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BY / E Supplement Unit 29 Card PunchRe: Order No. S225-3357-3This Supplement No. SS23-4069Date Novomber 2 3 , 1 9 7 0Previous Supplement Nos. None

IBM FIELD ENGINEERING MAINTENANCE MANUALIBM 29 CARD PUNCH@IBM Corp. 1965, 1969

Pages to be inserted and/or removed are :Title Page, Prefac e 4-1 through 4-12iii through vi 4-17 through 4-221-9 , 1 -10 4-29 , 4 -302 - 3 , blank 4-35 through 4 - 4 1 , blank3-1, 3-2 X-1 through X-5, blank3-5, 3-6

A change to the text is indicated by a ver tic al line to the left of the change; a changed o radded illustra tion is denoted by the symbol to the lef t of the caption.Summary of AmendmentsMaintenance Manual addition to list in PrefaceAdditional troubleshooting aids in Chapter 1Lubrication changes in Chapter 3Checkout procedure change in Chapter 2Adjustment tolerance changes in Chapter 4Figure 4-41 changed to improve figure-to-component associationNote: Pl ea se file this cover l ette r a t the back of the manual to provide a record of-hanges.

Corporation, Produc t Publications, P.0. ox 390,Pough keeps ie, N. Y . I2602


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Field ~ngineerirbgMaintenance Manual

2 Card Punch


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S225-3357-3FES: SS234069Preface

This publicatibn provides information for the maintenanceof the IBM 29 Card Punch. The manual is written withpresupposition tfiifithe reader has a working knowledge ofthe machine. As much applicable information as possible isin each section of this manual. The sections are numberedfor easy reference. The sections are presented in a sequencesimilar to the card p ath through the machine.

Timing adjustments for some units may vary amongmachines due to features and engineering changes; refer tothe individual machine wiring diagram for accurate timing.

Special features are treated individually in a separatemanual, Field Engineering Theory - Maintenance, IBM 29C a d Punch F eatures, IBM 29 Interpreting Card Punch,Model C, S223-2926.

Other related manuals are:Field Engineering Theory of Operation, IBM 2 9 CardPunch, S225-3358

Illustrated Parts Catalog, IBM 29 Card Punch,S 1 2 4 4 0 8 5

Reference Manual, IBM 29 Card Punch, GA24-3332Field Engineering Maintenance Manual, Motors, Genera-tors, Relays, Circuit Breakers, Test Instruments, Miscella-neous Components, S225-3422

Four th Edition (April 1969)This a major revision of, and obsoletes, Form 225-3357-2, FE Supplement Fo rmS23-4035, and all earlier editions. Significant changes have been made throughoutthis manual, including: new d iagnostic flowch arts, Chap ter 1 ; a new chapter,Chapter 2; new lubricant specifications, Chap ter 3 ; revised starwhee l adjustme ntsand revised print suppress adjustments, Chapter 4. This manual should bereviewed in its entirety. Changes are periodically made to the specificationsherein; any such changes will be reported in sub sequen t revisions or FESupplements.This manual h as been prep ared by th e IBM Sys tems Development D ivision,Product Publications, Dept B96, PO Box 390, Poughkeepsie, N.Y. 12602. A formfor readers' comm ents is provided at th e back of this publication. If the form hasbeen removed, com ments may b e sent to t he above address.@Copyright International Business Machines Corporation 1965, 1 96 9


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S225-3357-3FES: SS234069Contents

.hapter 1 ~ d e re n c e ata and Service Aids . . . . -1.ection 1 Reference Data . . . . . . . . . . . -11.1 Operations . . . . . . . . . . . . -11.2 Sequence of Operations . . . . . . . . -11.2.1 Functions . . . . . . . . . . . . -1.ection 2 Diagnostic Techn iques . . . . . . . . -21.3 Initial Approach . . . . . . . . . . . -21.4 Diagnostic Flow charts . . . . . . . . . -21.4.1 Start and Run Failures . . . . . . . . . -21.4.2 Card Tran sport Failures . . . . . . . . -21.4.3 Interposer Selection Failures . . . . . . . -21.4.4 Escapement Failures . . . . . . . . . -21.4.5 Punch Drive Cycle Failures . . . . . . . . -71.4.6 Printing Con trol Failures . . . . . . . . -71.5 Machine Service Feature s . . . . . . . . -71.5.1 Motor Switch . . . . . . . . . . . -71.5.2 Test Probe . . . . . . . . . . . . -71.6 Servicing Tech niques . . . . . . . . . -71.6.1 Forcing . . . . . . . . . . . . . -71.6.2 Interrupting Machine Operation . . . . . . -81.6.3 Jumpering . . . . . . . . . . . . -81.6.4 Measuring . . . . . . . . . . . . -81.6.5 Cycling M anually . . . . . . . . . . -101.6.6 Interchanging Units . . . . . . . . . . -101.7 Difficult-to-Analyze and Inte rmitte nt Failures . . 1-101.7.1 Left-Zero F eature . . . . . . . . . . -111.7.2 Diagnosis of "Heavy" or Stiff Keyboards . . . -1 11.7.3 Stacker . . . . . . . . . . . . . -121.7.4 Starwheel Adjustment . . . . . . . . . -12Chapter 2. Console and Maintenance Facilities . . 2-1.ection 1 Basic Unit . . . . . : . . . . . . -12.1 installation Procedures . . . . . . . . . - 12.1.1 Shipping M aterial . . . . . . . . . . -12.1.2 Power . . . . . . . . . . . . . . -12.1.3 Keyboard Operations . . . . . . . . . -12.1.4 Program and Function (Model A) . . . . . . -12.1.5 Program and Function (Model B) . . . . . . -22.1.6 Final Checkout . . . . . . . . . . . -3.ection 2 Features . . . . . . . . . . . . . -32.2 Installation Procedures . . . . . . . . . -32.2.1 Feature Checkout . . . . . . . . . . -32.2.2 Final Checkout . . . . . . . . . . . -3Chapter 3. Preventive Maintenance . . . . . . . -1Section 1 Basic Un it . . . . . . . . . . . . -13.1 Cleaning . . . . . . . . . . . . . -13.2 Adjus tment . . . . . . . . . . . . -13.3 Safety . . . . . . . . . . . . . . -13.3.1 Safety Devices . . . . . . . . . . . -13.3.2 Electrical Hazards . . . . . . . . . . -13.3.3 Chemical Hazards . . . . . . . . . . -13.4 Lubrication . . . . . . . . . . . . -1Section 2. Features . . . . . . . . . . . . . -8Chapter 4. Checks. Adjustments. and Removals . . 4-1

.ection 1 Basic Unit . . . . . . . . . . . . -14.1 Base . . . . . . . . . . . . . . -14.1.1 Diodes . . . . . . . . . . . . . -1

Arc Suppressors . . . . . . . . . . . -1Drive . . . . . . . . . . . . . . -1Drive Motor . . . . . . . . . . . . -1. . . . . . .rive Motor Belt Ad justments 4-1. . . . .ackspace Mechanism Service Check 4- 1. . . . .ackspace Mechanism Adjustm ent 4- 1. . . . . . . . . . .riction Drive 4- 1. . . . . . .riction Drive Service Check 4- 1Friction Drive Torque Adjustment . . . . . -2Friction Clutch Removal . . . . . . . . -2Escapement Unit . . . . . . . . . . -2EscapementUnitServiceCheck . . . . . . -2Escapement Unit Adjustments . . . . . . . -3Card Feed . . . . . . . . . . . . 4Hopper Adjustments . . . . . . . . . 4Feed Clutch Adjustment . . . . . . . . 4Card Feed Latch Magnet Adjustments . . . . -5Hopper-to-P repunch Bed Service Checks . . . . -5Pressure Rail Ad justments . . . . . . . . 6Card Guide Adjustments . . . . . . . . -6. . . . . .ard Re gistration Service Check 4-7

. . . . . . . .usher Arm Adjustment 4-7. . . . . . .ard Stop Cam Adjustment 4-7Pressure Roll Service Check . . . . . . . -7Pressure Roll Adjustm ents . . . . . . . . -7Registration Adjustments . . . . . . . . -7Feed Wheel Removal and Replacemen t . . . . -9Card Feed Circuit B reaker Service Check . . . . -9Card Feed Circuit Breaker Adjustment . . . . -9. . . . . . . . . . . .unch Drive 4-9. . . . . . . .ndex Pointer Adjustment 4-9. . . . . .nterposer Magnet Adjustment 4-9Guide Comb and Bumper Adjustment . . . . -9Punch Interposer M agnet Assembly Adjustment . 4-10Interposer Bail Con tact Assembly Adjustment . . 4-1 1Punch Drive Remo val and Replacement . . . . -11Clutch M agnet A djustment . . . . . . . . -12. . . . . . .unch C lutch Service Check 4-12. . . . . . . .unch Clutch Adjustments 4-13High-speed CB Assembly Service Check . . . . -14. . . .igh-speed CB Assembly Adjustm ent 4-14High-speed Cam Removal . . . . . . . . -14. . . . . .ie and Str ipper Service Check 4-14Die and Stripper A djustment . . . . . . . -14Die and Stripper Removal and Replacement. . . . . . . . .With Print Feature) 4-14Die and Stripper Removal and Replacement. . . . . . . .Without Print Feature) 4-14. . . . . .unch Penetration Adjustments 4-15. . .unch Removal and Replacement . . .in Bail Drive Link A djustmentPin-Sense Unit . . . . . . . .. . .in-Sensing Unit Service Checks. . . .in-Sensing Unit Adjustm entsPin-Sensing Unit Removal and Replacem entSensing Pin Removal . . . . . .Eject Unit . . . . . . . . .EjectUnitAdjus trnents . . . . . .. . . . . . . . .tacker UnitStacker Unit Adjustments . . . . .

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. . . . . . . .rogram Drum UnitSensing Assembly Service Check . . . .. . . .ensing Assembly Ad justmentsSensing Assembly Removal and Replacem entProgram Cam Con tacts Service Check . .

. . .rogram Cam Co ntacts AdjustmentProgram D rum interlock Arm (Split Hub). . . . . . . . .djustment

. . . . . . . . . .rint UnitPrint Assembly Serv icech ecks . . .Print Assembly Adjustmen ts . . . . .Print Assembly Removal and Replacement .Ribbon Feed Pawl Adjustment . . . .Print Drive Adjustmen t . . . . . . .Print Suppress Magnet Adjustment . . .Key board . . . . . . . . . . .Contact Adjustments . . . . . . .Hook Support Bar Adjustment . . . .Permutation Bar Adjustment . . . . .Restoring Magnet Adjustment . . . . .

l lustrations

Figure TitleChapter 1. Reference Data and Service Aids1-1 Characteristics . . . . . . . . .1-2 Operations . . . . . . . . . .1-3 Sequence of Operations . . . . . .

