User manual IBM 29 CARD PUNCH - MAINTENANCE MANUAL

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 Interposer Assembly . . . . 4 4 5 Vertical Drive Rod Assembly 4-46 CharacterPatternsE'L1. 4 4 7 CharacterPatternsE'A'. . . . . 4 4 8 Test Patterns. . . . . . . . 4 4 9 Print Drive Unit . . . . . . . 4-50 Print HeadRemoval. 4-51 Print Wire Replacement 4-52 Print Suppression Magnet Adjustment 4-53 Keyboard Adjustment 4-54 Keyboard Permutation Unit - Rear 4-55 Keyboard Permutation Unit - Bottom Page ..... ...... . .. . . .... ..... . . . . . . . . . . . . .4-21 . . . . . 4-23 Figure Title 4-56 Keyboard Key Unit and Permutation Unit 4-57 Keyboard Interlock Disks . . . . . ..... .... ..... . .. .. .. . .. .. ... . . . . . . . . ... ... .... Page 440 . 441 . . . . . . ; . ... . . . . . . . . . . . . . . . 4-25 .4-27 . 4-29 . 4-29 .4-30 . 4-30 . 4-31 .4-32 . 4-33 .4-34 .4-34 .4-35 .4-36 .4-36 . 4-37 .4-38 .439 Chapter 5. Power Supplies 5-1 Power Supply . . . . . . 5-2 Power and Receptacle Requirements .... .... Chapter 6. Locations Combination and Numeric Keystem Numbering Locations - Relay Board and Relays . . . . SMS Printed Wiring Cards . . . . . . . WireContact Relay Machine Relay Gate - Card Side View . . . . . . . . . . . Locations - Front View . . . . . . . Locations - Rear View (Reed-Relay Machine) . Locations - Rear View (Wire-Contact Relay Machine) . . . . . . . . . . . Locations - Rear . . . . . . . . . Locations - Front . . . . . . . . . Abbreviations A alpha AMP auto ampere alphabetic amphenol pin automatic circuit breaker customer engineer Customer Engineering Memorandum card feed character circuit column, columns control direct current definition duplicate friction clutch IBC intlk LZ max ms MULT PCH NC NO No. num FCC PM Prgm sec SMS interposer bail contact interlock left zero maximum millisecond multipunch normally closed normally open number numeric program cam contact preventive maintenance ProkTm second Standard Modular System volt CB CE CEM CF chat ckt col, cols ctrl dc def dup HSS Hz high-speed skip Hertz (cycles per second) v 5225-3357-3 FES: SS234069 Safety Procedures Safety cannot be overemphasized. To ensure personal safety and the safety of co-workers, each CE should make it an everyday practice to 'observe safety precautions at all times. All CEs should be familiar with the general safety practices and procedures for performing artificial respiration that are outlined in CE Safety Practices, S229-1264. For convenience, the -1 printing of this form has been reproduced. Always use a reliable voltmeter to verify that power is actually off after using power-off switches. Although all power supplies are provided with bleeder resistors to drain off capacitor charges when power is dropped, it is wise to check all capacitors with a meter before attempting maintenance. A defective bleeder resistor could create an unexpected hazard. Anyone working near elect~ical circuits may accidentally come in contact with live voltage. Round off sharp edges on plastic guides; replace broken guides. Check that all applicable safety devices are on the machine. Check all safety devices for proper operation. Do not permit machines to be run unattended with covers open or 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 open area. Breathing the concentrated vapors, even for a short time, may cause immediate reactions. Review Customer Engineering Memorandums (CEMs) for current safety practices. CE SAFETY PRACTICES All Cu~tomerEngineers ore .xp.cted to toke every sofety pre. caution p o ~ ~ i b lond observ. the following safety procticas e while mointoining IBM equipmant: 1. You should not work alone undar hazardous conditions or oround equipment with dangerous voltage. Always adrim your monoger if you MUST work olon.. 2 Remove oll power AC ond DC when removing or ossem. bling moior components, working in immediate areo of power supplies, performing mechonicol inspection of power supplies ond instolling chonges in machine circuitry. 3 Wall box power switch when turned off should be locked . togs, form or togged in off position. "Do not Operat." 