3592 Manual Cleaning Procedure

01/21/04
3592 Manual Cleaning Procedure
Version 1.0
Abstract: This document describes a procedure that would allow manual cleaning of the major tape path components and sensors located within the tape drive. The document is divided into three parts: 1. A procedure for preparing the drive for cleaning which includes removal from the existing system and disassembly of the canister and removal of covers. 2. A procedure for cleaning the major tape path components and all the sensors. 3. A procedure for installing the covers and to reassemble the drive back into the canister. Preparation of the Tape Drive for Cleaning: This section describes a procedure for removing the drive from its canister and removing the required covers. Refer to the 3592 Tape Subsystem Maintenance Information, part number 18P9781, guide for instructions about removing the tape drive from the particular system it is installed in. The operator should were an electrostatic ground strap throughout the following procedure. The tools required after removal are: 1. A size P1 (3/16) Phillips screwdriver. 2. A size P2 (1/4) Phillips screwdriver. The drive should be placed on a flat surface for this procedure. Remove the four screws holding the fan housing as shown in the following illustrations using the size P1 Phillips screwdriver.
Remove the fan cover and disconnect the cables inside the drive canister from the drive end as shown in the illustrations below.
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Remove the four screws holding the drive in the canister using the size P2 Phillips screwdriver as illustrated in the pictures below.
Remove the drive from the canister. The illustration to the left shows the assorted parts after removing the fan cover, unplugging all the cables, and removing the drive. The next step will be to remove the bezel. The pictures below show the location of the three screws holding the bezel. Remove the three screws using the size P1 Phillips screwdriver.
Remove the bezel being careful to not break the attached cable. Disconnect the cable from the bezel as shown in the illustration below on the left. The next step is to remove the two covers on the drive. First remove the six screws holding the covers using the size P1 Phillips screwdriver as shown in both of the illustrations below.
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Next, remove both covers. The large box cover overlaps the air exhaust cover. The illustration below on the left shows the covers removed. The last step is to remove the RFI shield. The illustration below on the right shows the two screws removed, but the cable still in place. Remove the two screws with the size P1 Phillips screwdriver. Carefully slide the cable out from the RFI shield as it is being removed.
The drive is now disassembled sufficiently for cleaning.
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Cleaning Procedure: The following steps are suggested as a manual cleaning procedure for 3592 drives operating in oily / dusty environments over extended periods of time. The procedure will cover the cleaning of all the major tape path components and the eleven drive sensors. The parts should be cleaned with IBM Tape Unit Cleaner, part number 13F5647, using a Q-tip or lint free twill cloth and then dried with compressed air that is passed through a dryer and filtered to a 10 micron level using 10 p.s.i or less. A long, thin air nozzle will provide the best access. The operator should wear an electrostatic ground strap throughout the procedure. The following is a discussion of accessing these parts. The picture below labels the major parts for later explanations. The two large gears perform the cartridge load and the tape thread operations. Small motors and gears drive each of these two assemblies and turning these small gears allows for manual movement of the large gears. The loader and threader sensors will be accessed by positioning the appropriate gear opening over each sensor. Proper access to the tape path is achieved when the threader gear is in the appropriate position.
The following sequence should be used when rotating the loader and threader gears. The loader gear must be moved first. The two pictures below show how to release the leader block latch to allow the loader to move back. Push in on the leaderblock latch release pin labeled on the picture below and to the left by inserting your finger into the loader as shown on the picture below on the right. Rotate the loader gear clockwise with respect to the front of the drive as shown by the arrow in the same picture and the loader gear should rotate clockwise and the loader tray should move into the drive as indicated in the picture.
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Hold the leaderblock latch release pin until the leaderblock latch has moved from the position in the picture below on the left to the picture below on the right. The small loader gear may now be rotated without holding the release block pin. When the loader tray is returned to its starting position, the leaderblock latch release pin must be held after the tray has moved up and started out of the drive until it is returned to its original position.
The loader gear must be rotated its full clockwise movement as shown in the picture below and to the left before the threader gear is moved. The small threader gear is rotated counter clockwise with respect to the right side of the drive as shown by the arrow in the picture below and to the right producing a clockwise motion of the threader gear.
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Now that the sequence and direction of the small gear rotation is understood, the cleaning procedure is explained next. The first sensor to be cleaned is the bezel sensor. It is located on the bezel card shown in the picture below on the left. Clean each sensor with a small amount of IBM Tape Unit Cleaner on either a Q-tip or twill cloth. Blow dry with compressed air as defined in the beginning of this section. Insert your finger into the loader and push the leaderblock latch release pin to clear the Cart In sensor flag from the sensor as shown in the picture below on the right. Clean this sensor in the same manner.