. . . . .-4 Diagnostic Flowchart Symbo ls1-5 Start and Run Failures . . . . . . .. . . . . .-6 CardTranspor tFai lures1-7 lnterpo ser Selection Failures . . . . .

. . . .-8 Escapemen t Failures (Part 1 of 2)

. . . .-8 Escapemen t Failures (Part 2 of 2)1-9 Punch Drive Cycle Failu res . . . . .1-10 Print Con trol Failures . . . . . . .1-11 Test Probe . . . . . . . . . .1-12 Reed Relay insertion . . . . . . .

Page

. . . -1. . -1

. . -2

. . . -2

. . . -3

. . -4

. . -5. . 1-6. . -7. . -8

. . . -9

. . -10. . -10Chapter 2. Console and Maintenance Fa cilit'm'2-1 Program Card . odel A . . . . . . . . . -22-2 Program Card . odel B . . . . . . . . . -2Chapter 3. Preventive Maintenance3-1 Preventive Maintenance Rou tines . . . . . . . -23-2 Lubrication . ight Front . . . . . . . . . -3.-3 Lubrication Front . . . . . . . . . . -43-4 Lubrication . ron t (Machine Bed Tilted) . . . . -53-5 Lubrication . ear 3-6. . . . . . . . . .3-6 Pun ch Unit Lub rication . . . . . . . . . -73-7 Keyboard Lubrication . . . . . . . . . . -8Chapter 4. Checks. Adjustments. and Removals4-1 Friction Drive Adjustment . . . . . . . . . -14-2 Escapement Adjustment (Part 1 of 2) . . . . . -24-2 Escapement Adjustment (Part 2 of 2) . . . . . -34-3 Hopper Adjustment . . . . . . . . . . . . -4

4.12.5 Upper Permutation Supp ort Adjustment . . . . -3 9. . . . . . . . ..12.6 Key Unit Adju stmen t 4-394.12.7 Key Unit Remov als . . . . . . . . . . -4 0Section 2. Features . . . . . . . . . . . . . -41. . . . . . . . .hapter 5 Power Supplies 5-1

Section 1 Basic Unit . . . . . . . . . . . . -1Section 2. Features . . . . . . . . . . . . . -1Chapter 6. Locations . . . . . . . . . . . -16.1 Keystem Numbering . . . . . . . . . -16.2 Reed-Relay Card . . . . . . . . -16.2.1 Reed Relays . . . . . . . . . -26.3 Wire conta ct Relays . . . . . . . . . -36.4 Stand ard Modular System (SMS) . . . . . . -36.4.1 SMS Card Rece ptacle s . . . . . . . . . -36.4.2 SMS Locations and Pin Numbering . . . . -36.5 Location Figures . . . . . . . . . . -5l ndex . . . . . . . . . . . . . . . . -1

Figure TitleCF Clutch M agnet Adjustment . . .CF Clutch Adjustment . . . . . .CF Latch Magnet Adjustment . . . .Pressure Rail Adju stmen t . . . . .Pressure Rail. ard-Lever Contac t . .Card Guide . etail Station . . . .Card Guide . aster Station . . . .

. . . . .etail Card Registration . . . . .ressure Roll Adjustm entMaster Station Registration Adjustment .. . . .rmature Pivot AdjustmentArmature Pivot Adjustm ent . ide View. . . . . .rmatureAdjustmentInterposer Unlatching Clearance . . .lnterposer Relatching Adjvstment . .

Armature Unlatching Clearance . . .lnterposer Bail Contact Adjustment . .lnterposer Bail Contact Rise AdjustmentPrint Drive Unit Cam Timing . . . .PunchClutchhlagnet . . . . . .Punch Clutch Componen ts . . . . .PunchClu tchA djus tment . . . . .. . . .igh-Speed Circuit Breaker. . . . . .unch Bed Fro nt ViewPunchandExtension . . . . . .Punch Penetration Adjustment . . .Sensing Pin C ontact A djustment . . .Pin Sensing Adjustm ent . . . . . .

. . . . . . . .tacker Timing. . . . . . .tacker AdjustmentTravelingCardCuide . . . . . .Timing Tool . . . . . . . . .Program Unit Timing Cha rt . . . .

Page. 4 - 5. 4 - 5. 4 - 5. 4 - 64 - 6. 4 - 6. 4 - 7. 4 - 7. 4 - 8. 4 - 8. 4 - 9. 4 - 9. 4-10. 4-10. 4-10. 4-11. 4-11. 4-1 1. 4-12. 4-12. 4-13. 4-13. 4-14. 4-15. 4-15. 4-16. 4-17. 4-17. 4-1C. 4-19. 4-19. 4-20. 4-21


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Figure Title4-37 Method of Holding Escapement Wheel4-38 Program Cam Contac t Adjustm ent .. . . .-39 OverlayforFigure4-40.. . . . .-40 Code Plate Chart E'L' . . . .4 1 Print Interposer Assembly4 4 2 Punch Drive and Yoke Adjustments .4-43 Printing Adjustm ent . . . . .4-44 Print Interposer Assembly . . . .4 4 5 Vertical Drive Rod Assembly . . .. . . .-46 CharacterPatternsE'L1. . . . .47 CharacterPatternsE'A' .4 4 8 Test Pat terns. . . . . . . .4 4 9 Print Drive Unit . . . . . . .4-50 Print HeadR emova l. . . . . .4-51 Print Wire Replace ment . . . .4-52 Print Suppression Magnet Adjustm ent4-53 Keyboard Adjustm ent . . . . .4-54 Keyboard Permutatio n Unit - Rear .4-55 Keyboard Permutatio n Unit - Bottom

AalphaAMPautoCBCECEMCFchatck tcol, colsctrldcdefdup

HSSHz

amperealphabeticamphenol pinautomatic

Page. . . 4 - 2 1. . . . . -23. . . . -25. . . . 4 - 2 7. . . . . -29. . . . . -29. . . . 4 - 3 0. . . . . -30. . . . . -31. . ; . . 4 - 3 2. . . . . -33. . . . 4 - 3 4. . . . 4 - 3 4. . . . 4 - 3 5. . . . 4 - 3 6. . . 4 - 3 6. . . . . -37. . . . 4 - 3 8. . . . . 4 3 9

circuit breakercustomer engineerCustomer Engineering Memorandumcard feedcharactercircuitcolumn, columnscontroldirect currentdefinitionduplicatefriction clutchhigh-speed skipHertz (cycles per second)

Figure Title4-56 Keyboard Key Unit and Permutatio n Unit . .. . . . . . .-57 Keybo ard Interlock DisksChapter 5. Power Supplies. . . . . . . . . .-1 Power Supply5-2 Power and Receptacle Requirements . . . .Chapter 6. Locations

Combination and Numeric Keystem NumberingLocations - Relay Board and Relays . . . .. . . . . . .MS Printed Wiring CardsWireCo ntact Relay Machine Relay Gate - Card. . . . . . . . . . .ide ViewLocations - Fron t View . . . . . . .Locations - Rear View (Reed-Relay Machine) .Locations - Rear View (Wire-Contact Relay. . . . . . . . . . .achine) . . . . . . . . .ocations - RearLocations - Front . . . . . . . . .

IBCintlkLZmaxmsMULT PCHNCNONo.nu mFCCPMPrgmsecSMSv

interposer bail contactinterlockleft zeromaximummillisecondmultipunchnormally closednormally opennumbernumericprogram cam cont actpreventive maintenanceProkTmsecondStandard Modular Systemvolt

Page. . 4 4 0. . 4 4 1

Abbreviations


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5225-3357-3F E S: S S 2 3 4 0 6 9

Safety Procedures

Safety cannot be overemphasized. To ensure personalsafety and th e safety o f co-workers, each CE should make itan everyday practice t o 'observe safety precau tions at alltimes. All CEs should be familiar with the general safetypractices and procedures for performing artificial respira-tion that are outlined in CE Safety Practices, S229-1264.For convenience, the -1 printing of this form has beenreproduced.Always use a reliable voltmeter t o verify th at p ower isactually off after using power-off switches. Although allpower supplies are provided with bleeder resistors to drainoff capacitor charges when power is dropped, it is wise tocheck all capacitors with a meter before attemptingmaintenance. A defective bleeder resistor could create anunexpected hazard.Anyone working near ele ct~i cal ircuits may accidentallycome in co ntac t with live voltage.

Round off sharp edges on plastic guides; replace brokenguides.

Check that all applicable safety devices are on themachine.Check all safety devices for prop er oper ation.Do not permit machines to be run u nattend ed with covers

open o r removed.Leave the escapement gearing cover in place at all times

when the machine is running.Turn off power when tilting the base.Use only IBM approved products. Read the labels. As a

general rule, cleaning fluids should be used only in an openarea. Breathing the concentrated vapors, even for a shorttime, may cause immediate reactions.

Review Customer Engineering Memorandums (CEMs) forcurrent safety practices.

CE SAFETY PRACTICESAll Cu~tomerEngineers ore .xp.cted to toke every sofety pre.caut ion po~~ib lend observ. the follow ing safety procticaswhile mointoining IBM equipmant:

1. You should not work alone undar hazardous conditions ororound equipment with dangerous voltage. Always adrimyour monoger if you MUST work oon..2. Remove oll power AC ond DC when removing or ossem-

bling moior components, working in immediate areo ofpower supplies, performin g mechonicol inspection of powersupplies ond instolling chonges in machine circuitry.3. Wall box power switch when turned off should be lockedor togged i n off position. "Do not Operat." togs, form229-1266, ofixed when opplicoble. Pull power supply cordwhenever possible.

4. When it is absolutely necessary to work on equipment haring exposed operating mcchonical ports or e x p o ~ d ir eelectrical circuitry anywhere in the mochine. the follo wingprecautions must be followed:o. Another person fomiliar with power off controls must

be in immediate vicinity.b. Rings, wrist watches, chains, bracelets, met01 cuff links,

sholl not be worn.c. Only insulated pliers ond screwdrivers shall be used.d. Keep one hond in pocket.e. When u~ingest instrument^ be artoin controls are set

correctly and proper copocity, in ~ula ted robes ore uu d.f. Avoid rontocting ground potential (metal floor strips,

machine frames, etc. - se suitable rubber mots pur-chased locolly if necessary).5. Safety Glos~ esmuat be worn when:

a. Using o hommer to drive pins, rive ting, stoking, etc.b. Power hond dril ling , reoming, grinding, etc.c. Using apri ng hook,, ottoching springs.d. Soldering, wire cutting, removing steel bond*.e. Ports cleoning , using solvents, sprays, cleaners. chemicals,

.Cf. All other wnditbns thot moy be ho~or dou s o youreyes. REMEMBER, THEY ARE YOUR EYES.

6. Special so ft ly ins tructions such as hondl ing Cothode RayTubel ond extreme high voltogea, must be followe d 01outlined in CEM's on d Safety Section of the Ma intenanceMonuols.7. Do not use solvents, chemicals, greases or oils that hovenot been opproved by IBM.

