1541

Maintenance Guide
 ~~
,PI,
PUBLISHED BY
PELTIER INDUSTRIES,INC
735 N. Doris
Wichita, Kansas 67212
Copyright 1984 by MICHAEL G. PELTIER

All rights reserved. Printed in the United States of America. No

part of this publication may be reproduced, stored in a retrieval
system or transmitted in any form or by any means, electronic,
mechanical, photocopying, recording or otherwise, without the
prior permission of the publisher.

The information in this manual has been reviewed and is believed

to be entirely correct. No responsibility, however, is assumed
for any personal or property damage incurred from the use of this
manual. The material in this manual is for information purposes
only, and is subject to change without notice.

Commodore Business Machines, Inc., and the author of this manual

advise that any attempt to repair the VIC-1541 or the 1541 disk
drives during the warranty period will void the factory warranty.

VIC-1541, VIC-20 and COMMODORE 64 are registered trademarks of Commodore

Business Machines.
 WARNING:
HIGH VOLTAGE EQUIPMENT
THIS EQUIPMENT CONTAINS CERTAIN CIRCUITS AND/OR COMPONENTS OF
EXTREMELY HIGH VOLTAGE POTENTIALS, CAPABLE OF CAUSING SERIOUS
BODILY INJURY OR DEATH. WHEN PERFORMING ANY OF THE PROCEDURES
CONTAINED IN THIS MANUAL. HEED ALL APPLICABLE SAFETY PRECAUTIONS.

RESCUE OF SHOCK VICTIMS

1. 00 NOT ATTEMPT TO PULL OR GRAB THE VICTIM
2. IF POSSIBLE, TURN OFF THE ELECTRICAL POWER.
3. IF YOU CANNOT TURN OFF ELECTRICAL POWER. PUSH. PULL OR LIFT
THE VICTIM TO SAFETY USING A WOODEN POLE. A ROPE OR SOME
OTHER DRY INSULATING MATERIAL.

FIRST AID
1. AS SOON AS VICTIM IS FREE OF CONTACT WITH SOURCE OF
ELECTRICAL SHOCK. MOVE VICTIM A SHORT DISTANCE AWAY FROM
SHOCK HAZARD.
2. SEND FOR DOCTOR AND/OR AMBULANCE.
3. KEEP VICTIM WARM. QUIET AND FLAT ON HIS/HER BACK.
4. IF BREATHING HAS STOPPED. ADMINISTER ARTIFICIAL
RESUSCITATION. STOP ALL SERIOUS BLEEDING.
 TABLE OF CONTENTS

Para. Title Page

No.

FRONT MATTER

Title Page
Copyright Page
Warning Page
Table of Contents i

Section l-INTRODUCTION

1-1 General 1-1

1-2 VIC-1541 vs. 1541 1-1
1-3 Warnings, Cautions and Notes 1-1

Section 2-CALIBRATION

2-1 General 2-1

2-2 Equipment Required 2-1
2-3 Preparation for Calibration 2-1
2-4 Calibration 2-2
2-5 Head Alignment 2-4
2-5-1 General 2-4
2-5-2 Equipment Required 2-5
2-5-3 Preparation for Mechanical Alignment 2-5
2-5-4 Head Alignment 2-5
2-6 Mechanical Alignment of Track #1 Stop 2-8
2-6-1 General 2-8
2-6-2 Preparation for Mechanical Alignment 2-8
2-6-3 Mechanical Alignment 2-8

Section 3-TROUBLESHOOTING

3-1 General 3-1

3-2 TROUBLESHOOTING-PART 1 3-2

Section 4-SCHEMATICS AND PARTS LAYOUT

4-1 General 4-1

APPENDICES

Appendix A Video Detector Fabrication A-I

Appendix B Timing Strobe Fabrication B-1

Page i
 SECTION 1
INTRODUCTION
 Section 1-INTRODUCTION

1-1. General

The 1541 Maintenance Guide is produced to give a brief, concise

source of pertinent information necessary for maintenance of the
VIC-1541 and the 1541 disk drives. Most of the information in
this Guide has come from the 1541 Maintenance Manual, which is
also published by Peltier Industries. For those persons desiring
more thorough coverage of the 1541 series of disk drives, the 1541
Maintenance Manual is available through authorized dealers.