The next sensor to be cleaned is one of the two loader tray position sensors. They are located between the drive casting and the main circuit card. The four pictures below illustrate the position of these sensors. These pictures are for reference only. The procedure does not include removal of the bottom cover and circuit card. As the four picture sequence shows, the loader tray position sensors are located in the front right corner of the drive, underneath the loader motor and drive casting. The last picture below on the right shows that the front sensor is blocked when the tray is up and in the unloaded position. Conversely, when the tray is down in the loaded position, the back sensor is blocked. Therefore, the cleaning sequence is setup to clean each sensor when it is not blocked.
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Clean the Cartridge Tray Sensor Back using only compressed air and a long, thin nozzle. Access is from the front of the drive where the RFI cover was removed. The red circle in the picture below to the left shows the location of the sensor. Clean the Index sensor shown in the picture below to the right. The reel motor flange can be moved to provide good access. The IBM Tape Unit Cleaner can be applied with a Q-tip or twill cloth. Blow the sensor dry with compressed air.
Rotate the loader gear to the position shown in the picture below to the left using the procedure defined in the beginning of this section. Remember to push the leaderblock latch release pin before moving the loader and to rotate the small loader gear clockwise with respect to the front of the drive. Clean the sensor using the IBM Tape Unit Cleaner applied with a Q-tip or twill cloth. Blow the sensor dry with compressed air. Rotate the loader gear to the position shown in the picture below on the right. Clean this sensor in the same manner.
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Clean the Cartridge Tray Sensor Front using only compressed air and a long, thin nozzle. Access is from the front of the drive where the RFI cover was removed. The red circle in the picture below to the left shows the location of the sensor. Move the File Protect sensor flag with your finger and clean the File Protect sensor shown in the picture below to the right. The IBM Tape Unit Cleaner can be applied with a Q-tip or twill cloth. Blow the sensor dry with compressed air.
The last three sensors to be cleaned are the threader sensors. Rotate the small threader gear counter clockwise as defined earlier in this section to the position shown in the picture below and to the left. Clean the two sensors using the IBM Tape Unit Cleaner applied with a Q-tip or twill cloth. Blow the sensors dry with compressed air. Rotate the threader gear to the position shown in the picture below on the right. Clean this one sensor in the same manner.
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After the sensors have been cleaned, continue to rotate the small threader gear counter clockwise until the position in the picture to the left is achieved. The leaderblock has now been moved past all the tape path rollers to the extreme left and the head brush is in the fully retracted position as shown in the picture below. The picture below shows all the major tape path parts, the four rollers, the two outriggers, and the head.
The rollers can be cleaned with IBM Tape Unit Cleaner applied to a twill cloth. The rollers can be rotated by hand in order to gain access to the whole surface. Blow the entire roller surface dry with compressed air. The outriggers and head can be cleaned with IBM Tape Unit Cleaner applied to a Q-tip and using a vertical wiping motion. Horizontal motions should be avoided. Again, dry the outriggers and head with compressed air. Insure the rollers, outriggers, and head are lint free by close inspection. The cleaning procedure is now complete. The next section describes how to reassemble the drive.
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Reassembly Procedure: The following section describes how to reassemble the drive for preparation of reinstalling back into its original subsystem. The operator should were an electrostatic ground strap throughout the procedure. The first step is to return the threader and loader gears back to their initial positions. The threader gear should be moved first by rotating the small threader gear clockwise with respect to the right side of the drive. The direction is shown in the picture below and the threader gear is shown in its initial position.
After the threader gear is back into position, rotate the small loader gear counter clockwise with respect to the front of the drive as shown in the picture above. When the tray has moved up and starts toward the front of the drive, insert your finger into the loader and push the leaderblock latch release pin. Continue to rotate the small loader gear until the large loader gear is back in its original position. The drive is now ready to have the covers installed. Install the RFI shield by lacing the bezel cable through the shield as shown in the picture below on the left and attach with two screws using the size P1 Phillips screwdriver. Next, install the exhaust air cover with two screws using the size P1 Phillips screwdriver. Install the box cover. It fits over the exhaust cover. The fit in the front may be tight and the cover may be opened slightly to clear the drive. Install the two screws in the back first and then the two screws in the front using the size P1 Phillips screwdriver.
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Install the bezel next. Connect the cable to the bezel card and then attach the bezel with three screws using the size P1 Phillips screwdriver. The picture below to the left shows the front two box cover screws and the cable and connector for the bezel. The drive is now ready to be installed into the canister. Install the drive into the canister taking care not to pinch any of the cables. Attach the drive to the canister with the four larger retention screws using the size P2 Phillips screwdriver. Next attach all the cables. The picture below to the right shows the cables and connections.
Install the fan and secure with four screws using the size P1 Phillips screwdriver. The reassembly is now complete. The pictures below show the assembled drive.
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01/21/04