You had not mentioned which file error. Although ,You can follow below steps.
1) Take a backup of necessary data.
2) Format H.D.( UNIX & not DOS Formatted )
3) Install Unix S/W completly.
4)Then load base , Data ,& last Patch Cart.
5)Even if ,it shows error, then use another set of IOP S/W.
6)One option is to change H.D.
Thanks.