IBY / FE Supplement Date Unit 29 Card Punch Re: Order No. S225-3357-3 This Supplement No. SS23-4069 Novomber 23, 1970 Previous Supplement Nos. None IBM FIELD ENGINEERING MAINTENANCE MANUAL IBM 29 CARD PUNCH @IBM Corp. 1965, 1969 Pages to be inserted and/or removed are: Title Page, Preface iii through vi 1-9, 1-10 2-3, blank 3-1, 3-2 , 4-1 through 4-12 4-17 through 4-22 4-29, 4-30 4-35 through 4-41, blank X-1 through X-5, blank 3-5, 3-6 A change to the text is indicated by a vertical line to the left of the change; a changed o r added illustration is denoted by the symbol to the left of the caption. Summary of Amendments Maintenance Manual addition to list in Preface Additional troubleshooting aids in Chapter 1 Lubrication changes in Chapter 3 Checkout procedure change in Chapter 2 Adjustment tolerance changes in Chapter 4 Figure 4-41 changed to improve figure-to-component association Note: - Please file this cover letter a t the back of the manual to provide a record of changes. IBM Corporation, Product Publications, P. 0. Box 390, Pough keepsie, N. Y. I2602 Field ~ngineerirbg Maintenance Manual 2 Card Punch S225-3357-3 FES: SS234069 Preface This publicatibn provides information for the maintenance of the IBM 29 Card Punch. The manual is written with presupposition tfiifithe reader has a working knowledge of the machine. As much applicable information as possible is in each section of this manual. The sections are numbered for easy reference. The sections are presented in a sequence similar to the card path through the machine. Timing adjustments for some units may vary among machines due to features and engineering changes; refer to the individual machine wiring diagram for accurate timing. Special features are treated individually in a separate manual, Field Engineering Theory - Maintenance, IBM 29 C a d Punch Features, IBM 29 Interpreting Card Punch, Model C, S223-2926. Other related manuals are: Field Engineering Theory of Operation, IBM 29 Card Punch, S225-3358 Illustrated Parts Catalog, IBM 29 Card Punch, S1244085 Reference Manual, IBM 29 Card Punch, GA24-3332 Field Engineering Maintenance Manual, Motors, Generators, Relays, Circuit Breakers, Test Instruments, Miscellaneous Components, S225-3422 Fourth Edition (April 1969) This a major revision of, and obsoletes, Form 225-3357-2, FE Supplement Form S23-4035, and all earlier editions. Significant changes have been made throughout this manual, including: new diagnostic flowcharts, Chapter 1; a new chapter, Chapter 2; new lubricant specifications, Chapter 3; revised starwheel adjustments and revised print suppress adjustments, Chapter 4. This manual should be reviewed in its entirety. Changes are periodically made to the specifications herein; any such changes will be reported in subsequent revisions or FE Supplements. This manual has been prepared by the IBM Systems Development Division, Product Publications, Dept B96, PO Box 390, Poughkeepsie, N.Y. 12602. A form for readers' comments is provided at the back of this publication. If the form has been removed, comments may be sent to the above address. @Copyright International Business Machines Corporation 1965, 1969 S225-3357-3 FES: SS234069 Contents Chapter 1 ~ d e r e n c e Data and Service Aids . Section 1.1 1.2 1.2.1 Section 1.3 1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.5 1.5.1 1.5.2 1.6 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 1.6.6 1.7 1.7.1 1.7.2 1.7.3 1.7.4 . 1 Reference Data . . . . . . . . . Operations . . . . . . . . . . Sequence of Operations ...... Functions . . . . . . . . . . 2. Diagnostic Techniques ...... Initial Approach . . . . . . . . . Diagnostic Flowcharts . . . . . . . Start and Run Failures . . . . . . . Card Transport Failures ...... Interposer Selection Failures . . . . . Escapement Failures . . . . . . . Punch Drive Cycle Failures . . . . . . Printing Control Failures . . . . . . Machine Service Features . . . . . . Motor Switch . . . . . . . . . Test Probe . . . . . . . . . . Servicing Techniques . . . . . . . Forcing . . . . . . . . . . . Interrupting Machine Operation . . . . Jumpering . . . . . . . . . . Measuring .......... Cycling Manually . . . . . . . . Interchanging Units . . . . . . . . Difficult-to-Analyze and Intermittent Failures Left-Zero Feature . . . . . . . . Diagnosis of "Heavy" or Stiff Keyboards . Stacker . . . . . . . . . . . Starwheel Adjustment . . . . . . . . ... .. .. .. .. .. .