1-2. VIC-1541 vs. 1541

The VIC-1541 (also known as the 1540) was the first generation of
the 1541 disk drive. Basically, COMMODORE selected certain
discrete components which were present on the VIC-1541 Disk
Controller PC Board and combined them in custom IC's. When they
did this, they renamed the disk drive the 1541 and changed the
reference designators (schematic identification of parts).
Functionally, there is very little difference between the two
versions. Text in this Guide refers to the VIC-1541. Section 4
contains the 1541 Disk Controller Schematic and Disk Controller PC
Board Parts Layout. For a complete discussion of the differences
between the two versions, the 1541 Maintenance Manual may be
consulted. For the purposes of this Guide, the following table
and close inspection of the 1541 Disk Controller Schematic will
enable 1541 owners to calibrate and troubleshoot their units.
1541 owners must cross-reference all test points before attempting
any of the procedures in this Guide.

Jack/Plug Numbers
VIC-1541 1541

Jl/Pl is Jl/Pl
J2/P2---''_is J8/P8
J3/P3 - _ is·--, J2/P2
J4/P4" i-s -. ·---~J3/P3
J5/P5 '--'is J5/P5
J6/P6{~ J6/P6
J7/P7 / is __ J7/P7
J8/Pg/ is'--J4/P4
J9 is J9

1-3. Warnings, Cautions and Notes

Throughout this Guide are a number of Warnings, Cautions and

Notes. A warning means that there is a possibility of serious
injury, or even death, to the technician if the Warning is not
heeded. A Caution means that there is a possibility of damage to
the VIC-1541 if the Caution is not heeded. A Note is intended to
serve as an aid to the technician in understanding text or in
following a procedure.
Page 1-1
 SECTION 2
CALIBRA TION
 Section 2-CALIBRATION

2-1. General r 14q

I'l c
T~tion "contains step-by-step p:t;"ocedures for calibrating the
/"-\71(:-154)J Only one calibration adjustment, to adjust the speed of
--iL-tl"'le"""""Clisk to 300 rpm, is provided in the VIC-1541. Perform the
calibration procedure at the following intervals:

1. Every 6 months.

2. During the process of troubleshooting.

3. After a repair action.

2-2. Equipment Required

1. Small slotted screwdriver

2. Phillips screwdriver

3. Timing light (Refer to Appendix B)

[Nont
• Any strobe light with an accurate
frequency of 50 Hz (+/- 1%) or 60 Hz (+/-
1%) may be used in place of the timing
light.

4. Blank floppy disk (5 1/4 inch, single sided)

2-3. Preparation for calibration (Detailed disassembly/assembly

instructions can be found in the 1541 Maintenance Manual.)

1. Remove top cover.

2. Remove RFI shield.

3. Disconnect pi from J1.

4. Reinstall RFl shield.

5. Remove bottom cover.

6. Place disk drive on left-hand side. Use a thin book or

magazine to prop up drive. (Refer to Figure 2-1).

Page 2-1
 ACCESS HOLE FOR VRl

TIMING DISK
Hz TIMING MARKS

Hz TIMING MARKS

Figure 2-1. VIC-1541 Prepared for Calibration

2-4. Calibration
1. Connect VIC-20/COMMODORE 64 to video monitor or TV.
(Refer to computer User's Guide for proper connection.)
1
2. Connect serial bus cable between P;yon VIC-1541 and serial
bus connector on VIC-20/COMMODORE 64.

3. Connect AC power cord between J9 on VIC-1541 and AC

outlet.
IWARNINGI

• USE EXTREME CARE TO AVOID CONTACT WITH

FRAME COMPONENTS. HIGH AC VOLTAGE
POTENTIALS ARE PRESENT DURING
CALIBRATION. THESE VOLTAGE POTENTIALS
CAN CAUSE BODILY INJURY OR DEATH.

4. Place VIC-1541 power switch to ON.

5. Apply power to VIC-20/ COMMODORE 64.

6. If a VIC-20 is the computer being used, enter the

following command:
OPEN 15,8,15,"UI-":CLOSE 15 <Return>

7. Insert blank floppy disk into VIC-1541.

8. Plug timing strobe light into AC outlet. position light

near timing disk (Refer to Figure 2-1).