8. Avoid win g tools or test equipment thot hove no1 b..napproved by IBM.9 . Replace worn ar broken tools and test equipment.10. Lift by standing or pushing up w ith stronger leg muscles-this tokes strain off bock muscles. Do not liH any equip-ment or ports weighing over 60 pounds.

11. All safety devices such as guards, shields, signs, gro undwires, ctc. shall be restored ofter m aintenonu .

KNOWING SAFETY RULES IS NOT ENOUGHAN UNSAFE ACT WILL INEVITABLY LEAD TO AN ACCIDENTUSE GOOD JUOGMENT- ELIMINATE UNSAFE ACTS

S229-1264-1

12. Each Customor Enginoer in responsible lo be cortain thatno oction on his part renders product unsofo or exposelhozards to customer personnel.

13. Ploce removed machine covers in o sofe out-of-the-wayploce where no one con trip over them.

14. A11 mochin. covers mul l be in ploce before mochino is re-turned to customer.

15. Always CE tool kit awoy from wolk oreos where noone con trip over it (i.4.. under desk or loblo).

16. Avoi d touching m.chanicol moving ports (i.e., when lub ri-coting, checking for play, etc.).

17. Wh in using stroboscope -d o not touch ANYTHING- itmoy be moving.

la. Avoid wearing loose clothing thot may be cought in machin.err. Shirt sleeves mu11 be left buttoned or rolled obove theelbow.

19. Ties must be tucked in shirt or hove a tie clasp (prefer ablynonconductive) opproximotely 3 inches from end. Tie chain1ore not recommended.

110. Befor. storting equipm ent, make certain fello w CEs an dcustomer personnel ore not in a horardous position.

21. Maintain good housekeeping in oreo of mochines while per-forming and after completing mointenonce.

L .i.i . i d h: d

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Chapter 1. Reference Data and SerLice Aids

Section 1. Reference Data 4. Card Transport: Mechanical contro l of the movement ofthe card through the machine.Figure 1-1 shows machine characteristics for th e IBM 29 5 . Punch Drive Cycle: Controlled rotation of the punchCard Punch. drive unit index shaft. According to the function, this isrequired to punch a hole in the card at the punch station1.1 OPERATIONS or t o read a hole in the card at the pin-sense station.The 29 Card Punch operations may be divided, as shown inFigure 1-2, for troubleshooting. These operation s are:1. Start and Run: Establishment of power (electrical and

mechanical) necessary for machine operations. Thisincludes the operation of the card feed and thepick-and-hold of th e card lever relay.2. Interposer Selection: Engagement of an interposer orinterposers with the punch bail in preparation forpunching.

3. Escapement: Advancement of the program d rum and ofthe escapement-driven feed wheels.

1 Chorocteristics I Description ISpeed:

Manuol punchingManual duplicationAutomatic duplicationSkippingReleasingFeed from pre-register to detail

station

Without Print With Print20 col/sec 18 col/sec10 col/sec 9 col/sec20 col/sec 18 col/sec80 col/sec80 col/sec0.250 sec

/ 500 cords I1 Stacker 1 50 0 cards IFigure 1-1. Characteristics

I

Figure 1-2. Operations

InterposerSelectian

1.2 SEQUENCE OF OPERATIONSIt is essential that the customer engineer be aware of thecorrect sequence of operations as they are used in anymachine function.

I I I

Escapement

1.2.1 Functions

Punch DriveUnit Cycles

When the function is t o punch a character from th ekeyboard, the sequence of operations is:1. S tart and run2. Interposer selection3. Escapement4. Card transport5. Punc h drive cycleUsing the numbers only, the sequence is:1

23 45Showing escapement and card transport (3 4 ) side by side

ind icat es tha t 'hile 3 causes 4, they occur at t he same time.Using this notation , the sequence of these operations for allof the functions of the 29 Card Punch is shown in Figure1-3.The functions shown in Figure 1-3 are the responses ofthe machine to th e inputs shown here:Key Punch Press any character.Multiple Punch Press the multiple punch key and anynumeric key.Key Skip Press the skip key in numeric or alpha-betic shift.Manual Duplicate Press the duplicate key f or one or morecolumns with no programming.Blank Column Manual Press the duplicate key for one or moreDuplicate blank columns with no programmingand with the machine in alphabeticshift.Auto Duplicate Pressing the duplicate key or the readingof a "0" in the program card in acolumn followed by "12's" in theprogram card.Blank Column Auto Same as "Auto Duplicate" but for blankDuplicate columns with the machine in alphabetic shift.Skip: Release, Auto, Press release key if starwheels are up orDrum if they are down in a column p r egrammed "12". An " 1 1" in a programcard. Card-tecard skip.Release, Auto Space Press release key in a nonprogrammedfield but with the starwheels down.

29 FEMM (4169) 1-1


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BlankColumn

( irection comment )

iunctlon

Col

SecondondOtherCols

Figure 1-4. Diagnostic Flowchart Symbols

BlankColumn

Figure 1-3. Sequence o f Operations

KeyPunch

23 - 45RepsotforAllColr

Section 2. Diagnostic Techniques

Skip:Release,

1.3 INITIAL APPROACH

Release

The first ste p in troub leshoo ting is t o reduce the possibletrouble sources to one of the five operations. Locate theoperation that breaks the correct sequence for the failingfunction.The second step is to vary the machine function to on e inwhich the failing operation occurs in another sequence.This tests the same operation with a different input. Forexample, interposer selection is faulty during keypunching(2, 3 4 , 5). Varying th e function t o manual duplication(5-2, 3 4 , 5) allows interposer selection from the pin-senseinput instead of the key input. The cause of the failure, ifin a particular input path,can be discovered in this way. Ifthe same operation fails, regardless of the input path used,the failure is common to all paths.Enough information may be gained in this way to findthe cause of the failure by using the wiring diagram and thetest probe.

For those troubles that cannot be found by using thisapproach, refer to the appropriate section in Cha pter 4.Diagnosis of the complete failure of all machine opera-

tions should be preceded by a continuity check of thefuses. If attempted punching fails to occur after a card hasbeen registered at the punch station, the card lever relayshould be checked first. Consistent blowing of fusesindicates a short or a ground on the machine. Lineterminals and/or cam contacts can be checked, one at atime, t o locate this type of failure. Some commo n possiblesources of grounds are the starwheel contact and the latchmagnet contact.

Mult SkipPunch Key

1.4 DIAGNOSTIC FLOWCHARTSFigure 1 4 defines the symbols used in the diagnosticflowcha rts (Figures 1-5 throug h 1-10). These flowcha rts aidin locating the trouble area when diagnosing fairly consist-ent failures.

k n m lD y

F i r s t 1 1 1 1 I 1 1 1 I5 - 23 - 4

RapedforAllCols

23 - 452-5Rspmtk r A l lCycla

1.4.1 Start and Run FailuresTo loc ate sta rt and run failures (Figure 1-5), the starwheelsmust be raised and blank cards must be used.

34- 5

3-4R e v tforField

1.4.2 Card Transport FailuresDiagnosis of the failure causing incorrect card movementshould include an initial visual check to confirm that thecomponents of the card transport mechanisms are oper-ating. When card transport failure occurs, any mark or nickon the card will help to indicate the source of trouble(Figure 1-6).

A change in registration during the duplication of onepunched card can be a false indicatio n of card transportfailure. If the escapement moves while the sensing pins arestill up through the holes in the card, the card will beretarded. The sensing pins usually leave marks on the card.(See 1.4.4.)

Improperly inserting cards into the pin-sense station cancause trouble. The card to be duplicated should not beforced into the pin-sense station before registering the card.

~onu.1) Auto

1.4.3 lnterposer Selection Failures

AutoDup

53 - 4

3 - 45 - 2Rfor

D y

53 - 4

R e v tforAllCols

Interposer selection may be incorrect from either thekeyboard or pin-sense units, or both. If either unit operatescorrectly, the circuits and com ponen ts of the other unitmust be considered as a source of the trouble. If both unitsfail, the trouble is assumed to be in the interposer magnetsand associated circuitry or in the interposer mechanism(Figure 1-7).

Note that when the interposers have been tripped for anyreason, they must be restored by a drive-unit cycle.To avoid confusion in diagnosis, the starwheels must beraised t o locate interpose r selection failures.

D y

5 - 23 - 45 5 5 53 - 45 - 2Rspeotf a

1.4.4 Escapement Failures

Auto,D r u

3 -4

RspmtforAllCols

Faulty escapement is defined as: escaping too far, not farenough, not at all, or at the wrong time.Program control is used with Figure 1-8 to locateescapement failures. The program card should be punchedfor alternate threeco lumn duplications and two colu mn

AutoSP u

3 - 45

RepmtforAllColr


13/92

Slowly or overheah N oI I

( Check motor start relay 1 Check mainline voltageCheck motorI elease ond feed carda Check mainline furera

Check motor stort relayaCheck motorII Check w nc h clutch Ioperation 1

Cord ir not fed to pre-register $totion Drum doer not go to column 1

Check cord feed clutchmechanismI

Check CF clutch magnetaCheck cord feed mechanism

Check card lever operation

cord tronrport flowchart

IRegister the cord andspace out

Check skip relay'-4to ercopement flow -chart (Figure 1-8)

Doer not register Nospacing or punch drive cycles

Check CF latch mechanismtI( Check CF latch magnet / Check cord lever contactrl

f N o rouble found, goto ercopement flowchart(Figure 1-8) i f norpocing, or go to~ u n c hrive cyclerflowchart (Figure 1-91i f no punch drive cyclesFigure 1-5. Start and Run Failures

29 FEMM (4169) 1- 3


14/92

Feed card from hopper+Doer no1 leave hopper movement Crooked ot pre-register station

$atisfactoryCheck hopper pressureplate Check hopper adjustments

1 Release cord 1D o n not slide along

Hesitater or buc kln upper railReleeerCheck pin-senre preuure Check pin-$ ewe prerrvreheck hopper adjustments-Check troveling card Check prnsure roilCheck feed knivesICheck feed pressure rolls I

Check eject guide Check troveling card

Register carda Check cardCIRegirterr Crooked

Check cord pusher Check operotion of cordmechanism oligne r fingers

Stock corduOffset Stocks No or crooked

Check trwc lin g card Check troveling cordguide guideoll opening (bent, curled, etc.)

Check for obstru ction Check card pusherin punch throot I Chcck eject guide I I Check eject gvide I

Check eject roll or Check eject roll orroll opening

Releme cardI

Check stocker consuHeritat- or bucklesI.oes n ot slide along upper rail-7 Check stacker mechonirmDCheck punch pressureroll for nlignment Dup cards. Measure \

at various columns

No Goes beyondII Check pin-senre prerwre I I Check pin-sense pressure] Repeot testmro ll o~eni na I ro ll openingI

feed ond observestacking mechanism

Check regirtrotion ormI /Figure 1-6. Card Transport Failures


15/92

and olphobaticcharacter keys

Check interposer relotchaCheck keyboard restore No

selected

Check interposer relotch Check int erp an magnet

Check pin-sere contochvCheck cornmar bar=?

