IBM 1402 User manual

"7J//7 ~
Issued to: --FC>~..of4:-. .. -+; _' ~/;Ll~.(-.<·/::. • .JO:~·:::(,,;:-- ______ _
/1
Branch Office :------,ts-<'t'--'7""---.~~ ... ,l..-----------
Department: ________________ _
If this manual is misplaced, it should
be returned to the above address,
frl CjD)o l.\I.7
~d.E)~ Customer Engineering Instruction-Reference
1402 Card Read-Punch
© 1960, 1961, 1962 by International Business Machines Corporation

This manual, Form Number 231-0002-2, is a major reVISIOn of
the preceding Form 231-0002-1. Many minor changes and addi-
tions have been made. Major revisions include new punch feed,
transport, and brush timing procedures, the addition of solar cell
CB instructions and adjustments, and a more complete coverage
of belt replacement and retiming procedures.
This manual, Form 231-0002-2 makes obsolete Forms 231-0002-0
and 231-0002-1.
Address comments regarding this publication to:
IBM, Product Publications Department, Rochester, Minnesota
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . 1-1
FUNCTIONAL PRINCIPLES. . . . . . . . 1-1
OPERATING LIGHTS AND CONTROLS 1-2
FUNCTIONAL SWITCHES . . 1-3
SPECIFICATIONS .. 1-3
READ FEED. . . . . . . . . . 2-1
DRIVE MECHANISM. 2-1
Speed. . . . . . . 2-1
READ CLUTCH. . . . 2-1
Principles of Operation. 2-1
Clutch Adjustments. . . . 2-2
Clutch Timing. . . . . . . 2-4
Clutch Pulley Assembly Removal 2-4
Clutch Pulley Assembly Installation. 2-4
Clutch Drive Removal. . . 2-4
Clutch Drive Installation. 2-4
FILE FEED. . . . . . . . . . . . . 2-5
Principles of Operation. . 2-5
Clutch Adjustments. . . . . 2-6
Clutch Removal. . . . . . . 2-6
Service Checks . . . . . . . 2-7
Joggler Adjustments. . . . 2-7
HOPPER AND PICKER KNIVES 2-7
Principles of Operation. . 2-7
Adjustments 2-8
CARD GUIDES. . . . . 2-9
Adjustments ..
CARD LEVERS ...
Adjustments .
BRUSH ASSEMBLY
Adjustments .
Timing .....
TRANSPORT AND STACKERS
SELECTION MECHANISM ....
Principles of Operation ..
Chute Blade and Selector Magnet
Adjustment . . . . . . . . . ....
TRANSPORT ROLL ADJUSTMENTS
JAM BAR ADJUSTMENTS .. .
STACKERS ............... .
Principles of Operation. . . .
stacker Joggler Adjustments
Stacker Adjustments .
PUNCH FEED .......... .
DRIVE MECHANISM
....... .
PUNCH FEED CLUTCH ..... .
Principles of Operation ..
Clutch Adjustments. . .. .
Clutch Timing. . . ... .
Clutch Ratchet Removal.
GENEVA ............. .
Principles of Operation.
Adjustments . . . . . . . .
Timing ........ ' .... .
HOPPER AND PICKER KNIVES
Principles of Operation ..
Adjustments . . . . . .
CARD GUIDES ........... .
Adjustments . . . . . . . . . . . . . . . . .
FEED ROLLS AND ALIGNER STATIONS.
Principles of Operation. . . ... '.'
Timing Check of Punch Transport.
Adjustments of Punch Transport. .
2-9
2-9
2-9
2-10
2-10
2-10
3-1
3-1
3-1
3-1
3-2
3-2
3-2
3-2
3-3
3-3
4-1
4-1
4-1
4-1
4-1
4-3
4-3
4-3
4-3
4-3
4-3
4-4
4-4
4-4
4-4
4-4
4-4
4-4
4-5
4-7