9. Enter following command into VIC-20/COMMODORE 64:

OPEN 15,8,15,"NO:CAL,OI":CLOSE 15 <Return>

Page 2-2
10. Adjust VR1 (Refer to Figure 2-1) until timing disk
appears to stop.

• If 60 Hz AC is being used, calibrate with

the outer set of timing marks on the
timing disk.

• If 50 Hz AC is being used, calibrate with

the inner set of timing marks on the
timing disk.

• If further time is required to adjust

VR1, go back to Step 9 and re-enter
command given.

11. After drive motor has stopped, place VIC-1541 power

switch to OFF.

12. Remove serial bus cable and AC power cord.

13. Reassemble the VIC-1541.

Page 2-3
2-5. Head Alignment

2-5-1. General

This procedure aligns the read/write head to the physical tracks

on a floppy disk. A truly accurate alignment requires the use of
an alignment reference disk and a test program disk. The
procedure which follows allows the user to "get by" without such
software. However, the degree of success achieved will depend on
the accuracy of the disk which is used. Consequently, the
alignment may cause compatibility problems when using software
recorded on other drives or when using other drives to read disks
recorded on a drive aligned with this procedure. This problem may
be reduced by selecting a pre-recorded disk which has not been
written to since it was recorded at the factory. Although this
procedure is not 100% accurate, it will usually suffice for the
home user. For an accurate alignment of the drive unit, one of
the following alignment systems is recommended:

1. COMMODORE System

This system is available from:

Commodore Business Machines,Inc.
Customer Service Dept.
1200 Wilson Dr.
Westchester, Pa. 19380

Alignment disk 970160-01 $130

Test program disk 970154-01 $ 26
Service manual 9900445 $ 25
Total= $181

The above items, plus a dual trace oscilloscope, are

required to align a disk drive using the COMMODORE
system.

2. Peltier Industries System

This system is available from:

Peltier Industries,Inc.
735 N. Doris
Wichita, Ks. 67212

Disk Alignment System (DAS-1541) $39.95

The system includes:
Alignment reference disk
Control disk
Instruction manual
Video detector

The above items, plus a 3 1/2 digit, 100 Kohm digital

voltmeter, are required to accurately align a disk drive
using the Peltier Industries System.

Page 2-4
2-5-2. Equipment Required

1. Alignment standard-use a factory recorded disk which has

not been written to since purchase, or a disk which has been
formatted on a VIC-1541 which is known to be in proper
alignment.

2. Digital Voltmeter

3. Video detector-see Appendix A

2-5-3. Preparation for Mechanical Alignment (Detailed

disassembly/assembly instructions can be found in the 1541
Maintenance Manual.)

1. Remove all external cables from VIC-1541

2. Remove upper cover. ~\ "

'0-

~ ~ !
\ '. "

3. Remove RFI Shield.

4. Remove Disk Controller PC Board.

5. Remove Drive Unit.

(2 !c
6. Reconnect J1 to PI, Ji to Pt, J5 to P5, J6 to P6 and J7
to P7 in such a manner that access is still allowed to the
stepping motor mount screws (See Figure 2-2).

DO NOT ALLOW PATHWORK ON DISK CONTROLLER

PC BOARD TO CONTACT THE FRAME OR DRIVE
UNIT ASSEMBLIES. USE AN INSULATING
RUBBER MAT, IF NECESSARY, TO INSULATE THE
DISK CONTROLLER PC BOARD FROM THESE
ASSEMBLIES.
---'~~

7. Connect, video detector between DVM and pins/7 arid 8 oj::

)JH'r:' . U :-f I ".

8 . '-Remove any Glyptol or other substance from stepping motor

mount screws (See Figure 2-2).

2-5-4. Head Alignment

1. Connect VIC-20/COMMODORE 64 to video monitor or TV.

(Refer to computer User's Guide for proper connection.)

2. Connect serial bus cable between P3 on VIC-1541 and

serial bus connector on VIC-20/COMMODORE 64.

Page 2-5
3. Connect AC power cord between J9 on VIC-1541 and AC
outlet.