Check throot plates and

Check inkrpoler

Check keybod shift cktwCheck for mopat impulse.I f no ~ul re, roceed to

Check k yb or d contoch1Check m tor e circuita Check pin-tare contoch+heck rm in g pin=7Check c o d regirtrotionFigure 1-7. Interposer Selection Failures29 FEMM (4169) 1-5


16/92

A. A lp h a b e t i c Du p l i c a teswitch o ff . kev duo, ,( olphobet ic and b lank )

Extra column or ot wrong t ime

Check 12 program contact a n d c i rc u i t

Check dup re loy re tup

Check PI cam contac t Check escape c ircu i t

to interposer selectionf lowchart (F igure 1-7)

0 . Numeric Duplicate and Sk ip

Yer

auto dup 011 I 2 digits,

Perform B ond C

Check dup relaysaCheck dup c i rcu i ts-o trouble found, g o(

to in terposer se lec t ionflowchart (Figure 1-7)

T oo fa r N o Ye r (n i c k e d or to rn ho ler)

Check re tup o f IBC-es I Check ercope c ircu i t I N oto in terpmer se lec t ionflowchort (Figure 1-7)

Perform A and CC

Check escapementin ter lock re lay

Check PI cam contac t

Check that punchinterposer isengaging ba i l

I

Figure 1-8. Escapement Failures (Part 1 of 2)

Check 0 ragrom canto c t

Check auto rk ip /dupswitch

Check dup re loy

I I

Check PI t iming anddurat ion Check 12 program contoc t

Check punch c lu tch

Check escape interlockrelay

Check dup relor

Check dup c i rcu i t


17/92

C . Ksv Punch

PerformA and BCheck escape mechanism

Tm far No

I

Check drive g s a train+Check FC torque

Check P I cam contact

Check FC torque or escapemognet

onolyre originalfoiling condition

I I

Figure 1-8. Escapement (Part 2 of 2)

skips through column 38. This is followed by a 25columnskip (ending in column 63) , an l lcolumn alphabet icduplication, a Scolumn skip, and duplication of column80.1.4.5 Punch Drive Cycle FailuresLocate punc h drive cycle failures with the starwheels raised(Figure 1-9). Diagnosis of clutch failures should include aninitial manual cycle of the punch drive unit. Incorrectclutch overthrow or a defective detent can be found whileperforming this operatio n1.4.6 Printing Control FailuresThe program card used for locating escapement failures canbe used for locatin g programm ed printing failures. Diagnos-tic flowchart is Figure 1-10.1.5 MACHINE SERVICE FEATURESThe 29 Card Punch has two diagnostic features that havebeen incorporated to aid the customer engineer. These are:

Motor switchTest probe

1.5.1 Moto r SwitchThe motor switch turns the motor off and allows otherareas of the m achine to remain energized. It is useful whenmanually cycling the machine. Some adjustments are madewith the motor stopped.1.5.2 Test ProbeThe test probe (Figure 1-11) contains a neon indicator inseries with a resistor. One lead of th e indicator is conn ected

to the power supply. The other lead is used to trace circuitsleading t o coils or magnets. A jack is provided on the po wersupply chassis.

CAUTIONCare must be used when probing relay points because thepoint of the probe might spread the pin connectors andcause the reed switch to make poor contact or break thepin. Be careful in the use of the test probe; an accidentalshort could tack several relay points. The probe shouldno t be used to estim ate circuit voltages. Use the meter forvoltage measurem ents.Reed relays should be probed through the top of the

bobbin because the vertical rows of holes on the landpattern for a particular relay position do not, in all cases,connect to the relay connector.Note: When probing P3, a false indication may occur; P3appears not to make. This is due to the timing relationshipbetween the short duration of P3 (7 ms) and the 60-Hznegative line pulse used to bias th e probe.1.6 SERV ICING TECHNIQUES1.6.1 ForcingExtra pressure can be applied to various com pon ents tosimulate malfunction. For example, the friction drive canbe forced or retarded manually at the to p of the programdrum , or finger pressure can be applied to the escapemagnet armature t o help or hinder its operation. Magnetismof the escape magnet can be detected, and its strengthestimated with any lightweight steel blade (screwdriver orburnishing to ol).

29 FEMM (4169) 1-7


18/92

f i n t c y c le d vp , o n dmu l t i p u n c h

I Na (Some) vro u t in e to d imn o s e fa u l t Ch e c k c lu tc h c i rc u i t s

M u l t i p u n c h

punched column.Watch Prerr c o mb in a t io n k e y andp u n ch b a i l wa tc h p u n ch b o i l

Prcsr character key.

Cy c le r More th a n one per keyc y c le )

I (After ercape cyc le) I ICheck ercopement Check c lu tc h rnechanirm 1 Ch e c k c lu tc h c i rc u it s I ( Ch e c k mu l t i p u n c h re la y Ch e c k in te rp a e r b a i lI I c ~ " t o C tCheck escope intlk Ch e c k c lu tc h me ch a nism Ch e c k mu l t i p u n c h c i rc u i t Ch e c k c lu tc h c i rc u i t s

Check c lu tch mechanisma Check dup re lay sett ing Check c lu tc h c i rcu i ts Check c lu tc h mechonirmCh e c k c lu tc h c i rc u i t Check escape contac t

to interposer re le c t io nf lo wc h a r t (Fioure 1 - n

Figure 1-9. Punch Drive Cycle

1.6.2 Interrupting Machine Operation 1.6.3 JumperingTh e sequence of machine operation can be interrupted andcontrolled by removing a lead from the controlling mag-nets . For exam ple, a lead can be removed from the escapemagnet or from the punch clutch magnet. Operation canthen be controlled by retouching the lead long enough forone operat ion t o occur .

Portions of circuitry suspected of being open can bejumpered to determine whether they are open. I t is alsouseful t o jumper the desired voltage int o a circuit , todetermine ho w mu ch of the circuit operates correctly.Circuit Card Tab Connections: Individual wires are easilyremoved from the c onnec tors to facili tate circuit diagnosisor com ponen t isolation. T o remove wires from Amph enolconnectors , use AMP* disconnect tool (part 452815).CAUTIONTh e machine should no t be left s tatic in the middle of an

operating sequence for a long period o f t ime.1.6.4 Measuring

The source of undesired operations can often be locatedby removing leads along the undesired circuit until thesource is found. This should not be done in reed-relaycircuits with power o n.

A voltmeter can be used while the machine is s tatic tomeasure th e magnitude of a voltage. Manual operation may*Trademark of Amp , Incorporated


19/92

kypunch and dupall chamctan

Prink

Chock print wppmsmechanism

With print switch on m dstamheals up, ke+unchI a d rint al; ~ h o r i t o n

Check platenQWrong, smudgy, or toa l ight No I

for obstruction

Check ribbon

chomcterr under progromcontrol

Check print supprascircuit

Check print switchQI II Chock print switch I

Check p in t dr iveN o

Check print relaycontach I

Check print wppossmagnet circu ih- l

Ym

Ym N o

No troublesfound, see 4.11

Extranwm x u a No lmt chaacter

Invufficient ze m

Chock print relay pickcircuit

Check print relay-heck print suppress

I

Cb c k print suppressI circuit ICheck I2 stowh..l

Check print suppressmochmimChock print supprau

I C k k LZ switch I

No

Cha k card Iw u relaya

mechanism

Check ac-o interlocka

ICheck 12 program contac(pint relay hold circuit)

C h a k U rint switchm C W i n t relaymFigure 1- 10.Print Contro l Failures

29 FEMM (4169) 1-9


20/92

S225-3357-3FES: SS234069

Figure 1-1 1. Test Probe

1.6.6.3 Reed RelaysWhen inserting reed relays on th e circuit board, care mustbe exercised no t to exert pressure on the coil portion o f therelay. Pressure exerted on the coil can cause the relay toflex, and breakage of the glass reed switch may occur. Toprevent this breakage, the relay must be positioned andpressed on the card with -equal pressure exerted on each ofthe plastic ends of the relay (Figure 1-12).A short caused by a defective part or a slip of the handwhile trou bles hoo ting could damage several relays. Allrelays in the circuit between the s hort and the line shouldbe checked because th e sudden surge of current could causethe interceding relay points to weld or develop a tackingcondition. Do nor remove or replace relays during amachine cycle.If tacking is suspected, do not jar the machine becausethe tacking problem may disappear temporarily. Do notinterchanfe relnys or relay types. If the relay used doe s no t. . -have a hold coil, do not put one that has a hold coil in itsbe performed to determine the timing of circuit breakers. place. DO not interchange relay reeds The individual relayThe voltmeter can also be used while the machine is reeds are matched an d should not be interchanged byoperating, to d etect the presence and relative magnitude of disassembly or use of one s from ot he r relays.Ihe "Itage' Remember. when measuring power Repeated relay insertions an d removals can caur the glasswith no secondary fuse, a short in the secondary indicates envelope t o break; Berg connectors m ay lose tension andlittle or no voltage. A secondary short may n ot blow the cause intermittent failures. Check connector alignment withprimary fuse. a 0.010-inch feeler gage, aligning it with adjacent con-

1.6.5 Cycling Manually nector.Turn the motor switch off. Observe machine functionswhile manually operating the escapement gear train and thepunch clutch. This allows voltages to be checked at anytime during the machine cycle.1.6.6 Interchanging UnitsKeyboards, relay boards, or relay gates may be inter-changed with othe r machines of the same type and featureconfiguration. This can help isolate suspected units whendiagnosing intermittent troubles.1.6.6.1 Relay GateThe relay gate in either type of machine is easily remove-) able. In the reed-relay machine, slide the relay gate out ofthe guide tracks through the slots provided. In thewire-contact relay machine, first slide one tab out of theslot, then slide the oth er tab o ut.1.6.6.2 Arc Suppression

Figure 1-1 2. Reed Relay InsertionArc suppression is necessary for the proper operation andlongevity of the reed-relay switches. If trouble is suspectedin an arc suppression network, it must be substituted with 1.7 DIFFICULT-TO-ANALYZE AND INTERMITTENTanother. FAILURESThere are some sources of trouble in th e 29 Card Punch

CAUTION th at cause varying results and are difficult to diagnose.Removal of arc suppression for diagnosis can cause Among these are:considerable damage as well as faulty opera tion. I 1. Friction drive totqu e (too m uch, t oo little, or erratic)


21/92

2. Punch clutch spring (broken, dry or gummy, or loss oftension)3. Punch clutch armature (broken or worn)4. Punch clutch detent pivot stud (worn or loose)5. Punch clutch overthrow (too much or too little)6. Relays (high resistance shorts or hold points burned orwelded)7. High-speed cam contacts (binding roller, strap tension,or loose contact pile-up)8. Interposer bail contacts (strap tension, air gap, orcontact condition).An intermittently failing machine should not be returned t othe custom er without investigating every suspected cause ofthe failure.1.7.1 Left-Zero Feature