229-1266, ofixed when opplicoble. Pull power supply cord whenever possible. 4. When it is absolutely necessary to work on equipment har ing exposed operating mcchonical ports or e x p o ~ dlire electrical circuitry anywhere in the mochine. the following precautions 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 ~ i n g test instrument^ be a r t o i n controls are set probes ore uud. correctly and proper copocity, in~ulated f. Avoid rontocting ground potential (metal floor strips, use suitable rubber mots purmachine frames, etc. chased locolly if necessary). 5. Safety Glos~es muat be worn when: a. Using o hommer to drive pins, riveting, stoking, etc. b. Power hond drilling, reoming, grinding, etc. c. Using apring hook,, ottoching springs. d. Soldering, wire cutting, removing steel bond*. e. Ports cleoning, using solvents, sprays, cleaners. chemicals, .C t. f. All other wnditbns thot moy be ho~ordousto your eyes. REMEMBER, THEY ARE YOUR EYES. 6 Special softly instructions such as hondling Cothode Ray . Tubel ond extreme high voltogea, must be followed 01 outlined in CEM's ond Safety Section of the Maintenance Monuols. 7. Do not use solvents, chemicals, greases or oils that hove not been opproved by IBM. 8. Avoid wing tools or test equipment thot hove no1 b..n approved by IBM. 9. Replace worn ar broken tools and test equipment. 10. Lift by standing or pushing up with stronger leg muscles this tokes strain off bock muscles. Do not liH any equipment or ports weighing over 60 pounds. 11. All safety devices such as guards, shields, signs, ground wires, ctc. shall be restored ofter maintenonu. 1 . Each Customor Enginoer in responsible l o be cortain that 2 no oction on his part renders product unsofo or exposel hozards to customer personnel. 13. Ploce removed machine covers in o sofe out-of-the-way ploce where no one con trip over them. 14. A11 mochin. covers mull be in ploce before mochino is returned to customer. 15. Always C tool kit awoy from wolk oreos where no E one con trip over it (i.4.. under desk or loblo). 1 . Avoid touching m.chanicol moving ports (i.e., when lubri6 coting, checking for play, etc.). 17. Whin using stroboscope - d o not touch ANYTHING- it moy be moving. la. Avoid wearing loose clothing thot may be cought in machin. err. Shirt sleeves mu11 be left buttoned or rolled obove the elbow. 19. Ties must be tucked in shirt or hove a tie clasp (preferably nonconductive) opproximotely 3 inches from end. Tie chain1 ore not recommended. 110. Befor. storting equipment, make certain fellow CE's and customer personnel ore not in a horardous position. 21. Maintain good housekeeping in oreo of mochines while performing and after completing mointenonce. - L .. ii . rid h: d - KNOWING SAFETY RULES IS NOT ENOUGH AN UNSAFE ACT WILL INEVITABLY LEAD TO AN ACCIDENT USE GOOD JUOGMENT ELIMINATE UNSAFE ACTS - S229-1264-1 - " r ' d Chapter 1. Reference Data and SerLice Aids Section 1. Reference Data Figure 1-1 shows machine characteristics for the IBM 29 Card Punch. 1.1 OPERATIONS 4 . Card Transport: Mechanical control of the movement of the card through the machine. 5 . Punch Drive Cycle: Controlled rotation of the punch drive unit index shaft. According to the function, this is required to punch a hole in the card at the punch station or to read a hole in the card at the pin-sense station. 1.2 SEQUENCE OF OPERATIONS The 29 Card Punch operations may be divided, as shown in Figure 1-2, for troubleshooting. These operations are: 1. Start and Run: Establishment of power (electrical and mechanical) necessary for machine operations. This includes the operation of the card feed and the pick-and-hold of the card lever relay. 2. Interposer Selection: Engagement of an interposer or interposers with the punch bail in preparation for punching. 3. Escapement: Advancement of the program drum and of the escapement-driven feed wheels. It is essential that the customer engineer be aware of the correct sequence of operations as they are used in any machine function. 