.I WARNING I
4t USE EXTREME CARE TO AVOID CONTACT WITH
FRAME COMPONENTS. HIGH AC VOLTAGE
POTENTIALS ARE PRESENT DURING
CALIBRATION. THESE VOLTAGE POTENTIALS
CAN CAUSE BODILY INJURY OR EVEN DEATH.

4. Place VIC-1541 power switch to ON.

5. Apply power to VIC-20/COMMODORE 64.

6. If a VIC-20 is the computer being used, enter the

following command:
OPEN 15,B,15,"UI-":CLOSE 15<Return>

7. Insert disk which will be used as the alignment standard

into the VIC-1541.

B. Enter the following program into the computer. This

program will place the head on track 16 and will leave the
drive motor running.

10 OPEN 15,8,15,"U+":OPEN 2,B,2,"#":OPEN B,B,B,"#"

20 PRINT #15,"B-P:";8;0:PRINT #15,"UA:";2;0;16;1
30 FOR X=l TO 9:READ Y
40 PRINT #8,Y;
50 NEXT X
60 PRINT #15,"M-E"+CHR$(0)+CHR$(5)
70 STOP
BO DATA 173,O,28,9,4,141,0,2B,96

9. Type RUN<Return>.

10. Loosen two screws (See Figure 5-2) securing stepping

motor housing to drive unit. Do not remove screws. Screws
should be just loose enough to permit rotation of the
stepping motor housing.

11. Rotate stepping motor housing while observing DVM

display. Voltage reading on DVM will increase or decrease
while rotating stepping motor housing. Correct position for
stepping motor housing is the position which produces the
largest voltage reading on DVM. Tighten the two screws when
this position is reached.

12. Turn off DVM, disk drive and computer.

13. Disconnect all cables and test accessories from disk

drive.

Page 2-6
 14. Apply small amount of Glyptol or fingernail polish to
the two screws securing stepping motor housing to keep them
from coming loose.

15. Reassemble the VIC-1541.

Stepping motor housing ~W' (2 places)

Stepping motor housing

Figure 2-2. Head Alignment Adjustment

Page 2-7
2-6. Mechanical Alignment of Track '1 Stop

2-6-1. General

This procedure adjusts the Track #1 Stop. The Track #1 Stop is

used by the computer in the VIC-1541 for only two purposes:

1. Formatting a blank floppy disk ("New" command).

2. Soft error recovery.

The procedure that follows should only be used after carefully

verifying that the rest of the VIC-1541 is properly operating.
(Complete coverage of proper operation is given in
Troubleshooting-Part 2, in the 1541 Maintenance Manual.)

2-6-2. Preparation for Mechanical Alignment (Detailed

disassembly/assembly instructions can be found in the 1541
Maintenance Manual.)

1. Remove all external cables from VIC-1541.

2. Remove upper cover.

3. Remove RFI Shield.

4. Remove Disk Controller PC Board.

5. Remove Drive Unit. (I'

'6
6. Reconnect J1 to P1, J~ to pi, J5 to P5, J6 to P6 and J7
to P7 in s'uch a manner that access is still allowed to the
Track #1 Stop adjustment. (See Figure 2-3)

@AUTION!

• DO NOT ALLOW PATHWORK ON DISK CONTROLLER

PC BOARD TO CONTACT THE FRAI'IE OR DRIVE
UNIT ASSEMBLIES. USE AN INSULATING
RUBBER MAT, IF NECESSARY, TO INSULATE THE
DISK CONTROLLER PC BOARD FROM THESE
ASSEMBLIES.

2-6-3. Mechanical Alignment

1. Connect serial bus cable between P3 and VIC-20/COMMODORE

64.

Page 2-8
Figure 2~3. Track #1 Stop Adjustment.

Page 2-9
2. Connect AC line cord between J9 and AC outlet.

I WARNING I
• DO NOT CONTACT THE FRAME ASSEMBLY OR
WIRING. THE VOLTAGE POTENTIALS PRESENT
ON THESE PARTS COULD CAUSE SEVERE INJURY
OR DEATH.

3. Place VIC-1S41 power switch to ON and place power switch

on computer being used to ON •

• If the VIC-20 is the computer in use,

enter the following command:
OPEN lS, 8, lS, "U-": CLOSE lS <return>.