1.7.1.1 Left-Zero Overflow/lncorre ct PunchoutIncorrect punchout of left-zero information occurs if theoperator keys-in more digits than the field can contain.Reed-relay machines continue shifting the bits in theregisters; the firs t digits keyed-in are lost. Wir econtac t relaymachines accumulate the overflow of bits in the firstregister.Examples: In a reed-relay machine with a five-position fieldprogrammed, the ope rator keys-in 1, 2, 3, 4 , 5, 6. Th emachine punches out 2 , 3 , 4 , 5 , 6 when the left-zero key ispressed. In a wire-con tact relay m achine with a five-positionfield programmed, the operator keys-in 1, 2 ,3 ,4 ,5 ,6 . Themachine punches 3, 3, 4, 5, 6 when the left-zero key ispressed.1.7.1.2 Intermittent Lossof BitsCommon causes for loss of information during read-in orread-out operations are:1. Keyboard latch or bail contact adjustments2. Keyboard restore bail contact adjustment3. Error reset contact or backspace switch intermittentlybreaking contact4. Loose slip-on connectors to punch interposer magnet

unit5. Loose connectors in 0-volt or 48-volt net t o LZ relays6. Punch CBs out of adjustment.1.7.2 Diagnosis of "Heavy" or Stiff KeyboardsTo isolate the source of trouble when a keyboard feels"heavy" or stiff, mak e the following checks.1.7.2.1 Key PressureKey pressure can be affected b y lubrication, by interferencebetween the keystem and the cover, or by sluggish interlockdisks.

Lubrication: Check to be sure that the proper lubricant isused in the co rrect places. Refer to "Chapter 3."Interference: Check to be sure that the keyb\uttons arecentered within the holes in the cover face.Interlock Disks: Check for dirty, magnetized, or oilyinterlock disks.1. W ith the machine on , press the P-key.2. Using a gram gage, operate the P-key; 55 to 65 gramsshould be read. Note the actual pressure required tooperate the key.3. Press the Q-key.4. Using the gram gage, operate the P-key again. Thepressure required should not exceed 10 grams more thanthe reading noted in step 2.5. If step 4 failed to meet the requirements specified,remove the interlock disks.a. Wash the disks and the race in IBM cleaning fluid toremove all traces of oil or dirt.

b. Test for magnetism by sliding the disks down aninclined steel surface ; replace all sticking disks.1.7.2.2 Keyboard Cycle TimeTo check for slow keyboard restore:1. Open keyboard base and place machine in numeric shiftby inserting a card between the numeric keystem

contacts.2. Feed a card to column 1 .3. Short latch contact 6 and time the punching of 80columns. Timing should be approxim ately 4.5 seconds.4. If the time exceeds 7 seconds, repeat the punchingoperation with one thickness of card inserted betweenthe keyboard restore magnet armature and th e core.5. If an increase in speed of the punching operation oc curs,adjust the arm atur e-to cor e clearance to 0.005 inch. (Noincrease in speed indicates a slow machine cycle.)Note: Keyboard restore magnet coils are connected inparallel. A short or open in either coil upsets the balance ofthe circuit. Symptoms include slow keyboard cycles,double punching, or extra spaces.1.7.2.3 Machine Cycle TimeTo ch eck machine cycle timing:1. Install an 80column autodup program card on theprogram drum.2. With the m achine in alphabetic shift, time the au toma ticduplication of 80 columns (using blank cards). Timingshould be 4 to 4.5 seconds.3. If timing ex ceeds the limit, slow action is due to thepunch clutch, the friction clutch, or the escapementmechanisms.

29 FEMM (4169) 1-11


22/92

4. Place the machine in numeric shift and time theautomatic duplication of 80 columns (using punchedcards). Timing should be 4 to 4.5 seconds.5. If timing exceeds the limit, slow action is due to theinterposer magnet assembly:a. Excessive mag net-to-arm ature air gap.b. Interposer bail contacts.1.7.3 StadterThe base should not be raised or lowered by using thestacker plate as a handle; relative position of the stackerplate to the stacker assembly may be changed and mayrequire readjustment. Improper adjustment of the travelingcard guide can cause difficulties in reading the end portionof a card.

1.7.4 StarwheelAdjustmentTh e 29 Card Punch is designed so that the starwheelduration is about 9 ms. One tooth on the escapement wheelequals 12 ms. This timing is critical because too much ortoo little duration could cause relay points to arc. Thiscould be compounded if the relays develop a tackingcondition.


23/92

Chapter 2. Console and Maintenance Facilities

Section 1. Basic Unit2.1 INSTA LLAT ION PROCEDURES2.1.1 Shipping Material1. Visually check for any machine damage before signingthe bill of ladin g. If machine is severely damaged; no tifyyour branch office before continuing the installation

procedure.2. Using packinglunpacking instructions (pa rt 73 31 107),locate and remove spacers, washers, and screws on baserubber mounts. Also, remove the two screws in the basepivot brackets to allow tilting of the base for servicing.

3. Check for loose cables, connectors, and com ponents.4. Adjust line cord t o keep excess cord off the floor.5. For Model C machines, refer to Field Engineering

Theory-Maintenance, IBM 29 Card Runch Features129Interpreting Card Punch, Model C, Form 223-2926.2.1.2 Power1. Com pare voltage req uirem ents with those supplied.

Chapter 5 shows power and receptacle requirements.2. Turn power on and observe the punch drive for smoo thoperation.

10. Compare holes in the cards:a. Holes in the cards should compare with the keyspressed in steps 6 throug h 8.b . Machine with print feature prints special char-acters in corresponding columns.

11. Check registration by using a card gage.

2.1.4 Program and Function (Model A )1. S et the following switches:a. A uto skip/dup - OFF.b. Program select - ONE.

c. Auto feed - ON.d. Print - ON.e. Left-zero print - ON.

2. Install Model A program card (Figure 2-1) on drum,install dru m in ma chine, and lower the starwheels.3. Feed two cards from the hopper.2.1.4.1 First Card1. Press 0 hrough 9 keys.2. Press skip key. The cards move to column 34.3. Backspace to colum n 14 to check th at registration ismaintained for 20 columns of backspacing.

2.1.3 Keyboard Operations 4. Press dash key. If machine has x-skip feature, programdrum skips to column 34; if not, press skip key and1. Set the following switches: program skips to column 34.a. Starwheels raised. 5. Press all alphabetic chara cter keys (A throug h Z).b . Punchlinterpret - UNCH (M odel C). 6. Press skip key. Program drum should be at column 80.c. Auto skip/dup - OFF. 7. Multipunch 0 through 9 in column 80. Multipunch keyd. Auto feed - OFF. must be pressed and held w hile keying-in 0 thro ugh 9.e. Print - OFF.f. Left-zero print - OFF. 2.1.4.2 Second through Fifth Cards2. Put cards in the hopp er. 1. Set au to skipldup switch to on position.3. Press release key:a. Column indicator revolves 8 0 columns and returns 2. Se t left-zero print switch to off position. A "0" shouldbe punched but no t printed in column 1 .to column 1. 3. Press dup key. Machine duplicates card and programb. No cards feed from the hopp er. drum skips to column 8 0.4. Press register key. Card feed cycle occurs, but no cards

feed from the hopper. 4. Press space key.5. Press and hold feed key. Two cards feed from thehopper.6 . Press A through Z and 0 through 9 keys.

a. Press each key twice to detect binding keystems.b. Hold numeric key while keying numbers.7. Release and register second card.8. Set print switch to on position and press all specialcharacter keys.9. Operate the c lear switch. Both cards should feed to the

stacker. No cards feed from th e hopper.

2.1.4.3 Sixth Card1. Set au to skip/dup switch to off position.2. Set program select switch to TWO.3. Press program two key.4. Press du p key (duplicate to column 11).5. Press skip key (skip to column 34).6. Press dup key (duplicate to column 6 0).7- Press skip key (skip to colum n 7 8).8. Press and hold alpha k ey; press Z, A, and Q keys.

29 FEMM (4169) 2-1


24/92

2.1.4.4 Seventh through Tenth Cards 2.1.5 Program and Fu nction (Model B)Set auto skip ldup switch t o on position.Press dup key. Machine duplicates and skips the entirecard. Dup key is pressed once for each card.

2.1.4.5 Eleventh Card1 . Press program o ne key.2. Press dup key. Machine duplicates card and programdrum skips to column 80.3. Operate clear switch. The three remaining cards should

feed t o the stacker.

1. Set rhe following switches:a. Auto skipldup - OFF.b. Program select - ONE.c. A uto feed - ON.d. Print - ON .e. Left-zero print - OF F .2. Install Model B program card (Figure 2-2) on drum,install dru m in m achine, and lower starwheels.

3. Press release key t o seat starwheels, and feed o ne cardfrom the hopper.

4. Press feed key to feed second card from the ho pper.

111111111 11111111111111111111II 1111111111111111111111111 1111111111111111111029 1 Program Card--Model A 10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ~ 0 0 0 0 0 0 0 ~ 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ~ u 0 0 0 0 0 0 0 0 0I 2 3 4 5 6 1 1 9 OlII2l3I41516111119202122232425262121293031~~~1Y353ol31394O4142434445464l4849M5I525I5455565l51596O616261r(65r(61M19lOll12l3l4l5l~lll1l91D1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ~ 1 1 1 1 1 1 1 1 1 1 1 1 l 1 1 1 1 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 23 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 34l1llll1114111111111111111111111141111111111111111111111111~I B B I I I I I I I I I I I I I 4 115 5 5 5 5 5 5 5 5 5 1 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 1 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 56 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 1 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 1 6 67 7 7 7 7 7 7 7 7 7 7 7 7 7 1 7 7 7 7 7 7 7 7 7 7 7 7 1 7 7 7 7 7 ~ ~ ~ ~ 1 1 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 1 ~ 7 7 7 7 7

8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 R 89 9 9 9 9 9 9 9 9 9 Y 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 Y 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 91 2 3 4 5 6 1 R 9 10 11 I2 13 14 IS I6 11 I8 19 2021 2223 24 25 2621 23 29103l 3233 335 16 31 3839 4041 424344 43464 14149 M51 52 5354 55565158596061 626 364 65U 616 069 loll 12 13 14 15 1611 11 1980

I." rn

Figure 2-1. Program Card-Model A

/ 1 I~IIIIIII~~~~IIIIIIIIIIIIIIII 1111111111111111111029 1 Program Card -- Model B 1

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ~ 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0I 2 3 4 5 6 1 1 9 10 I1 12 I3 I4 I5 16 11 18 19 20 21 22 23 24 25 26 21 21 29 30 31 17 71 Y 35 36 31 38 39 40 41 42 41 44 5 46 41 48 4950 51 52 53 54 IS 56 31 51 59 60 61 62 63 64 65 66 61 68 9 10 11 12 13 14 15 16 11 18 19 10