1.2.1 Functions 1 Chorocteristics Speed: Manuol punching Manual duplication Automatic duplication Skipping Releasing Feed from pre-register to detail station I Description Without Print 20 col/sec 10 col/sec 20 col/sec 80 col/sec 80 col/sec 0.250 sec With Print 18 col/sec 9 col/sec 18 col/sec I / 500 cords I 1 Stacker 1 500 cards I When the function is t o punch a character from the keyboard, the sequence of operations is: 1. Start and run 2. Interposer selection 3. Escapement 4. Card transport 5. Punch drive cycle Using the numbers only, the sequence is: 1 2 34 5 Showing escapement and card transport (34) side by side indicates that 'hile 3 causes 4, they occur at the same time. Using this notation, the sequence of these operations for all of the functions of the 29 Card Punch is shown in Figure 1-3. The functions shown in Figure 1-3 are the responses of the machine to the inputs shown here: Key Punch Multiple Punch Key Skip Manual Duplicate Blank Column Manual Duplicate Auto Duplicate Press any character. Press the multiple punch key and any numeric key. Press the skip key in numeric or alphabetic shift. Press the duplicate key for one or more columns with no programming. Press the duplicate key for one or more blank columns with no programming and with the machine in alphabetic shift. Pressing the duplicate key or the reading of a "0" in the program card in a column followed by "12's" in the program card. Same as "Auto Duplicate" but for blank columns with the machine in alpha betic shift. Press release key if starwheels are u p or if they are down in a column p r e grammed "1 2". An " 1 1" in a program card. Card-tecard skip. Press release key in a nonprogrammed field but with the starwheels down. 29 FEMM (4169) Figure 1-1. Characteristics Interposer Selectian I Escapement I Punch Drive Unit Cycles I Blank Column Auto Duplicate Skip: Release, Auto, Drum I Release, Auto Space Figure 1-2. Operations 1-1 Key iunctlon Punch F Col i r 2 3-4 5 Mult Punch s 2 3-4 5 t Skip Key 1 Blank Column k n m l ~onu.1) Auto Dy Dy Dy 1 5-2 3-4 5 1 1 Blank Skip: Column Release, Release Auto Auto, Auto D r u SPu Dup 1 5 3-4 5 1 1 3 4-5 5 3-4 5 I 5-2 3-4 5 3-4 I 3-4 5 3-4 Second Repsot 2-5 3-4 Raped R e v t 3 - 4 forAll Rspmt R e v t forAll forAll 5 - 2 ond 5-2 k r A l l for Other Colr Cols Rspeot R Cols t Cycla Field Cols fa for Rspmt Repmt forAll forAll Colr Cols ( Direction comment ) Figure 1-4. Diagnostic Flowchart Symbols Figure 1-3. Sequence o f Operations 1.4.1 Start and Run Failures Section 2. Diagnostic Techniques 1.3 INITIAL APPROACH To locate start and run failures (Figure 1-5), the starwheels must be raised and blank cards must be used. 1.4.2 Card Transport Failures The first step in troubleshooting is to reduce the possible trouble sources to one of the five operations. Locate the operation that breaks the correct sequence for the failing function. The second step is to vary the machine function to one in which the failing operation occurs in another sequence. This tests the same operation with a different input. For example, interposer selection is faulty during keypunching (2, 3 4 , 5). Varying the function to manual duplication (5-2, 3 4 , 5) allows interposer selection from the pin-sense input instead of the key input. The cause of the failure, if in a particular input path,can be discovered in this way. If the 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 find the cause of the failure by using the wiring diagram and the test probe. For those troubles that cannot be found by using this approach, refer to the appropriate section in Chapter 4. Diagnosis of the complete failure of all machine operations should be preceded by a continuity check of the fuses. If attempted punching fails to occur after a card has been registered at the punch station, the card lever relay should be checked first. Consistent blowing of fuses indicates a short or a ground on the machine. Line terminals and/or cam contacts can be checked, one at a time, to locate this type of failure. Some common possible sources of grounds are the starwheel contact and the latch magnet contact. 