4. Load the Display T&S program into the computer. This

program may be loaded from the Test Demo disk or it may be
manually entered from the keyboard (The Display T&S program
is listed in Appendix C of the VIC-1S41 Single Drive Floppy
Disk User's Manual.).

S. Place a factory recorded floppy disk into the VIC-1S41.

6. Enter "RUN" <return> into the computer.

7. When the Display T&S program asks for a Track and Sector,
enter Track 1, Sector 1.

8. After the head settles and the Display T&S program begins
displaying Track information, adjust the Track #1 Stop
adjustment in the following manner (See Figure 2-3)~

a. Loosen the adjustment lock-down screw.

b. Place .006 inch feeler gauge between Stop and

potrusion on the stepping motor hub. Carefully adjust
the Stop until feeler gauge just touches the potrusion
on the stepping motor hub and the Stop .

• 00 not disturb position of the stepping

motor shaft.

c. Tighten the adjustment lock-down screw.

9. Place VIC-1S41 and VIC-20/COMMODORE 64 power switches to

OFF.

10. Reassemble the VIC-1S41.

Page 2-10
 SECTION 3
TROUBLESHOOTING
 Section 3-TROUBLESHOOTING

3-1. General

This section requires only a Mul timeter (digital type is

recommended) and will isolate a problem down to the sub-assembly
level. It is set up so that even an electronics novice can
perform the procedures. Troubleshooting consists of step~by-step
procedures with accompanying illustrations. Each step either asks
a question or refers to the following step. When a question is
asked, answer the question with a "Yes" or "No". Below each
question are two blocks labeled "Yes" and "No". Follow the
instructions in the appropriate block. The instructions will
either lead to another step or will isolate the problem to a
particular sub-assembly. At this point, the faulty sub-assembly
may be replaced or the sub-assembly may be repaired down to the
component level using the procedures in Troubleshooting-Part 2 in
the 1541 Maintenance Manual.

Page 3-1
8-2. TROUBLESHOOTING-PART 1

STEP PROCEDURE ILLUSTRATION

1 Remove AC line cord and serial
bus cables. Remove top cover.
Remove fuse from fuseholder.
Measure resistance of the fuse
as follows:

1. Set DMM (Digital

Multimeter) to Ohms x 10 or
Ohms x 100.

2. Connect common lead of DMM

to one end of fuse (A).

3. Connect positive lead of

DMM to other end of fuse (B).

Does DMM display less than 10

ohms?

YES NO

Install fuse Replace fuse

and proceed with a new fuse
with Step 2. of proper rat-
ing & size.
Then proceed
with Step 2.

Page 3-2
STEP PROCEDURE ILLUSTRATION

2 Determine proper operation of

the frame assembly as follows:

1. Disconnect J1 from Pl.

2. Set DMM to measure Volts

AC.

3. Connect negative lead of

DMM to pin 1 of J1 (A).

4. Connect positive lead of

DMM to pin 4 of J1 (B).

5. Connect AC line cord

'between J9 (the AC power
receptacle) and an AC outlet. Pi

IWARNINGI

DO NOT CONTACT ANY AC

DISTRIBUTION LINES.

6. Place power switch to ON.

Does DMM display between 15 and

21.5 Vrms?

YES NO

'Proceed to Place power

Step 3. switch to OFF.
Remove AC line
cord. Fault
lies in Frame
B
Assembly. Re-
pair or
replace Frame
Assembly.

Page 3-3
STEP PROCEDURE ILLU~T~TION

3 (Continue testing Frame Assembly

,as follows:

1. Place power switch to OFF.

2. Connect negative lead of

iDMM to pin 2 of J1 (A) •

3. Connect positive lead of

.DMM to pin 3 of J1 (B) •

4. Place power sw;itch to ON.

Does DMM display between 9.5

and 13.5 Vrms?

YES NO

Frame Assembly Place power

appears to be switch to OFF.
·working pro- Remove AC line
perly. Pro- ,cord. Fault
ceed to lies in Frame
Step 4. Assembly. Re-
pair or
replace Frame
Assembly.