~ 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I 1 1 ~ ~ ~ ~ ~ ~ ~ l l l l l l 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Figure 2-2. Program Card-M odel B2-2 (4169)


25/92

S22.5-33.57-3FES: SS2340 69

2.1.5.1 First Card1. Press 1, 2, and 3 keys. Machine performs punch cycles

but does not escape from column 1.2. Press error reset key.3. Press left-zero key. Three zeros are punched, but onlythe last one is printed.4. Press skip key. Cards skip to column 3 4.5. Backspace to column 14 to check that registration ismaintained for 20 columns of backspacing.6. Press dash key. If machine has X-skip feature, program

drum skips to column 34; if not, press skip key andprogram drum skips t o column 34.7. Press A through Z keys.8. Press skip key t o move card t o column 80.9. Multipunch 0 through 9. .Multipunch key must bepressed and held while keying-in 0 through 9.2.1.5.2 Second through Fifth Cards1. Set auto sk ipldup switch to on position.2. Set left-zero print switch to on position.3. Press 7 and 9 keys.4. Press left-zero key. The 0, 7, and 9 are punched andprinted, and m achine skips and duplicates to colum n 80.5. Press space key.2.1.5.3 Sixth Card

1 1. Set au to skipldup switch t o off position.2. Set program select switch to TWO.3. Press program tw o key.4. Press l , 2 , 3 , and dash keys.a. A 1 and 2 are punched and printed in columns 1and 2.

b. A 3 and dash are punched and printed in column 3(a dash is an 1 1 hole) .5 . Press 1, 2, 3, 4, and left-zero keys. A 1 , 2 , 3 , and 4 arepunched and printed.6 . Press 1 , 2 , 3 , 4 , 5 , and left-zero keys.7. Press 1 through 6 and left-zero keys.8. Press 1 through 7 and left-zero keys.9. Press 1 through 8 and left-zer o keys.10. Press du p key. Machine duplicates to column 6 0.

1 1. Press skip key. Program drum skips to column 78.12. Hold alpha key and press Z, A, and Q keys.2.1.5.4 Seventh Card1. Set auto skipldup switch to on position.2. Repeat steps 4 through 9 of 2.1.5.3. Machine auto-matically duplicates and skips the remainder of the card.2.1.5.5 Eighth Card1. Press program on e key.2. Press 7 ,9 , and left-zero keys. The 0, 7, and 9 are punched

and the machine duplicates and skips t o column 8 0.3. Operate clear switch. The three remaining cards shouldfeed to the stacker.

2.1.6 Final CheckoutOperator should set up and test machine using a practicalapplication.

Section 2. Features2.2 INSTALLATION PROCEDURES2.2.1 Feature CheckoutRefer to Field Engineering Theory-Maintenance, I B M 2 9Chrd Punch Fea tures/29 Interpretin g Card Punch, Mode l C,1 S223-2926. Set up and check out the special featuresaccording to t he feature description.Note: Perform the installation procedure for the basic unitmodel before checking the features. For Model C machines,use procedure for Model A machines.2.2.2 Final CheckoutOperator should set up and test machine using a practicalapplication.

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S225-3357-3FES: SS234069Chapter 3. Preventive Maintenance

Section 1. Basic UnitThe customer engineer's approach to preventive mainte-nance is important to machine performance and customersatisfaction. Effective scheduled maintenance is essentialfor good machine performance. Time spent systematicallyon scheduled maintenanc e results in complete inspection ofmajor machine uriits. Figure 3-1 is a suggested guide formaintaining a stan dard machine if normal usage is 40 hoursper week. Refer to Field Engineering Maintenance Manual,Motors, Generators, Relays, Circuit Breakers, Test Instru-ments, Miscellaneous Components, S225-3422, for addi-tional scheduled maintenance inform ation.3.1 CLEANINGA clean machine is importan t to good performance. Whilecleaning a machine, observe the bearings, cams, linkages,and other moving parts for rust accumulation. Rustaccumulation indicates wear. Redu ction o f corrective main-tenance is the goal of scheduled m aintenance.3.2 ADJUSTMENTA properly adjusted machine is more reliable than one thathas had compensating adjustments made for wear ormalfunction in some other area. As part of a PM routine,check the following adjustments regardless of operatingconditions. A quick check of the same areas is alsorecommended at th e time of each.maintenance call. Th eadjustmen ts for these areas are in Chapter 4.

Friction clutchEscapementFeed throatPunch clutchCBsProgram unit3.3 SAFETYPreventive maintenance also implies the prevention ofaccidents to operating and maintenance personnel andconcern f or their he alth and well-being.

IANGERDo not permit machines to be run u nattended with coversopen o r removed.3.3.1 Safety DevicesCheck that all applicable safety devices are on t he machine.If they are operating devices, check them every time youperform a routine PM. Refer to CEMs for curre nt safetyinformation.

3.3.2 Electrical HazardsDANGERAnyone working near electrical circuits may accidentallycome in contact with live voltage. Be alert and careful.Note : Immediate mouth-to-mouth resuscitation isimperative for unconscious victims of electrical shock.Always disconnect voltage.

3.3.3 Chemical HazardsDANGERUse only IBM-approved products. Read the labels. As ageneral rule, cleaning fluids should be used only in anopen area. Breathing the concentrated vapors, even for ashor t time, may cause immediate reactions.

3.4 LUBRICATIONLubrication points are shown in Figures 3-2 through 3-7.Frequency of keyboard lubrication depends on machineusage and local conditions.Applicable IBM lubrican t part numbe rs are:

Lubricant Qrcontity Part NumberIBM #6 4 ounces 460052IBM #6 1 pint 223980IBM #23 112 ounce 128044IBM #23 1 pound 1280442Siliconegrease 341016

29 FEMM (11170) 3-1


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S225-3357-3FES: S234069

Reventive k i nt em n ce Routine Chart

PrintkiPunch Clutch1 1 1 Drive 1

Clean dirt from moving parts.1 Lubricate gears, cons, and pi mt sObserve

LubricationFigure Reference

Frequency(Months)

Each servicecal l

Check card feeding1 and stacking. 1 3-2Adjustment

Sectionequired k int en onc e

Lubricate gears, greorc fitt ing, andoi l wicks.

Lubricate grease fitti ng.

I Check printing.Clean contacts. Lubricate c a m I Check for contoct wearand rollers. and pits. I 3-6

Check overthrow andouter sleeve lead.

3-43-6

I Lubricate ai l wicks, cam, and pivots.Lubricate motor bearings.

--Figure 3-1.Preventive Maintenance Routines

4.6.8 ~I

Lubricate clutch wit h silicone grease.Clea n dirt from moving parts and bore.

Check for worn cams,bearings, and link age.Check far worn belts.Check torque.Check far loose wires,terminals, and grounds.

3-6

-- -4.6

4.2

3-3-- -

4.3

---


29/92

Spring Ends

' / I

5.Pin-Sense Mechanism

Punches and Stripper

Figure 3-2. Lubrication - Right Front

Lubrication Hints:1 . Die and punches may be lubricated by saturating a

blank card with IBM # 6 oil and punching all columns ofthe card.

2. Pin-sense unit may be lubricated by applying two orthree drops of IBM # 6 oil t o the wicks through the twoholes in the pinsense casting. Do not overlubricate.

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Belt TeI 0

SiliccPart

im e Grease341016

JGear TnIBM #2.

Figure 3-3. Lubrication - Front

Lubrication Hint: To prevent grease migration to theescapement wheel and the friction clutch, apply IBM # 23grease sparingly to the escapement gear train. To preventprint suppress armature from sticking, apply IBM # 2 3grease sparingly to pivot and block.

t and Blockt r . #-a

-=YA\lo Lubriw


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S225-3357-3FES: SS23-4069

Figure 3-4. Lubrication - Front (Machine Bed Tilted)

Lubrication Hint: After greasing tha punch clutch, removeexcess grease from the sleeves and collar. This preventsgrease from splashing onto the armature and magnet.

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Figure 3-5. Lubrication - Rear


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IBM '6th

Figure 3-6. Punch Unit Lubrication

LubricationHint: Do not oversaturate the felt wicks thatseparate the punch drive arms. The oil will run down ontothe CBs.

nature PivcIBM '23/

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Figure 3-7 . Keybo ard Lubr ica t ion

Lubrication Hint: T o prevent s ticking, apply all lubricants Section 2. Featuressparingly on keyboa rd parts.Lubrication of features should be performed at the discre-tion of the custom er engineer, using the guidelines in FieldEngineering Theory-Maintenance, IBM 29 Ca rd PunchFeatureslZ9 Interpreting Card Punch, Model C, Form223-2926 .


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Chapter 4. Checks, Adjustments, and Removals

Section 1. Basic UnitProcedures outlined for removal and adjustment of themachine units are intended as guides. Adjustments shouldbe kept close to the specification, but the procedurespreferred m ay vary among experienced customer engineers.

88 of program drum. Each backspace should causeescapement wheel tee th to move 1-1 /4 teeth past end ofarmature.2. Position backspace switch to operate with 1116-inchdepression of the actuating arm.

4.1 BASE 4.3 FRICTION DR IVE4.1.1 DiodesCheck diodes for shorts or opens by using an ohmm eter.4.1.2 Arc SuppressorsCheck the arc suppression RC units by substitution, neverby running the machine with the arc suppressors removed.The RC units are highly efficient at reducing destruc tivearc.

CAUTIONOperation of the machine without arc suppressors maycause considerable damage.4.2 DRIVE

4.2.1 Drive MotorFactory lubrication of the motor should last one year, ifnormal usage is 40 hours per w eek. Pil sparingly.

4.3.1 Friction Drive Service CheckThe friction clutch should provide sufficient torque todeflect gram gage 275 to 325 grams when measured in thefollowing manner. Manually escape the machine until thehole in the escapement wheel is straight up. Use the 10Xblade in the gram gage. Hold the gram gage in the left hand(Figure 4-1) and engage the escapem ent wheel.

IANGERMake sure the starwheels are up when checking torque ifhigh-speed skip feature is installed.Press the release key and place right index finger on the10X blade. Gradually release the pressure of the left handuntil only the b lade prevents turning of the wheel. Read the

gram gage.Gram tension should be measured and adjusted after themachine has warmed up.4.2.2 Drive Mo tor Belt Adjustments4.2.2.1 Belt TensionElongated motor-mounting holes permit adjustment of belttension for 1/4-inch deflection midway between pulleys.4.2.2.2 Belt SizeCheck part number of belt. A different size belt is usedwhen machine has print feature.4.2.3 Backspace Mechanism Sewice CheckCheck that 20 consecutive columns of backspacing does notaffect card registration. The actuating arm should bestraight and free of binds so tha t its spring can return it tonormal position.