1.4 DIAGNOSTIC FLOWCHARTS Diagnosis of the failure causing incorrect card movement should include an initial visual check to confirm that the components of the card transport mechanisms are operating. When card transport failure occurs, any mark or nick on the card will help to indicate the source of trouble (Figure 1-6). A change in registration during the duplication of one punched card can be a false indication of card transport failure. If the escapement moves while the sensing pins are still up through the holes in the card, the card will be retarded. The sensing pins usually leave marks on the card. (See 1.4.4.) Improperly inserting cards into the pin-sense station can cause trouble. The card to be duplicated should not be forced into the pin-sense station before registering the card. 1.4.3 lnterposer Selection Failures Interposer selection may be incorrect from either the keyboard or pin-sense units, or both. If either unit operates correctly, the circuits and components of the other unit must be considered as a source of the trouble. If both units fail, the trouble is assumed to be in the interposer magnets and associated circuitry or in the interposer mechanism (Figure 1-7). Note that when the interposers have been tripped for any reason, they must be restored by a drive-unit cycle. To avoid confusion in diagnosis, the starwheels must be raised to locate interposer selection failures. 1.4.4 Escapement Failures Figure 1 4 defines the symbols used in the diagnostic flowcharts (Figures 1-5 through 1-10). These flowcharts aid in locating the trouble area when diagnosing fairly consistent failures. Faulty escapement is defined as: escaping too far, not far enough, not at all, or at the wrong time. Program control is used with Figure 1-8 to locate escapement failures. The program card should be punched for alternate threecolumn duplications and twocolumn Slowly or overheah No I I ( Check motor start relay 1 Check mainline voltage I Check motor a Release ond feed card Drum doer not go to column 1 I Register the cord and space out a a I Check mainline furer Check motor stort relay Check motor I Cord ir not fed to pre-register $totion I Check w n c h clutch operation 1 I a I Check CF clutch magnet Check cord feed mechanism Check card lever operation cord tronrport flowchart Doer not register Check CF latch mechanism t Check cord feed clutch mechanism '-4 Check skip relay to ercopement flowchart (Figure 1-8) Nospacing or punch drive cycles ( I Check CF latch magnet / r l Check cord lever contact f Figure 1-5. Start and Run Failures N o trouble found, go to ercopement flowchart (Figure 1-8) i f no rpocing, or go to ~unch drive cycler flowchart (Figure 1-91 i f no punch drive cycles 29 FEMM (4169) 1-3 Doer no1 leave hopper + Feed card from hopper movement $atisfactory Crooked ot pre-register station 1 Hesitater or b u c k l n Check pin-senre preuure Release cord 1 D o n not slide along upper rail Check hopper pressure plate Check hopper adjustments Releeer Check hopper adjustments Check pin-$ewe prerrvre I Check feed knives I Check feed pressure rolls I Check troveling card Check prnsure roil Check eject guide Check troveling card a Register card Regirterr Crooked Check operotion of cord oligner fingers (bent, curled, etc.) Check card pusher roll opening Releme card CI Check card Offset Check t r w c l i n g card guide Check cord pusher mechanism u Stock cord Stocks No or crooked roll opening Check troveling cord guide Check for obstruction in punch throot I Chcck eject guide I I Check eject gvide I Check eject roll or Check eject roll or I Heritat- or buckles Check punch pressure roll for nlignment -oes not slide along upper rail I. 7 u D Check stocker cons Check stacker mechonirm Dup cards. Measure at various columns \ No Goes beyond I Check pin-senre prerwre I I roll o ~ e n i n a I I I Check pin-sense pressure] r o l l opening I m Repeot test feed ond observe stacking mechanism I/ Figure 1-6. Card Transport Failures Check regirtrotion orm and olphobatic character keys a Check interposer relotch Check keyboard restore selected No Check interposer relotch Check interpan magnet v =? Check pin-sere contoch