Side Aligner Removal . . . . . . . . . . . . .
Forward Aligner Removal . . . ..
First Stepped Feed Roll Removal
Fourth Upper Feed Roll Removal
Fifth Upper Feed Roll Removal. .
Second Stepped Feed Roll Removal ... .
ROLL OPENING DEVICE .............. .
Principles of Operation. . . . . . . . . . . .
BRUSH ASSEMBLIES ................ .
PUNCH UNIT ...................... .
Principles of Operation ... .
Punch Unit Removal ..... .
Punch Unit Installation ... .
Cam Follower Bearing Adjustments.
Cam Follower Assembly Removal. .
Cam Follow Assembly Timing . . ..
Interposer Setup Bail Adjustment . .
Interposer Setup Bail Removal . . . .
Magnet Bar Assembly Adjustment. . ...
Magnet Bar Assembly Removal .
Magnet Unit Adjustments ..
Magnet Unit Removal . . . . . . . .
Magnet Unit Installation . . . . . .
Interposer Guide Bar Adjustment
Interposer and Interposer Link
Removal .............. .
Stripper Assembly Removal. . . .
Stripper Assembly Installation . . . . .. .
Latch Removal. . . . . . . . . . . . . . . .. .
Punch Removal . . . . . . . . . . . . .... .
Punching Registration. . . . . . . . . . . . .
Punch Unit Timing . . . . . . . . . . . . . . .
TIMING DRIVE BELTS ................... .
PUNCH FEED INSTALLATION
PROCEDURES ................... .
Main Drive Belt ................ .
Drive Motor Belt ............... .
CR Idler Belt .................. .
Timer Index Belt. . . . . ..
PCCB Drive Belt ............... .
Idler Belt .................... .
PACB Drive Belt ............... .
Second Stepped Feed Roll Drive Belt .. .
PLCB Drive Belt ............... .
Punch Unit Drive Belt ............ .
First Stepped Feed Roll Drive Belt ... .
READ FEED BELT INSTALLATION.
Clutched Feed Roll Drive Belt .
Read Feed Belts . . . . . . .
ELECTRONIC COMPONENTS '" ..... .
SOLAR CELL CB ............. .
Introduction . . . . . . . . .
Principles of Operation ..
Timing Procedure . . . . .
Adjustment Procedure. . .
Removal and Replacement .
PERMISSIVE MAKE RELAYS .. .
Principles of Operation .. .
Contact Replacement . . . .
CIRCUIT BREAKERS ....
Open Strap Contacts . . . . .
4-9
4-9
4-9
4-9
4-9
4-10
4-10
4-10
4-10
4-10
4-10
4-12
4-12
4-12
4-12
4-13
4-13
4-14
4-14
4-14
4-14
4-14
4-14
4-15
4-15
4-15
4-15
4-15
4-16
4-16
4-17
5-1
5-1
5-1
5-1
5-1
5-1
5-1
5-1
5-3
5-3
5-3
5-3
5-3
5-4
5-4
5-4
6-1
6-1
6-1
6-1
6-2
6-3
6-3
6-3
6-3
6-4
6-4
6-5
SERVICE AIDS ....................... " 7-1
CUSTOMER ENGINEERING SERVICE
PANEL ....................... .
SPECIAL FEATURES .................... .
51-80 COLUMN DEVICE. . . . . . . ..... .
Mechanical Adjustments .......... .
PUNCH FEED READ ................. .
Principle of Operation ........... .
Card Guide Adjustments . . . . . . . . . . .
EARLY CARD READ ................. .
SERVICE HINTS ....................... .
INSTALLATION PROCEDURE .......... .
READ FEED ...................... .
Reader Stop Lights. . . . . . . . . . . . . . .
Reader Check Lights ............ .
Validity Lights ................ .
Picker Knife Timing Check . . . ..... .
Brush Timing . . . . . . . . . . . . . . . . . .
Circuit Breaker Timings .......... .
PUNCH FEED ..................... .
Punch stop Lights. . . . . . . . . . . . . .
Punch Check Lights . . . . . . . . . . .
Punch Check Brushes Out of Time ..
Punching Registration .. .
Dropping Punches ..... .
Multiple Punches ..... .
Damaged Cards or Jams .
7-1
8-1
8-1
8-1
8-1
8-1
8-3
8-3
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-2
9-2
9-2
9-2
9-2
9-2
PREVENTIVE MAINTENANCE ....... .
..... 10-1
APPROACH TO PREVENTIVE
MAINTENANCE ................... 10-1
PREVENTIVE MAINTENANCE
PROCEDURE ..................... 10:"1
1402 CIRCUITS ........................ .
POWER SUPPLY AND INTERLOCK
CIRCUITS ....................... .
Power On Sequence .............. .
Power Off Sequence . . . . . . . . ..... .
READ FEED CIRCUITS ................ 11-1
Load Key Operation .............. 11-1
start Key Operation .............. 11-2
Card Reading (RLCB Machines) ...... 11-2
Reader Non-Process Run-Out ........ 11-2
Stop Key Operation ............... 11-2
Card Jam Circuits ............... 11-2
Clutch Check Circuit ............. 11-3
PUNCH FEED CIRCUITS ............... 11-3
Punch Motor Start and Run ......... 11-3
Punch Feed Cycles .............. ; 11-3
Punch Feed Read ................ 11-3
Card Punching .................. 11-3
Punch Check Brushes ............. 11-3
Punch Non-Process Run-Out ........ 11-4
Stop Key Operation. . . . . . . . .. 11-4
Card Jam Circuits ............... 11-4
Clutch Check Circuit. . . . . . . .... 11-4
Stacker Select Circuits. . . .... 11-4
1402 MODEL 2 ., ....................... 12-1
DESCRIPTION ...................... 12-1
VARIATIONS BETWEEN THE MODEL 1
AND
MODEL 2 ................... 12-1
Read Feed Roll Number 4 .......... 12-1
Punch Emitter .................. 12-1
Electrical Changes. . . . . . . . ....... 12-1
Operating Controls and Lights ....... 12-1