4 Place power switch to OFF.

Remove AC line cord. q.j.Remove 'b
shield. Disconnect Jf from pi, SEE FIG. 9-2
,J5 from P5, J6 frpm P6, J7 from
P7 and Jj{ from P~..1 Proceed to
$tep 5. '1 V\

5 Reconnect J1 to Pl. Connect AC

line cord to VIC-1541. Connect
common lead of DMM to (-) side
of C52 (A). Set DMM to 20 VDC
range. Proceed to Step 6.

Page 3-4
STEP PROCEDURE ILLUSTRATION

6 Place power switch to ON.

Measure tests points in table
below. Touch positive lead of
DMM to indicated test point.
Verify that each measurement is
within the minimum and maximum
limits given.

Test Point Min. Max.

PS,pin1(A) +4.6V +5.25V
P7,pin1(B) +11.4V +12.6V
P7,pin2(C) +11.4V +12.6V
P5,pin2(D) +11. 4V +12.6V
P6,pinS(E) +4.75V +5.25V
P6,pin2(F) +4.6V +5.25V

Are all measurements above

within limits specified?

YES NO

Place power Place power

switch to OFF. switch to OFF.
Proceed to Remove AC line
Step 7. cord. Fault
lies in Disk
Controller PC
Board. Repair
or replace.

7 Connect J~ to Pj. Place power

swi tch tofON. '1
Is green LED illuminated?

YES NO

Place power Place power

switch to OFF. switch to OFF.
Proceed to Remove AC line
Step S. cord. Fault
lies in Case
Assembly.
Repair or
replace.

Page 3-5
STEP PROCEDURE ILLUSTRATION
8 Connect J6 to P6. Place power
switch to ON.

Does red LED come on

momentarily?

YES NO

Place power Proceed to

switch to OFF. Step 9.
Proceed to
Step 10.

9 Using a short piece of wire,

carefully short pin 10 of UF2E
(A) to pin 1 of P6 (B) while
observing the red LED
(Error/Access LED).

Does red LED illuminate?

YES NO
Place power Place power
switch to OFF. switch to OFF.
Fault lies in Fault lies in
Disk Control- Drive Unit.
ler PC Board. Repair or
Repair or replace.
replace.
10 Connect JS to PS. Place power
switch to ON.

Does drive motor turn while red

LED is on?

YES NO
Place power Place power
switch to OFF. switch to OFF.
Proceed to Proceed to
Step 12. ,Step 11.

Page 3-6
STEP PROCEDURE ILLUSTRATION

11 Connect positive lead of DMM to

pin 3 of J5 (A). Observe DMM
while placing power switch to J5
ON.

Does DMM indicate 0.0 to +0.8 V

when the red LED is
illuminated?

YES NO

Place power Place power

switch to OFF. switch to OFF.
Fault lies in Fault lies in
Drive Unit PC Disk Control-
Board. Repair ler PC Board
or replace. Repair or
replace.

12 Using two short lengths of

wire, carefully connect pins 1
and 2 of J7 to pin 1 of P7.
Place power switch to ON.
Using a third piece of wire,
short sequentially between pin
1 of P6 and each of the test
points indicated below.
Observe read/write head while
shorting each test point.

1. J7, pin 4 (A)

2. J7, pin 5 (B)
3. J7, pin 3 (C)
4. J7, pin 6 (D)

Verify that the read/write head

moves toward the front of the
VIC-1541. Repeat the procedure
in reverse order and verify
that the read/write head moves
toward the rear.

Does the read/write head move

in the proper direction?

YES NO

Place power Place power

switch to OFF. switch to OFF.
Proceed to Fault lies in
Step 13. Drive Unit.

Page 3-7
STEP PROCEDURE ILLUSTRATION
13 Remove wires from J7. Connect
J7 to P7. Remove negative lead
of DMM from (-) side of C52.
Set DMM to Ohms x 10 or Ohms x
100 range. Connect negative
and positive leads of DMM to
pins of J,~as indicated in
table below. Verify
resistances indicated on DMM
are within limits given in J2
table.

(-) (+) Ohms Ohms

lead lead Min. Max.

pin1(A) pin5(D) 29 39
pin1 pin4(C) 12 22
pin1 pin3 (B) 23 33
[... 9n!
This resistance check of the
read/write head does not check
its dynamic characteristics.
If in doubt about the condition
of the read/write head, refer
to Part 2 of Troubleshooting.