Check cornmar bar Check throot plates and Check k y b o r d contoch Check m t o r e circuit Check inkrpoler w Check k e y b o d shift ckt Check for mopat impulse. I f no ~ u l r e ,proceed to 1 a Figure 1-7. Interposer Selection Failures + =7 Check pin-tare contoch Check r m i n g pin Check c o d regirtrotion 29 FEMM (4169) 1-5 A . Alphabetic Duplicate ( switch off.. kev duo , , olphobetic and blank ) Extra column or ot wrong time Yer Perform B ond C Check 12 program contact and circuit Check dup reloy retup Check P I cam contact Check escape circuit to interposer selection flowchart (Figure 1-7) 1( - a Check dup relays Check dup circuits N o trouble found, go Check 12 program contoct Check dup relor Check dup circuit 0. Numeric Duplicate and Skip auto dup 011 I 2 digits, Too far Yes Check escapement interlock relay Check P I cam contact Check that punch interposer is engaging bail I to interposer selection flowchart (Figure 1-7) No Check 0 pragrom cantoct Check auto rkip/dup switch Check dup reloy Yer (nicked or torn holer) No Check PI timing and duration Check punch clutch Check escape interlock relay I I Check retup of IBC I Check ercope circuit I to interpmer selection flowchort (Figure 1-7) C Perform A and C Figure 1-8. Escapement Failures (Part 1 of 2) C . Ksv Punch T far m No Check FC torque mognet I I Check FC torque I Perform A and B or escape Check escape mechanism + Check drive g s a train onolyre original foiling condition Check P I cam contact Figure 1-8. Escapement (Part 2 of 2) skips through column 38. This is followed by a 25column skip (ending in column 63), an llcolumn alphabetic duplication, a Scolumn skip, and duplication of column 80. 1.4.5 Punch Drive Cycle Failures to the power supply. The other lead is used to trace circuits leading to coils or magnets. A jack is provided on the power supply chassis. CAUTION Care must be used when probing relay points because the point of the probe might spread the pin connectors and cause the reed switch to make poor contact or break the pin. Be careful in the use of the test probe; an accidental short could tack several relay points. The probe should not be used to estimate circuit voltages. Use the meter for voltage measurements. Reed relays should be probed through the top of the bobbin because the vertical rows of holes on the land pattern for a particular relay position do not, in all cases, connect to the relay connector. Note: When probing P3, a false indication may occur; P3 appears not to make. This is due to the timing relationship between the short duration of P3 (7 ms) and the 60-Hz negative line pulse used to bias the probe. 1.6 SERVICING TECHNIQUES 1.6.1 Forcing Locate punch drive cycle failures with the starwheels raised (Figure 1-9). Diagnosis of clutch failures should include an initial manual cycle of the punch drive unit. Incorrect clutch overthrow or a defective detent can be found while performing this operation 1.4.6 Printing Control Failures The program card used for locating escapement failures can be used for locating programmed printing failures. Diagnostic flowchart is Figure 1-10. 1.5 MACHINE SERVICE FEATURES The 29 Card Punch has two diagnostic features that have been incorporated to aid the customer engineer. These are: Motor switch Test probe 1.5.1 Motor Switch The motor switch turns the motor off and allows other areas of the machine to remain energized. It is useful when manually cycling the machine. Some adjustments are made with the motor stopped. 1.5.2 Test Probe The test probe (Figure 1-11) contains a neon indicator in series with a resistor. One lead of the indicator is connected Extra pressure can be applied to various components to simulate malfunction. For example, the friction drive can be forced or retarded manually at the top of the program drum, or finger pressure can be applied to the escape magnet armature to help or hinder its operation. Magnetism of the escape magnet can be detected, and its strength estimated with any lightweight steel blade (screwdriver or burnishing tool). 29 FEMM (4169) 1-7 f i n t cycle dvp, ond multipunch I