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . .. . 1-1 1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-7 1-7 1-7 1-7 1-7 1-7 1-7 1-8 1-8 1-8 1-10 1-10 1-10 1-1 1 1-11 1-12 1-12 2-1 2-1 2- 1 2-1 2-1 2-1 2-1 2-2 2-3 2-3 2-3 2-3 2-3 Section 1. Basic Unit . . . . . : 2.1 installation Procedures . . . Shipping Material . . . . 2.1.1 2.1.2 Power . . . . . . . . 2.1.3 Keyboard Operations . . . 2.1.4 Program and Function (Model A) 2.1.5 Program and Function (Model B) 2.1.6 Final Checkout . . . . . Section 2. Features . . . . . . . 2.2 Installation Procedures . . . 2.2.1 Feature Checkout . . . . 2.2.2 Final Checkout . . . . . Chapter 2. Console and Maintenance Facilities ...... ...... ...... .. . . . . . . . . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1. Basic Unit . . 3.1 Cleaning Adjustment . . 3.2 Safety . . . . 3.3 Safety Devices . 3.3.1 3.3.2 Electrical Hazards 3.3.3 Chemical Hazards 3.4 Lubrication . . Section 2 Features . . . Chapter 3. Preventive Maintenance . . . . . . . 3-1 3-1 . . . . . . . . . . . . . 3-1 .......... . .......... .......... .......... .......... .......... .......... .......... 3-1 3-1 3-1 3-1 3-1 3-1 3-8 4-1 4-1 4-1 4-1 Section 1. Basic Unit 4.1 Base . . 4.1.1 Diodes . Chapter 4 Checks. Adjustments. and Removals . .. ............ ............ ............ Arc Suppressors . . . . . . . . . . Drive . . . . . . . . . . . . . Drive Motor . . . . . . . . . . . Drive Motor Belt Adjustments . . . . . . Backspace Mechanism Service Check . . . . Backspace Mechanism Adjustment . . . . Friction Drive . . . . . . . . . . Friction Drive Service Check . . . . . . Friction Drive Torque Adjustment . . . . Friction Clutch Removal . . . . . . . Escapement Unit . . . . . . . . . EscapementUnitServiceCheck . . . . . Escapement Unit Adjustments . . . . . . Card Feed ........... Hopper Adjustments . . . . . . . . Feed Clutch Adjustment . . . . . . . Card Feed Latch Magnet Adjustments . . . Hopper-to-Prepunch Bed Service Checks . . . Pressure Rail Adjustments . . . . . . . Card Guide Adjustments . . . . . . . Card Registration Service Check . . . . . Pusher Arm Adjustment . . . . . . . Card Stop Cam Adjustment . . . . . . Pressure Roll Service Check . . . . . . Pressure Roll Adjustments . . . . . . . Registration Adjustments . . . . . . . Feed Wheel Removal and Replacement . . . Card Feed Circuit Breaker Service Check . . . Card Feed Circuit Breaker Adjustment . . . Punch Drive . . . . . . . . . . . Index Pointer Adjustment . . . . . . . ..... Interposer Magnet Adjustment Guide Comb and Bumper Adjustment . . . Punch Interposer Magnet Assembly Adjustment Interposer Bail Contact Assembly Adjustment . Punch Drive Removal and Replacement . . . Clutch Magnet Adjustment . . . . . . . Punch Clutch Service Check . . . . . . Punch Clutch Adjustments . . . . . . . High-speed CB Assembly Service Check . . . ... High-speed CB Assembly Adjustment High-speed Cam Removal . . . . . . . Die and Stripper Service Check . . . . . Die and Stripper Adjustment . . . . . . Die and Stripper Removal and Replacement (With Print Feature) . . . . . . . . Die and Stripper Removal and Replacement (Without Print Feature) . . . . . . . Punch Penetration Adjustments . . . . . Punch Removal and Replacement . . . Pin Bail Drive Link Adjustment . . . Pin-Sense Unit . . . . . . . . Pin-Sensing Unit Service Checks . . . Pin-Sensing Unit Adjustments . . . . Pin-Sensing Unit Removal and Replacement Sensing Pin Removal . . . . . . Eject Unit . . . . . . . . . EjectUnitAdjustrnents . . . . . . Stacker Unit . . . . . . . . . Stacker Unit Adjustments . . . . . . 4-1 . 4-1 . 4-1 . 4-1 . 4-1 . 4-1 . 4-1 . 4-1 . 4-2 . 4-2 . 4-2 . 4-2 . 4-3 . . . . . . . . . 