, removal and replace-
ment procedures, and also adjustment instructions for customers'
engineers.
2.0 MAINTENANCE TOOLS AND TEST EQUIPMENT
The following tables list the maintenance tools, maintenance
supplies, test equipment and exerciser for the YO-38D.
2.1 Maintenance Tools List
TOOL
Y-E DATE PIN
Phillips Screwdriver (for M3)
141034-01
Phillips Screwdriver (for M2.6) 141627-01
Flat Head Screwdriver
141035-01
Cutters
141039-01
Needle Nose
Pliers
141040-01
Tweezers 141042-01
CE Disk
145173-01
Cleaning
Disk
145174-01
Hex
Wrench
1.27
mm 140266-03
Hex
Wrench 1.5 mm
140266-01

2.2 Maintenance Supplies
Supplies
Y-E DATA PIN
Tie Wrap (TY-23M,
Kitagawa)
031005-01
2.3 Test Equipment
Test Equipment
Multimeter
Electronic Counter*
Oscilloscope*
* For use at Maintenance Level 2
2.4 Exerciser
Equipment
Exerciser
Y-E DATA PIN
YD-164T

3 .0 PREVENTIVE MAINTENANCE
3.1 General
In a reasonably dust-free environment, preventive maintenance
should be performed on the YD-380 every two years. This
includes a visual check and cleaning.
In a dirty environment, the interval between maintenance checks
should be shortened •
.
3.2 Visual Check
Visual inspection should be the first step in any ma~ntenance
operation. Always look for corrosion, dirt, wear, binds, and
loose connections. Checking for these problems can help reduce
downtime later.
3.3 Cleaning
All cleaning of the YD-380 should be performed carefully.
Remove gently all dus~ deposits with lint free gauze or an
applicator moistened with isopropyl alcohol.
CAUTION
The head/carriage assembly is adjusted and tested at
the factory and is not field serviceable. Do not, for
any reason, attempt to repair this component.
Check
Points for Preventive Maintenance
Part
Check
Correction
Frame
Dirt and
dust
on
the connectors,
Connectors other areas.
Clean
sensors,
Sensors
Misc.
Loose
Screws
Tighten

4.0 SERVICE CHECKS, REPLACEMENTS AND ADJUSTMENTS
This chapter contains detailed maintenance procedures for the
assemblies listed below. Note that the list is separated into
two maintenance levels:
Levell:
Level 2:
Can be performed without special training or tools.
Special training and tools required.
Level 1
4.1 PWB
4.2 Index
Sensor
4.3
Track
00 Sensor
4.4 Write
Protect Sensor
4.5 Media Sensor
4.6
In Use Lamp
Level 2
4.7 Carrier
4.8 Index Lamp (on Motor Control PWB)
4.9 Drive Motor (on Motor Control PWB)
4.10 Head Load Solenoid
4.11 Front Lever
4.12 Front Bezel
4.13 Stepper
4.14 Head/Carriage Assembly
Note:
Refer to Chapter 5 for Parts/Assemblies Locations,
Chapter 6 for Test Points/Connector Pin Assignments and
Chapter 9 for Exploded View.

[ Levell]
4.1 PWB (Refer to Chapter 5, Figure 1)
4.1.1 PWB Replacement
1. Disconnect the 4 connectors (J1, J2' J3, J4) from the PWB.
2. Remove the four screws securing the PWB to the frame
casting.
3. Remove the PWB.
4. For reinstallation, reverse the above procedure.
Note: Make sure to mount the PWB below the carrier cover when
reinstalling.
J4 Connector
J3 Connector
o
I
PWB Screws
Screws
(with lock and washer)
4-M3 x6
Figure 4.1.1
Jl Signal
Connector
,--,
I ,
, I
,:
I ,
--
J2 Connector

4.2 Index Sensor Assembly (Refer to Chapter 5, Figure 3)
4.2.1 Service Check~
1. Power up the drive.
2. Without inserting a disk, move the lever to lock position
and check for a to 0.5 V between the PWB connector J3 Pin
All and G (GND). Next, insert a disk and close the door;
the vol tage at the same points should be 2.5 to' 5.25 V'.
4.4.2 Replacement
1. Remove the PWB (Refer to 4.1)
2. Remove J3 connector housing 6. (Refer to Page 9, figure
4.2.2)
3. Take out the carrier cover screws and remove the carrier
cover. '
4.' Lift, up the lead clamps slightly and pullout the leads.
5. Remove the In Use Lamp.
6. Take out the screws for the front lever and carrier assem-
bly, and remove the front lever and carrier assembly.
7. Take out the screws to the Write Protect Sensor assembly,
and as shown in figure 4.4.1, remove the write protect
sensor assembly by pushing in the direction indicated.
CAUTION
When clamping the leads, be careful not to damage the
lead insulation.
8. For reinstallation, reverse the above procedure.
9. Perform a service check. (See 4.l.l)
Note: Make sure the front edge of the carrier plate spring
arm securing the Ready/Off plate does not come in
contact with the leads.