To ensure proper backspacing, check escapement arma-ture adjustments (4.4.1).4.2 .4 Backspace Mechanism Adjustment1. Position backspace ratchet with its three screws to causea card to backspace into column 1 and not into column

_ - - - - --..---,

K n ur ld w r w u w d

Figure 4-1. Friction Drive Adjustment

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S225-3357-3FES: S2340694.3.2 Friction Drive Torque AdjustmentI 1. Manually escape the machine until adjusting screw is at

the top.2. Turn power off and manually turn belt until hole at top

of housing is aligned with adjusting screw.3. Adjust screw for required to rqu e. (4.3.1). Turn screwclockwise to increase torque; a half-turn changes reading

about 60 grams.

4.3.3 Friction Clutch Removal1. Remove escapement gearing bracket and friction clutch

adjusting screw.2. Drive out spring pin holding clutch assembly on shaft.Remove clutch and separate hub assembly from housing.3. Remove nylon friction ring.4. Remove friction clutch spring.

I 5 . Reverse removal procedure for reassembly. Make surehub assembly is clean and free of dried grease and oil.1.4 ESCAPEMENT UN IT4.4.1 Escapement Uni t Service CheckCheck the residual on the left yoke end for wear; cleandirty points and lubricate armature pivot. Clean oil and dirtfrom escapement wheel. To o much torq ue on th e frictiondrive may make action of escapement armature sluggish.The escapement wheel m ust be free of lubricants. Incorrectstrap tension or improper make-time of the escape armaturecont act may cause double spacing or erratic escapement.

The conta ct operating pin should be free enough to allowpin t o be rota ted b etween the finger tips. A binding orcanted operating pin usually indicates poor adjustment ofthe unit.

Note- ero clearance

Add or remove steel .shim(port 305271) under core toobtain 0.004" to 0.008"clearance between armaiure

Arrnohrre touching residual

Figure 4-2. Escapement Adjustment (Part 1 of 2)


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S225-3357-3FES: SS23406 9Wipe off excess lubricant around escapement armature

pivot. Grease at this po int picks up dirt and card chips, andmay cause escapement failures. Observe the armature whilebackspacing. If the armature drags with the movement ofthe escapement wheel, the armature pivot spring requiresadjustment.4.4.2 Escapement Unit Adjustments1. Remove escapement magnet unit from machine.1 2. Make adjustments 1 through 7 in Figure 4-2.

Position me mb ly mountingbmcket so that armature sto pescape wheel with in onerevolution

i -J"\\\ Imert 0.010''

\ feeler gage\\' -_-

3. Replace magnet unit.4. Make adjustments 8 an d 9 in Figure 4-2 (Part 2).The escapement armature pivot spring must hold theescapement armature against the yoke at the pivot point asshown at 2, Figure 4-2. Avoid putting sh arp bends in springstraps while forming them. The outboard edge of thearmature is notched at a point near the hole for theoperating pin; the end is ground at a Sdegree angle. Thearmature must be upright for proper operation.

Armature just clear of escapewheel -- armature moy nip teethbut rota tion continues

/ / - - -0 .

/' \ \\\

I\\\ lruert 0.008"\ feeler goge

NO; made with 0.009" behvesnormature ond yoke

Figure 4-2. Escap ement Adju stmen t (Part 2 of 2)


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S225-3357-3FES: SS234069Escapement Gearing: Keep escapement gear train lubricatedon machines that use the drum-type friction clutch. Keepcard chips and other foreign matter out of escapement gearsand friction drive. Faulty escapement may be caused byincorrect torque at the friction drive. All gear shaftsprotruding through bearing support must be pulled to theextrem e forw ard position be fore tighte ning collars. Be sureunsealed bearings are capped.4.5 CARD FEED4.5.1 Hopper Adjustments4.5.1.1 Magazine SpringsForm m agazine springs to tou ch feed bed (1, Figure 4-3).4.5.1.2 Feed KnivesCheck card feed latch magnet adjustment. When card feedlatch m agnet adjustment is correct, manually cycle the cardfeed mechanism. With CF latch armature engaged with CFcam follower arm , adjust bo th feed knives evenly t o giveminimum clearance of 0.015 inch (0.040 inch maximum)from feed knives to top edge of cards in hopper (2, Figure4-3).

4.5.1.3 ThroatAdjust thro at block (3, Figure 4-3) to place crown in directline with top edge of throat knife. Adjust throat knife (4,Figure 4-3) for an opening of 0.008 to 0.010 inch . If

I hroa t is properly adjusted, a 0.008-inch gage should freelypass in three directions (Figure 4-3) but a 0.010-inch gageshould not.4.5 .1.4 Pusher Plate

I The card-feed pusher-plate spring (5, F igure 4-3) is adjustedto have 450-gram tension when one card is in the hopper.

4.5.2 Feed Clutch Adjustment1. Adjust magnet yoke adjusting screws (Figure 44) or0.032-inch to 0.036-inch clearance between armature

and yoke at the operating end.2. Form armature spring to exert tension of 100 to 12 0grams in direction o f A (Figure 4 4 ) and 230 to 250grams in direction of B (Figure 44 ) .

3. Position C F m agnet unit t o obtain 0.010-inch to0.014-inch unlatching clearance between armature andCF dog when arma ture is attracted (Figure 4-5).

Figure 4-3. Hopper Adjustment44 (11170)


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S225-3357-3FES: SS2 340 69Yoke Adiustina Screws

ArmatureSpring / \

0.032" to 0.036"A ISupport100 to 120Grams

Figure 4-4. CF Clutch Magnet Adjustment

Magnet UnitMounting Screws,

Clutch Latch Disk\ - - - d H

Figure 4-5. CF Clutch Adjustment4. Adjust the two jam nuts on the stacker end of the CFshaft for 0.003-inch t o 0.01 1-inch endplay.5. When previous adjustments are correct, clearance be-tween ratchet and latched dog will be at least 0.005inch. If clutch nipping or clutch ch atter persists, recheckspring tension as in item 2, then check timing of cardsto p cam shaft. (See 4.5.9).Note: When the cam follower is rising on the cam afterlatchup, the cam shaft and card feed shaft are pushedbackward which allows the clutch dog to drop against theratchet.4.5.3 Card Feed Latch Magnet Adjustments4.5.3.1 Yoke and Armature1. With cont acts aligned against con tact supports, turn

armature backstop screw until stationary contacts rise

Figure 4-6. CF Latch Magnet Adjustment

1132-inch off their supports (Figure 4-6).2. Position magnet yoke so that lower arm of yoke strikesarmature with a 0.010-inch gage between armature andmagnet core. Tighten screws.3. Turn backstop screw two full turns counterclockwiseand lock.

INote: Check feed knife adjustment after adjusting latchmagnet.4.5 .3.2 Mounting Plate Assembly1. Provide 3164-inch (0.047-inch ) clearance from latchmagnet armature to ear on CF cam follower arm (Figure

46).2. At same time, position assembly vertically to provide0.005-inch to 0.017-inch latching clearance from camfollower arm to armature tip when armature is attracted.4.5.4 Hopper-to-PrepunchBed Service Checks4.5.4.1 Card Feed Pressure Roll Service CheckCheck for even drag on a card inserted lengthwise downeither side. Rollers should be free of binds, and the two flatsprings should be straight when removed from machine.Misalignment or uneven tension on pressure roll bar maycause uneven feeding of cards.4.5.4.2 Aligner Finger Service CheckFactory adjustment for the card aligner fingers is 0.035-inch to 0.055-inch movement ahead of top card rail. Thecard must snap off the card aligner fingers and drop intoposition along the top rail before registration. Otherwise,the first 15 columns may be in-registration and the rest ofthe card may be off-registration to the left.

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S225-3357-3FES: SS234069

Figure 4-7. Pressure Rail Adjustment45.5 Pressure Rail AdjustnmntsWhen making the following adjustments, hold the gramgage as shown in Figure 4-7. In this position, gram gagereading and pressure rail movement can be simultaneouslyobserved.

4. Install assembly in machine and recheck adjustment byregistering a card.

4.5.5.3 Pressure Rail With Microswitch

Microswitch card levers in the detail station right-handpressure rail position and the master station left-handpressure rail position are adjusted at the facto ry to transferwithin the correct gram tension range. Replacement of theentire pressure rad and switch assembly is recommendedwhen any part is faulty. To install the microswitchassembly:1. Position the assembly vertically to provide 23-gram to31-gram (27-gram to 35-gram for master station) pres-sure against the card. The contact should be transferred.2. Remove the card and check that the contact returns toits normal position.

Figure 4-8. Pressure Rail - Card-Lever Contact4.5.6 Card GuideAdjustments

4.5 .5.1 Pressure Rail Without ContactForm pressure rail spring in detail station t o exert 23-gramto 31-gram (12-gram to 20-gram for master station)pressure on a registered card. Check tension necessary tomove rail away from card evenly.4.5.5.2 Pressure Rail With Strap Contact1. Remove card lever contact assembly from machine andstraighten stationary strap.2. Hold assembly at the same angle it has in the machine(45 degrees) and form operating strap to a contact airgap of 0.015 inch t o 0.020 inch (Figure 4-8).3. Form stationary strap for minimum contact rise of0.025 inch with 23-gram to 31gxam (27- to35-gram for master station) pressure applied at center oflip on rail.

4.5.6.1 Detail StationLoosen card guide holding screws and position card guide1 for 0.020-inch to 0.030-inch clearance to detail card bed(Figure 4-9).Debi l Station Cord Guide(dotted linerhwr later style)

0.020" o 0.030"Figure 4-9. Card Guide - Detail Station


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S225-3357-3FES: SS2 3406 94.5.6.2 Master Station 4.5.9 Card Stop Cam AdjustmentPosition master station card guide to obtain 0.013-inch to 1. Loosen setscrews on index shaft bevel gear.0.017-inch clearance to center bed plate at point closest to 2. With th e CF clutch latched, rota te card sto p cam to aeject unit (Figure 4-10). point where cam follower is at the approach but is notup on rise of cam.3. With some wink at the meshpoint of the bevel gears,

D Master Station Card Guide tighten the setscrews.4. Check timing by watching eject and register arms to beI-' sure that they do not start dow n again at the end of theT CF cycle. The beveled gears are spot-marked at the0.013 " to 0.017" Card factory so that this timing can be regained after removalof the feed by simply aligning the m arks.

Figure 4-10. Card Guide - Master Station4.5.7 Card Registration Service Check 4.5.10 Pressure Ro ll Service CheckCard registration should be checked every time the machine After a card is registered, turn power off. with the poweris serviced. To improve operation of the register and eject off, manually engage card feed clutch and turn the cardarms, lubricate the roller pivots with IBM # 6. feed mechanism. Check to see that the card is released by10 degrees and gripped again at 60 degrees.