Are all resistances correct?

YES NO

Place power Fault lies in

switch to OFF. Drive Unit.
Proceed to Replace.
Step 14.

Page 3-8
STEP PROCEDURE
, ILLUSTRATION

14 Connect J~ to vi. Perform

Calibration pro~edure in
Section 2.

Is drive motor rotating at

,correct speed?
J2
YES NO
At this point Fault lies in
the problem Drive Unit.
lies in the
Dis k Con tro 1- a...R.e.p.l.a_c.e••_"",!"_ _ _, ,
ler PC Board or in the Drive
Unit. To determine which of
the two sub-assemblies is
bad, refer to Part 2 of
Troubleshooting in the 1541
Maintenance Manual. Part 2
requires an oscilloscope
and some technical exper-
ience. If you do not wish to
attempt Part 2, try swapping
the Disk Controller PC Board
or the Drive Unit with a
known good assembly and see
if the problem is solved.
Also, check assemblies for
obvious signs of wear or
damage.

Page 3-9
 SECTION 4
SCHEMATICS
AND
PARTS LAYOUT
 Section 4-SCHEMATICS AND PARTS LAYOUTS

4-1. General

This section contains Schematics, Parts Layout Drawings, a

Functional Block Diagram and an Interconnect Diagram. These
figures are provided for reference purposes. The following index
is provided for user convenience:

Figure Title Page

4-1 Interconnect Diagram 4-2

4-2 Sub-Assembly Identification 4-3

4-3 Functional Block Diagram 4-5

4-4 Disk Controller, Schematic (Sht. 1 of 2 ) 4-6

4-5 Disk Controller, Schematic (Sht. 2 of 2 ) 4-7

4-6 Disk Controller, Parts Layout 4-8

4-7 Case Assy, Schematic 4-9

4-8 Case Assy, Parts Layout 4-9

4-9 Drive Unit, Schematic 4-10

4-10 Drive Unit, Parts Layout (Top) 4-11

4-11 Drive Unit, Parts Layout (Bottom) 4-11

4-12 Drive Servo Circuit, Schematic 4-12

4-13 Drive Servo Circuit, Parts Layout 4-13

4-14 Frame Assy, Schematic (115 VAC) 4-14

4-15 Frame Assy, Schematic (230 VAC) 4-14

4-16 Frame Assy, Parts Layout 4-15

4-17 1541 Disk Controller, Schematic (1 of 2) 4-16

4-18 1541 Disk Controller, Schematic (2 of 2) 4-17

4-19 1541 Disk Controller, Parts Layout 4-18

Page 4-1
 TRACK
SELECT
0E]
0 J7 ---------1/
DISK CONTROLLER
I
~~ G8,..-------,....---1/ DRIVE
UNIT

I
~~ ~~~--------I/
I
R~t!J 0f-------~/
I ~--------~

Ip~~~ BUS r: eJI~r-------f/ ~--------~

CASE ASSY
(PWR LED)

I
IJ)SER~ BUS
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Figure 4-1. Interconnect Diagram

Page 4-2
CASE ASSY (TOP HALF)

SHIELD

P7

DISK CONTROLLER PC
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J~
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Figure 4-2. Sub-Assembly Identification

Page 4-3/(Page 4-4 Blank)

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Page 4-6
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Page 4-7
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Figure 4-8 . Case Ass y, Parts L ayout

Page 4-9
 J5, DRIVE MOTOR
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Figure 4-10. Drive unit, Parts Layout (Top)

B2

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Figure 4-11. Drive Unit, Parts Layout (Bottom)

Page 4-11
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Page 4-13
 JI,AC INPUT

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JI,AC INPUT
TI
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Figure 4-15. Frame Assy, Schematic (For use with P.C.Bd. 1540001-xx)

Page 4-14
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Figure 4-16. Frame ASsy, Parts Layout

Page 4-15
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Page 4-16
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Page 4-17
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APPENDIX A
 APPENDIX A

Fabrication of Video Detector

Materials Required:

One set of meter leads

One capacitor .oluF,50V
One resistor lK,10%,1/4 W
One diode IN4148 or equivalent

Equipment and Supplies:

Knife
Soldering iron
Wire cutters
Needle nose pliers
Heat shrink tubing, 1/2 inch
Heat shrink tubing, 3/16 inch
Solder, 60/40 resin core
Scale (ruler)
Ohmmeter
String or two wire ties

Preparation:

1. Cut meter leads as shown below:

cut here

Strip off insulation

3/16" from both
sides of cut.