Front Bezel Side
Carrier Plate
Spring
Collet Guide
Figure 4.2.1
J3 Connector Housing ~ssignment
Connector
Number ---t--~
Index Sensor Screw
(with lock and washer,
M3 x 6)
Lead Clamp
Collet Shaft
Figure 4.2.2
Connector
Part
No.
1
Stepper
2Head Load
Solenoid
3
Drive
Motor
4
Write
Protect Sensor
5
In Use Lamp
6 Index
Sensor
7
Track
00 Sensor
8Media Sensor

4.2.3 Adjustment
1. Loosen the Index Sensor screws one quarter turn.
2. Power up the drive.
3. Connect an oscilloscope to the PWB test points lA, 1B, 3.
Connect channell to PWB TP lA, channel 2 to TP IB, and
connect the external scope trigger to TP3.
Set the oscilloscope controls as follows:
INPUT COUPLING MODE
AC
VERT MODE
ADD
INVERT (CH 2)
ON
TIME/DIV
0.1
ms
VOLTS/DIV
(CHI, CH2)
100
mV
4. Insert a CE Disk and turn the front lever to lock position.
5. Load the read/write heads against the disk and step t~e
head/carriage assembly to track 2. Adjust the sensor posi-
tion until the timing between the start of the sweep (index
signal from TP3) and the first part of the index burst (TP
lA, TP lB) is within -600 to 1400 ~s.
,.... ., , .. 1_
Index Signal (TP3)--------~
-600 to 1400~s
Burst Signal
(TP1A,TP1B) J
Figure 4.2.3
Note: To delay the Ind~x Burst, move the sensor towards the
front bezel (see Page 9, figure 4.2.1).

6. Verify that the timing between':the start of the sweep and
the first peak of the index burst is between -600 to 1400 ~s
at side 0and 1, track 02 and track 68.
4.3 Track 00 Sensor Assembly (Refer to Chapter 5, Figure 4)
4.3.1 Service Check 1, Track 00 Sensor
,
1. Power up the drive.· (Resets memo~ies in PWB)
2. Step the head/carriage assembly to a position near the
inner stop.
3. Check the following:
a. Track 00 Lamp:
The
voltage across PWB J3-A12 and G (GND) should be
between
1.0 and 1.7 V.
b. Track 00 Sensor:
The voltage across PWB J3-A13 and G (GND) should be
between 0 and 0.5 v.
4. Power the drive down and up again. (Resets PWB memories)
5. Check the following:.
a. Track 00 Sensor:
The voltage across PWB J3-A13 and G(GND) should be
"between
2.5 and 5.25 V.
Service Check 2, Track 00 Sensor Position Check
1. With power off, move the head/carriage assembly all the way
to the outer stop.
2. Power up the drive.
3. When power is applied, the head/carriage assembly should
move inwards slightly. The Track 00 signal (Jl-26) should
be at Low level (0 to 0.4 V).
4. Move the head/carriage assembly five steps inward and one
step outward. The voltage should change to aHigh level
of 2.4 to 5.25 v.

4.3.2 Removal and Replacement
1. Remove the PWB (See 4.1).
2. Remove J3 connector housing 7. (Refer to page 9, figure
4.2.2)
3. Cut the J3 cable tie wrap with cutters and remove the Track
00 sensor leads from the miniclamp•
...---------- CAUTION --------------,
Be careful not to damage the leads when cutting the tie
wrap.
4. Take out the Track 00 sensor assembly screw and remove the
assembly.
Note: Do not remove the sensor mounting screw or the adjust-
ment screw.
5. For reinstallation, reverse the above procedure.
Note: To attach the Track 00 sensor, push it against the
frame stop and tighten the screw.
6. Perform service checks 1and 2.
Figure 4.3.1 Stop
Track 00 Sensor
Screw (with lock
Iand washer,
M3 x 6)
00 Sensor
able Tie
"" Track 00 Mounting
screw