ffiM 1402 Card Read-Punch

INTRODUCTION
The IBM 1402 Card Read-Punch provides the 1401
data processing system with a punch card input and
output.
The read feed is a 20 cycle-point feed
equipped with a file feed which
has a capacity of 3600
cards. The read feed can process cards at a speed
of 800 cards per minute. The punch feed is a 16
cycle-point feed which can punch cards at 250 cards
per minute. Five radial stackers are used to accom-
plish stacking of the cards from both feeds. The
read feed and the punch feed are located at opposite
ends of the machine so that cards are fed from the
read feed and the punchfeed into a transport assembly
above the stackers. The card transport system is
driven by timing belts wherever possible to reduce
machine noise and maintenance. Power supplies for
other machines of the system are located in the 1402.
FUNCTIONAL PRINCIPLES
The 1402 Card Read-Punchcanreadcardsata maxi-
mum speed of 800 cards per minute. Actual card
speed is governed by the program routing. The read
feed is equipped with a 3600 card capacity file feed.
The
cards are fed through the read feed. 9 edge
first. face down. The card path is illustrated in the
feed schematic diagram (Figure 1-1). As the card
passes the read check brushes. 80 columns of the
card are read to condition the hole count check planes
in the 1401. It is then moved past the read brushes
where again 80 columns of the card are read and
entered into the read area of core storage. At the
same time the check planes are conditioned so that
a hole count check may be completed. Next. it is
transported past the stacker selection station and is
directed to the appropriate stacker under control of
programming. Three stackers are available to re-
ceive cards from the read feed. The NR (normal
read) stacker is used unless the cards are program-
directed to stacker 1 or stacker 2 (8/2).
The 1402 Card Read-Punch will punch cards and
check card punching at a maximum speed of250 cards
per minute. Cards are placed in the 1200 card ca-
pacity hopper. 12 edge first. face down. Card feeding
is illustrated in the feed schematic diagram (Figure
1-1). As the card passes the Punch Feed Read
(optional feature). 80 columns of the card are read
into the read areas of core storage of the 1401 if
PFR is called for. Before the card is punched. it is
aligned at the aligner station both vertically and
horizontally to insure correct punching registration.
Punching is done by a high-speed punch unit. As
the card passes the punch station. circuits are set up
in the 1401 which allows the card to be punched with
information contained in the punch area of core
storage. At the same time the check plane cores are
conditioned so that a hole count check may be per-
formed. After the card is punched. it is read at the
80 column punch-check brushes to condition the check
plane cores so that a hole count check may be com-
pleted. It is then moved past the stacker selection
station and is directed to the appropriate stacker
under program control. Three stackers are available
to receive cards from the punchfeed. The NP (Normal
Punch) stacker is used unless the cards are program-
directed to stacker 4 or stacker 8 (8/2). The 8/2
stacker cannot be used for collating between the punch
and
read feeds.
The card transport assembly located between the
punch feed and the read feed has a set of six feed
rolls along with two select magnets and chute blades
for the read feed as well as two select magnets and
chute blades for the punchfeed. A jam bar is located
in the transport assembly to provide an indication of a
jam and stops the machine when a card jam occurs
(Figure 1-2).
All stackers are the non-stop unloading radial
type stackers with a capacity of 1000 cards each.
Cards can be removed from the stackers without
PUNCH FEED
TRANSPORT
READ m='D
FI RST STEPPED
FEED ROLLS
PUNCH FEED
READ STATtON
Figure 1-1. 1402 Feed Schematic
NP
STACKERS
NR
READ STATION
NOTE
DARKENED FEED ROLLS ARE UNDER
CONTROL OF THE FEED CLUTCHES
1-1