44 44 44 4-5 4-5 46 4-6 4-7 4-7 4-7 4-7 4-7 4-7 4-9 4-9 4-9 4-9 4-9 4-9 4-9 4-10 4-1 1 4-11 4-12 4-12 4-13 4-14 4-14 4-14 4-14 4-14 4-14 4-14 4-15 . . . . . . . . . . . . . . . . . . . . . . . . . iii Program Drum Unit . . . . . . . . Sensing Assembly Service Check . . . . Sensing Assembly Adjustments . . . . Sensing Assembly Removal and Replacement .. Program Cam Contacts Service Check Program Cam Contacts Adjustment . . . Program Drum interlock Arm (Split Hub) Adjustment ......... .......... Print Unit .. Print Assembly Servicechecks . Print Assembly Adjustments . . . . . Print Assembly Removal and Replacement Ribbon Feed Pawl Adjustment .... Print Drive Adjustment . . . . . . . Print Suppress Magnet Adjustment . . . Key board . . . . . . . . . . . Contact Adjustments . . . . . . . Hook Support Bar Adjustment .... Permutation Bar Adjustment . . . . . Restoring Magnet Adjustment . . . . . 4.12.5 Upper Permutation Support Adjustment . 4.12.6 Key Unit Adjustment . . . . . . 4.12.7 Key Unit Removals . . . . . . . Section 2. Features . . . . . . . . . . . . . . . . . . . 4-39 . 4-39 . 4-40 . 4-41 5-1 5-1 5-1 6-1 6-1 6-1 6-2 6-3 6-3 6-3 6-3 6-5 Chapter 5 Power Supplies Section 1. Basic Unit . . . Section 2 . Features . . . . . ........ ......... ......... . . . . . ... ... .. .. ... . . . . . . Chapter 6 Locations . . . . . . 6.1 Keystem Numbering . . . . .... 6.2 Reed-Relay Card 6.2.1 Reed Relays . .... Wirecontact Relays . . . . 6.3 6.4 Standard Modular System (SMS) . 6.4.1 SMS Card Receptacles . . . . 6.4.2 SMS Locations and Pin Numbering 6.5 Location Figures ..... l ndex . ..... ..... .... ..... . . . . . . . . . . . . . . . . X- 1 lllustrations Figure Title Chapter 1 . Reference Data and Service Aids 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-8 1-9 1-10 1-11 1-12 Characteristics . . . . . . Operations . . . . . . . Sequence of Operations ... Diagnostic Flowchart Symbols Start and Run Failures . . . . CardTransportFailures . . . lnterposer Selection Failures . . Escapement Failures (Part 1 of 2) . Escapement Failures (Part 2 of 2) . .. Punch Drive Cycle Failures Print Control Failures . . . . Test Probe . . . . . . . Reed Relay insertion . . . . Page 1-1 1-1 1-2 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-10 Figure Title CF Clutch Magnet Adjustment ... CF Clutch Adjustment . . . . . . CF Latch Magnet Adjustment . . . . Pressure Rail Adjustment . . . . . Pressure Rail . Card-Lever Contact . . Card Guide . Detail Station . . . . Card Guide . Master Station . . . . Detail Card Registration . . . . . Pressure Roll Adjustment . . . . . Master Station Registration Adjustment . Armature Pivot Adjustment . . . . Side View Armature Pivot Adjustment . ArmatureAdjustment . . . . . . Interposer Unlatching Clearance . . . lnterposer Relatching Adjvstment .. Armature Unlatching Clearance . . . lnterposer Bail Contact Adjustment . . lnterposer Bail Contact Rise Adjustment Print Drive Unit Cam Timing . . . . PunchClutchhlagnet . . . . . . Punch Clutch Components . . . . . PunchClutchAdjustment . . . . . .... High-Speed Circuit Breaker Punch Bed . Front View . . . . . PunchandExtension . . . . . . Punch Penetration Adjustment ... Sensing Pin Contact Adjustment . . . Pin Sensing Adjustment ...... Stacker Timing . . . . . . . . Stacker Adjustment . . . . . . . TravelingCardCuide . . . . . . Timing Tool . . . . . . . . . Program Unit Timing Chart . . . . Page .4-5 .4-5 .4-5 .4-6 4-6 .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 ..... . . . ...... .... . .... . .... . . . . . . ... . ... . ..... ... . ... . ...... .... . .... . Chapter 2 Console and Maintenance Facilit'm' 2-1 Program Card . Model A . . . . . . . 2-2 Program Card . Model B . . . . . . . Chapter 3 Preventive Maintenance 3-1 Preventive Maintenance Routines . . . 3-2 Lubrication . Right Front . . . . . 3-3 Lubrication . Front . . . . . . 3-4 Lubrication . Front (Machine Bed Tilted) 3-5 Lubrication . Rear . . . . . . . 3-6 Punch Unit Lubrication ..... 3-7 Keyboard Lubrication . . . . . . . .. .. 2-2 2-2 . .... .... .... .... .... .... .... .. .. 3-2 3-3 3-4 3-5 3-6 3-7 3-8 4-1 4-2 4-3 Chapter 4 Checks. Adjustments. and Removals 4-1 Friction Drive Adjustment . . . . . . . 4-2 Escapement Adjustment (Part 1 of 2) . . . ... 4-2 Escapement Adjustment (Part 2 of 2) 4-3 Hopper Adjustment . . . . . . . . . . . .. . . 4-4 Figure Title 4-37 Method of Holding Escapement Wheel 4-38 Program Cam Contact Adjustment . 4-39 OverlayforFigure4-40. 4-40 Code Plate Chart E'L' 4 4 1 Print Interposer Assembly . . . . 4 4 2 Punch Drive and Yoke Adjustments 4-43 Printing Adjustment . . . . . 4-44 Print Inte ...