4.4 Write Protect Sensor (See Chapter 5, Figure 3)
4.4.1 Service Check
1. Power up the drive.
2. Check the following with no disk in the drive.
a. Write Protect Lamp:
The voltage across J3-A8 and G (GND) should be
between
1.0 and 1.7 v.
b. Write Protect Sensor:
The voltage. across J3-A9 and G (GND) should be
between 0and
0.5 V.
3. Check the following with a write protected d~sk (a disk
with a write protect seal over the write protect notch)
in the drive and the front lever in lock position.
a. Write Protect Sensor:
The voltage across J3-A9 and G (GND) should be
between
2.5 and 5.25 V.
4.4.2 Removal and Replac~ment
1. Remove the PWB (See 4.1).
2. Remove housing 4from the J3 connector. (See page 9,
figure 4.2.2).
3. Remove the carrier cover screws and remove the carrier cover.
4. Lift the tabs from the carrier and write protect lead clamps
(two
locations) and remove the leads.
5. Remove the In Use Lamp
6. Take out the screws for the front lever, and carrier assembly,
and remove the front lever and carrier assembly.

7. Take out the screws to the write protect sensor assembly,
and as shown in figure 4.2.2, remove the write protect
sensor assembly by pushing in the direction indicated .
....---------- CAUTION ----------...,
When removing or clamping leads, be careful not to
damage the lead insulation.
8. For reinstallation~ reverse the above procedure.
9. Perform a service check. (See 4.4.1)
Write Protect
Sensor Assembly
lock and washer, M3 x 6)
Figure 4.4.1
4.5 Media Sensor Assembly (Refer to Chapter 5, figure 3)
4.5.1 Service Check
1. Power up the drive.
2. Perform the following with no disk in the drive.
a. Check for 1.0 to 1.7 V across PWB J3-A14 and G (GND).
b. Check for 0 to 0.5 V across J3-A15 and G (GND).
3. Insert a disk and check the following.
a. Check for 2.5 to 5.25 V across J3-A15 and G (GND).

4.5.2 Removal and Replacement
1. Remove the PWB (See 4.1).
2. Remove J3 connector housing 8. (See Page 9, figure 4.2.2)
3. Remove the carrier cover screws and the carrier cover.
4. Remove the In Use Lamp.
5. Remove the media sensor assembly screws and the media
sensor assembly.
6. For reinstallation, reverse the above procedure.
7. Perform a service check. (See 4.5.1)
Note: The media sensor assembly should be attached perpen-
dicula~ly to the frame.
Media Sensor Assembly
Screw
(with lock and
washer, M3 x6)
Figure 4.4.2

4.6 In Use Lamp (Refer to Chapter 5, Figure 5)
4.6.1 Service Check
1. Power up the drive.
2. Set interface signal DRIVE SELECT 0 to Low level, and
install a shorting plug on shorting pin DS o.
3. The lamp should light up.
Note: When the lamp is lit, thl!voltage across J3-AlO and
G
(GND) should be betweel1 1.0 and 2.0 v.
4.6.2 Removal and Replacement
1. Remove Housing 5from the ~JB J3 Connector.
2. Remove the In Use Lamp asseIlllb1y screws and remove the
In Use Lamp assembly.
3. For reinstallation, reverse the above procedure.
4. Perform a service check. (See 4.6.1)

[Level 2 ]
4.7 Carrier Assembly (See Chapter 5, figure 3)
4.7.1 Removal and Replacement
1. Remove the PWB. (See 4.1)
2. Remove the carrier cover screws and remove the carrier
cover.
3. Lift the tabs for the clamps on the carrier assembly and·
remove connector housings 1, 2, 3and 7.
4. Remove the front lever screws.and remove the front lever.
5. Remove the carrier assembly screws and remove the carrier
assembly by pushing towards the rear of the drive. (See
page 18, figure 4.7.1)
6. For reinstallation, reverse the above procedure.
Notes: 1) Make sure that the bosses on the carrier fit
correctly into the matching frame holes when
reattaching the carrier.
2) Make su~e that the Ready/Off plate is below the
head arm hanger when reattaching the carrier
assembly. (See page 24, figure 4.10.1)

4.8 Index Lamp Assembly
4.8.1 Service Check
1. Power up the drive.
2. Check that the voltage across the PWB J3-A7 and G (GND)
is between 1.0 and 1.7 v.
4.8.2 Removal and Replacement
1. Removal procedure is included in the section on the drive
motor assembly (refer to 4.9.2)
Front Lever Screw
(M 3x 3)
Collet
Collet Guide
Screw
(with
washer, M3x 4)
In Use Lamp /
Mounting Screw
(with lock and
washer. MJx6)
Carrier
Assembly
I
Posi
tioning c::>
Boss (back)
Figure 4.7.1
Carrier Screw
(vith l-ock and washer, M3x 8)
Ready/Off Plate Screw
(with washer,. M3x4)
Drive Motor
Screw
(Countersink,
M3x6)
Clamp