JAM STOP
SWITCH
Figure 1-2. Transport Mechanism
stopping the machine . Two stackers are assigned
exclusi vely to the punch fe ed . The center (8 / 2)
stacker can be used by either unit, but it must be
assigned by the program to one or the other, in any
one
run (Figure 1-3).
Both feeds are equipped with jam and misfeed
detention devices .
OPERATING LIGHTS AND CONTROLS (Figure 1-4)
Read Switch: Controls the read section of the
machine . When this switch is off, the read feed is
inoperative.
Figur e 1-3 . Radial Stacker
1-2
STAC KER SE L EC TMA GN ETS
rpU NC H
Punch Switch: Controls the punch section of the
machine. When this switch is off, the punch feed is
inoperative by program control. Cards can be run
into the punch feed with the punch switch off by use
of the non-process runout punch switch .
Start Switch: Causes the read feed motor to start
when the read switch is on. Punch motor will start
if punch switch is on.
Stop Switch: Used to stop the system. If a pro-
gram instruction is in process, it is completed before
the stop occurs.
Non- Process Runout- Read Switch: Used to run
cards out of the read feed. The last two cards run
out will not be processed. The read hopper must be
empty to make this switch effective.
Non- Process Runout- Punch Switch: Used to run
cards out of the punch feed. The last two cards will
not be punched. When the punch switch is on, the
hopper must be empty to make this switch effective.
Load Switch: Used to start loading instruction
cards. PreSSing the load key causes the read feed
to operate until a card has passed the read brushes.
After the card is read at the read brushes, the pro-
gram can start and execute the instruction that is
punched in the card . Continued operation is under
control of programming. When the punch switch is
on, pressing the load key causes the punch drive
motor to run.
Check Reset Switch: Must be pressed to reset an
error indication before the start key can become
operative . This switch is operative only when the
feed, in error, is empty of all cards.
Power Light: When power is supplied to the read-
punch unit, this light is on.
Reader stop Light: A feed failure or a card jam
in the read-feed causes the machine to stop and the
reader-stop light to come on.