0.004"Right-Hand Bed Plate 1

Card Pusher Arm StopCurd Pusher Cam at 50'

Pusher Arm StudFigure 4-1 1. Detail Card Registration

4.5.1 1 Preoure Ro ll Adjustments4.5.11.1 Punch Station1. Turn card stop cam until cam follower is on high dwellof cam (index a t 22 degrees to 45 degrees).2. Adjust eccentric on sto p lever cam arm for 0.023-inch to0.032-inch opening between detail station pressure rolland large feed roll (1, Figure 4-12).4.5.1 1.2 Read Station1. Turn card stop cam until cam follower is on high dwellof cam (Figure 4-1 2).2. Loosen locking screw in pressure roll release lever(Figure 4-1 2).3. Twist release pin arm shaft until 0.020-inch to 0.030-inch clearance is between read station pressure roll andlarge feed roll (2 , Figure 4-1 2).4. Tighten locking screw.4.5.12 Registration Adjustments4.5.8 Pusher Arm Adjustment

1. Position card pusher arm sto p to 0.004 inch below upperedge of right bed plate (Figure 4-1 1).2. Pull back pusher arm stud t o be sure it does not interferewith registration.3. Set registration adjusting screw for best punching regis-tration.

Note: This adjustment is easier if a 114-inch socket isused to loosen and tighten the adjusting screw lock nut.4. Set card feed index at 50 degrees and adjust pusher amstud for 0.003-inch to 0.008-inch clearance to pusheram.

4.5.12.1 Detail StationCheck pressure rail tension before making this adjustment.1. Loosen registration locking screw (Figure 4-12).2. Adjust lateral position of detail pressure roll with theregistration ad justing screw so tha t card rides against theguide bar while manual duplication is perform ed.3. Tighten registration locking screw.4. Adjust upper rail (detail station) to eliminate anyvertical registration skew caused by nonparalIelismbetween the die and stripper assembly and the detailpunch bed.

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S225-3357-3FES: SS234069

Qx e d Wheel \\\Lever

0.023" to 0.032"

Stop Lever Cam ArCard Stop c b m

Figure 4-12. Pressure Roll Adjustment

INote: Nonparallelism exceeding 0.025 inch must be cor-rected at the factory.4.5.12.2 Master StationThe master pressure roll lever pivot is an eccentric.1. Loosen setscrew (Figure 4-13) and rotate pressure rolllever shaft until card does not pull away from upper railwhen spacing is perform ed.2. Tighten locking setscrew.3. Multipunch a card with 12 through 9 in column 40.

Check the card length and registration on a card gage.Register the card in the read station and space to column40 . While holding the card stationary, remove the ejectunit and check that bo th sensing pins are visible in eachhole.

4. Adjust the two setscrews in the eject throat plate toobtain the correct registration.Note: In addition to nonnal eject wear and malfunction,the following conditions may cause the preceding adjust-ment to vary for successive cards:Alternating long and short cards

Loose pins in escapement gear trainBent idler gear shafts in escapement gear trainImproper friction clutch torque Figure 4-13. Master Station Redstration Adjustment


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4.5.13 Feed Wheel Removal and Replacement4.5.13.1 Detail StationOn machines with print feature, remove chip tube, printhead, plastic bed plate, and die and stripper; then proceedwith steps 1 through 5. On machines without print feature,separate feed wheel and shaft using procedure listed in4.5.13.2, step 3; then remove die and stripper and proceedwith steps 1 through 5.1. Drive taper pins out of e scapemen t wheel and space gear.2. Remove collar from escapement wheel shaft.3. Slide shaft toward rear of machine and slip off escape-ment wheel and gear.4. Slide sha ft back far enough t o manually insert, one taperpin. Use thls pin to force ball bearing out of the basecasting.5. Pull pin and bearing free of the shaft and slip shaft

through to the inside base and out the top.When replacing these assemblies, pull escapement wheelshaft toward the bearing in the space gearing bracket andlock the collar. There should be little or no endplay of theescapement wheel shaft.Note: Check timing of program cam and sensing contacts,and check adjustment of backspacer. Check printing andadjust if necessary.4.5.13.2 Master StationThe feed wheel is pressed on as well as pinned to the shaft.1. Remove eject unit and stacker plate. (Check adjustmentof traveling card guide so that stacker plate can bereplaced in the same position.) .2. Remove pin-sensing unit.3. Withdraw the taper pin that holds space gear to feedwheel shaft but do n ot remove it from the feed wheel.4. Remove the three collars and outboard bearing plate.5. Remove friction drive (the pins will push out).6. Remove clip from read-p ressure-roll release arm and tu rnarm so that feed wheel shaft assembly can be pulled tofront of machine for removing bearing and bearing

adapter.7. Pull out feed wheel shaft assembly from the rear.To reassemble, reverse the removal procedure. Readjuststacker plate and pin bail drive link. Remove endplay fromeach shaft before tightening the th ree collars.4.5.14 Card Feed Circuit Breaker Service CheckReplace badly pitted or worn points. Check for wornoperatingarm rollers;4.5.15 Card Feed Circuit Breaker Adjustm ent1. Align points to m ake sides and faces of con tacts parallel.2. Adjust stationary contact for 0.020-inch to 0.025-inch

air gap on high dwell of cam.

S225-3357-3FES: SS2340 699/16"

Space

Armature Pivot Plate ,

1 / ~r mi tu re ivot Plate IDotted lines shaw l a k r style armature1 3-9/16" -

Figure 4-14. Armature Pivot Adjustment

(Side View)

Figure 4-15. Armature Pivot Adjustment - Side View4.6 PUNCH DR IV E4.6.1 lndex Pointer AdjustmentWith clutch detent back against clutch latch, set indexpointer to 345 degrees. Be sure that pointer clears indexwheel.4.6.2 Interposer Magnet Adjustm ent1. Position arma ture pivot plate as show n in Figures 4-14and 4-15.2. Form arma ture pivot by lifting tip of the arm ature untilthere is at least 118-inch free movement t o the opera tingend (Figure 4-16).4.6.3 Guide Comb and Bumper Adjurtm entWith clutch latched, adjust guide comb and bumper so thatbumper portion holds punch operating arms down againstpunch bail. When interposers are hooked under the bail,

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S225-3357-3F ES: SS23406 9

Figure 4-1 6. Armature AdjustmentGuide Comband Bumper

Figure 4-1 7. Interposer Unlat ching Clearancethere should be 0.003-inch minimum clearance betweenbottom of bail and interposers (Figure 4-17). Checkadjustment by placing th e hand on the punch arms t o takeup any clearance between top of bail and punch arms; thentrip all interposer armatures. All positions should latchunder th e bail.

enter their armature notches at 9 2 degrees and so th at allare in the notches at 100 degrees. Space interposermovement varies from that of the other interposers, butthe interposer should be in its armature notch at 100degrees (Figure 4 18).2. The heel of the latching end of the interposers has beenrounded to avoid contact with the opposite side of thenotch in the armatures. Shift the magnet unit toward oraway from the interposers to obtain 0.040-inch to0.050-inch clearance (Figure 4-17).The preceding adjustment should result in minimumunlatching clearance of 0.008 inch for each interposer,except the space interposer, which can have a minimumunlatching clearance of 0.005-inch (Figure 4-19).3. Adjust eccen tric screw on knockoff bail (Figure 4-18) tocause bail to contact an attracted armature at both ends

of unit between 13 degrees and 20 degrees. If theeccentricity is insufficient, inspect cam follower forwear. It may be necessary to pivot entire magnet unitaround armature latching point to bring bail closer toarmatures.4. Momentarily attract each armature electrically. Thespring should cause the armature to fall away from thecore. If the armatures hang up when the pick circuit isbroken, they should be replaced; the residual magnetismcauses excessive wear on the knockoff bail.

Guide Comb and BumprI

4.6.4 Punch Interposer Magnet Aosembly Adjustment > , ,' I 1 1 IThe position of the magnet unit affects three interrelated

x>%adjustments: unlatching clearances, reIatching of inter- 1posers in their arm ature notches, and kn ockoff bail.1. Install magnet un it w ith reasonable unlatching clearanceas a preliminary step. Do not overtighten screws becausemagnet unit will be readjusted in step 2. Restore al l bu t looafour interposers across the unit. While manually rotating 92 Oindex clockwise, position magnet unit so that theunlatched interposers in their downward motion start to Figure 4-18. Interposer ReIatching Adjustment


45/92

S225-3357-3FES: SS2340690.008" min imum un la tch ingc lea rance excep t spaceln te rpare r

\

Figure 4-1 9. Armature Unlatching Clearance

4.6.5 Interposer Bail Contact Assembly AdjustmentBail-contact assemblies may be removed after removing themaster bed plate or punch drive unit.1. Both contact assemblies must have equal tension. Formstationary contact strap to require 30 to 35 grams to

raise it off its support. Forming should be within thearea of the support stra p to reflect a true condition. Onemethod of forming the contact strap is to insert astraightened paper clip between th e stra p and itssupport. Form contact strap to obtain a point-to-pointcontact at outer tip of support strap. When strap isproperly adjusted, a crack of light will appear at tip ofsupport strap during measurement.2. With contact assemblies removed, form operating strapnear the mounting to require 20 to 25 grams to closecontac ts (Figure 4-20). Place gram gage finger underphenolic pad with 114-inch overlap when checkingadjustment; 5 0 t o 6 0 grams should then be required toclose contact and to raise stationary contact off supportstrap (Figure 4-21).

3. Reinstall the contact assemblies and adjust their mount-ing brackets for 0.017-inch contact gap with all arma-tures restored.

Figure 4-20. Interposer Bail Contac t Adju stmen t

Crack of light

Figure 4-21. Interposer Bail Contact Rise Adjustment

4.6.6 Punch Driv e Removal and Replacement4.6.6.1 With Print Feature1. Remove:a. Belt guard and punch drive belt.b. Auxiliary duplicating feature (if installed).c. Wires to punch drive unit.

d. Two screws in pin-sensing bail drive link.e. Flexible shaft (if installed).2. Unhook print drive spring (Figure 4-22) and trip punchclutch armature to prevent damage to it. Hold index andremove screw with left-hand threads from end of punch

shaft. Unscrew grease fitting from m ountin g plug.Note: The n ext step requires realigning the code plate whenreassembling. Refer to 4.1 1.2.3.3. Loosen knurled thum b screw or remove slotted clip onvertical drive rod to relieve tension and remove verticaldrive rod guide plate. Disengage the print rod from theprint arm (Figure 4-22) by applying slight pressure on

drive rod a t lower end.4. Lift print drive mechanism from rear mountin g plug.5. Remove two screws from each end of drive-unit anchorbar.6. Loosen screws in fro nt mou nting plug enough to permitdisengaging the plug. Remove rear mou nting plug screws.7. Shake drive unit up and down (bed in vertical position)to free moun ting plugs.8. Turn drive unit clockwise and remove fro m base.

Before reinstalling drive unit, manually push punchextensions in as far as po

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IBM029 Field Eng Maint Man r