2. Prepare diode as shown below:

3/16" --.r=~::rl- 3/16"

Page A-I
 3. Prepare resistor as shown below:

4. Tin all leads on resistor, diode and meter leads

Assembly:

1. Slide 1 1/2 inch length of 1/8 inch heat shrink tubing

onto red meter lead as shown below. Do not shrink the tubing at
this time.

Heat shrinkable tubing (3/16")

3" length of red meter lead

2. Solder diode, resistor and remaining end of meter lead

together as shown below. Note proper polarity of diode.

Cathode marking

Remaining end of red meter lead

Page A-2
 3. Slide heat shrink tubing over diode and resistor, leaving
one lead of resistor exposed, and then shrink the tubing.

4. Solder capacitor and black meter leads as shown below.

Tie meter leads where shown.
Solder here
Tie here

Tie here
5. Slide a 2 inch length of 1/2 inch heat shrink tubing over
capacitor and then shrink the tubing .

• USING OHMMETER, VERIFY RESISTANCE BETWEEN

POINTS A AND B IS INFINITY.

Page A-3
APPENDIX B
 APPENDIX B

Fabrication of Timing Light

Materials Required:

One neon bulb

One lamp cord with appropriate plug
One resistor 22K,10%,1/4 W (for 115 VAC)
47K,10%,1/4 W (for 220 VAC)

Equipment and Supplies:

Knife
Soldering iron
Wire cutters
Needle nose pliers
Heat shrink tubing, 1/8 inch
Heat 9hrink tubing, 3/16 inch
Solder, 60/40 resin core
Scale (ruler)
Ohmmeter

Preparation:

1. Prepare lamp cord as shown below:

2. Prepare resistor as shown below:

3/16" - r f t = f . - - 3 / 16"

Page B-1
 3. Prepare neon lamp as shown below:

11/16n~
1/4" .:::-1
c(~!It.f====t
~
I
4. Tin all leads on lamp cord, resistor and neon lamp.

Assembly:
1. Slide 1 inch lengths of 1/8 inch heat shrink tubing onto
each of the prepared leads of the lamp cord. Do not shrink the
tUbing at this time.

HEAT SHRINKABLE TUBING (1/8 R )

4DTIt===lll=/f~~
2. Solder components as shown below. Either lead of the line
cord may be soldered to the resistor as long as the other lead is
soldered to the neon lamp.
RESISTOR (22K FOR 11SV, 47K FOR 220V)

SOLDER HERE

Page B-2
 3. Slide both pieces of heat shrink tubing toward the base of
the neon lamp and then shrink the tubing.

4. Slide a 2 inch length of 3/16 inch heat shrink tubing over

neon lamp. Position the end of the heat shrink tubing 3/16 inch
up from the base of the neon lamp and then shrink the tubing.

IWARNING'
• BEFORE PLUGGING IN TIMING LIGHT, USE
OHMMETER TO VERIFY RESISTANCE BETWEEN
POINTS A AND B IS INFINITY.

Page B-3
About the Author
Mr. Peltier has nine years professional
experience in electronics, technical
writing, and circuit and software design.
Among his works are:

-1541 Single Drive Floppy Disk

Maintenance Manual
-1541 Programmers Reference Card
-1541 Heat Dissipating Kit
- DAS-1541 (Head Alignment Kit
for 1540/1 541 )

About the Maintenance Guide

By public request the author has compiled this maintenance guide.
This guide contains the following excerpts from the "1541 Single
Drive Floppy Disk Maintenance Manual":

-Calibration (including head alignment)

-Troubleshooting Part I (for the novice)
-Schematics and Parts Layout (reference data for those with
experience)

For additional information including; Theory of Operation, Advanced

Troubleshooting and more, see the "1541 Single Drive Floppy Disk
Maintenance Manual" (198 pgs.-118 illus.)