g
=
PUNCH
STOP
CHIPS
STACKER
Figure 1-4. Operating Controls
CHECK
RESET
Punch stop Light: A feed failure or a card jam
in the punch feed causes the machine to stop and the
Punch Stop light to come on.
Validity Light: This light comes on if an invalid
character is detected during read operation.
Reader Check Light: This light comes on under
control of the data processing system when anerror
is detected during card reading.
Punch Check Light: This light comes on under
control of the data processing system when an error
is detected during the punching of a card.
Stacker Light: If any of the five stackers become
full, the stacker light goes on and the machine stops.
The light may come on shortly before the machine
stops.
Transport Light: This light is turned on by the
jam contact. It indicates that a card has jammed in
the transport feed roll area.
FUNCTIONAL SWITCHES
Cover Interlocks: When a cover is opened, the
respective interlock switch will open the circuit to
the punch and reader, motor and run circuits.
Punch Magazine Interlock: When the magazine
locking lever is opened, this switch opens the circuit
to the punch motor and motor start relays.
Die Lift Interlock: This switch provides the same
function as the magazine interlock when the lowering
frame is lowered.
Crank Interlock: This is a manually operated
switch which must be turned off to insert the hand
crank. It provides the same function as the magazine
POWER REAOER
CHECK
TRANSPORT
BB
interlock while using the hand crank.
g
~
Die Interlock: This switch provides the same
function as the magazine interlock when the die is
removed or improperly located.
Stacker Switch: This switch operates whenanyof
the 5 stackers are filled. When transferred, it opens
the circuit to the punch and reader, start and run
circuits. It also closes the circuit to the stacker
indicating light when transferred.
Jam Bar Switch: When a jam occurs, this switch
provides the same function as the stacker switch
except that it completes a circuit to the transport
light when transferred.
Joggle Switch: This switch is operated when the
hinged front joggler assembly is opened. Itopens the
circuit to the reader motor control relay.
Chips 1 and 2 Switches: These switches operate
when the chip box is full or removed from the ma-
chine. Operation of either switch willopen the punch
motor and run circuits as well as light up the "chips"
indicating lamp.
SPECIFICATIONS
Dimensions:
57 1/2" wide
29 3/4" deep
45 1/4" high (plus read file feed 14 5/8")
Weight:
1300 lbs
BTU Rating:
3,500 BTU
1-3

READ FEED
DRIVE MECHANISM (Figure 1-1)
A 1/ 4 hp motor drives the input pulle y on the read
feed . The following are kept continuously running:
1. Timer index
2. Clutch ratchet
3. Two contact rolls
4. First feed roll after each contact roll
5. Continuously running CB/ s (RC)
6. File feed drive shaft
7. Three transport feed rolls
8. Stacker jogglers for NR, 1 and 8/ 2 pockets.
When the read clutch engages, power is transmitted
to the following:
1. Picker knife cam shaft
2. Feed knives
3. First feed roll before each contact roll
4. Clutch controlled CB's (RL) and solar cell
CB (if installed)
GENEVA ---fi
CHIP BOX--tlI--- .....
PMT (PUNCH MAGNET TERMINALS)
HD RELAYS AND MAIN CONTACTOR _ _ J
(BEHI ND FUSE PANEL)
BRUSH IMPULSE TRANSISTORS
(REAR OF RELAY GATE)
Figure 2-1. 1402 Front View
Adjust the motor pulley to feed cards 800+ 3- 20 cards
per minute.
READ CLUTCH
Principles of Operation
The clutch ratchet is continuously running and makes
one-half revolution each machine cycle. This ratchet
is engaged by a drive dog and detent, which are
controlled by the action of the drive arm and inter-
mediate arm.
The dog and detent are spring-loaded to engage
the ratchet. They pivot on studs that are part of the
drive arm and are controlled by studs that are part
of the intermediate arm. The intermediate arm pivots
on a sleeve that is the hub of the drive arm (Figure
2-3).
RLCB UNIT
GT (GATE TERMINALS)
2-1

SOLAR CELL CB ..... I---~ .I~
READER DRIV E ~I-I!!~~~ l~
MOTOR
-60 V OLT
SUPPLY
PC (PUNCH CONNECTORS)
Figure 2-2. 1402 Rear View
DRI VE AR M
S ECU R ED TO
PULLEY INTE
RM EDIA TE AR M
PI V OTS O N THIS HUB
IN TER MEDIA TE AR M
DOG
Figure 2-3. Clutch Assembly
2-2
PUNCH DRI VE
MOTOR
To see the engaging action of the clutch, assume
the clutch is latched as shown in Figure 2-4.
Impulsing the magnet releases the latch and allows
the intermediate arm to move in relation to the drive
arm. The intermediate arm moves clockwise due to
the spring-loaded dog and detent exerting force on the
control studs. As the intermediate arm moves, the
dog and detent are allowed to engage the ratchet and
rotate the mechanism that drives the feed knives and
controlled feed rolls.
Unless the clutch magnet is again impulsed, the
clutch will disengage when the opposite end of the
arm strikes the latch. The intermediate arm, having
moved clockwise in relation to the drive arm, will
strike the latch first. The drive arm continues to
move, and in so doing, causes the dog and detent to
be cammed away from the ratchet by the motion of
the pivot studs with reference to the control studs on
the intermediate arm. Inertia carries the drive arm
forward to strike the latch, and the keeper falls be-
hind it to hold the clutch latched at 3150.
Clutch A djustments
The read clutch may be adjusted either in the machine
or with the clutch drive unit removed from the base.
Steps 1 through 4 should be performed when a new

DRIVE ARM
KEEPER
RATCHET
Figure 2-4. Magnet Assembly Adjustments
clutch assembly is installed or when complete adjust-
ment is to be made of the center plate assembly and
clutch magnet assembly. When this is to be made, the
read clutch locating plate gage (PiN 610147) must be
used.
NOTE: Use of this tool will insure a parallel condi-
tion between drive arm latch surface and the latch at
latch-up time (Figure 2-4A).
Proceed to step 5 for the armature, latch, -and
magnet adjustments.
The following. sequence is used to adjust the clutch:
1. Remove clutch pulley as described in Clutch
Pulley Assembly Removal Procedure.
2. Remove latch keeper and latch from center
plate assembly.
3. Position locating gage on center plate assem-
bly studs and clutch pulley assembly shaft (Figure
B
SEE
NOTE
ADJUST
SCREWS
FOR.020" TO
•022" CLEARANCE
HERE
-_-l.-- CHECK. 001" TO
.003" CLEARANCE
HERE
NOTE: .008" to .012" UNLATCHING
CLEARANCE SHOULD GIVE 75% (OR
MORE) LATCH SURFACE CONTACT
LOCATING BLOCK
2-5). Position and secure locating block withcenter
plate assembly as far left as possible. Remove gage.
4. Reinstall latch keeper, spring, and latch.
Follow Clutch Pulley Assembly Procedure for re-
assembly of clutch pulley assembly.
5. Adjust armature pivot bracket to maintain
.002" to .005" clearance between armature and core
(Figure 2-4).
6. There should be .020" to .022" clearance be-
tween armature and yoke with latch against backstop
(Figure 2-4).
7. Manually attract the armature and position the
latch assembly plate for a .008" to .012" unlatching
clearance between the latch and the clutch drive
assembly. Tighten center plate assembly mounting
screws. At this time, there should be at least 75% of
the latch contacting the drive arm assembly in a
2-3

HORIZONTAL
Figure 2-5. Latch Assembly Plate Alignment
latched condition (Figure 2-4B).
NOTE: Be sure to keep plate against locatingblock.
8.
Loosen locating block mounting screws and
position locating block as far right (ear of locating
block against the plate) as possible. Lock mounting
screws.
9. Adjust eccentric keeper stop stud to obtain
.
000" to .. 020" between clutch drive arm and latch
~er (Figure 2-4C) at latch time.
10. Check for .002" clearance betweenthe step on
the
ratchet and detent (backlash) with clutch engaged.
If there is more than .002" clearl;l,nce replace with a
.
longer detent. "
N9TE: Seven new detents' (PIN 609737 through
609743 are available. These detents are e~ched 1
through 7. Detent#l is .002" longer than·the original
'alld #2 is .002" longer than #1. etc.
Clutch Timin~
Thi/:l adjustment insures that the read feed dynamic
timer is in time withthe clutch at engaging time.
1. Block the clutch armature attracted.
2. Crapk machine and listen or feel for latch
keeper to fall behind &-ive arm. This should happen
at 3150 ± 10. .
. 0 0
3. If the index is not at 315 ± 1 when the latch
keeper falls behindthe drive arm,loosen the clamped
. 0
hub onthe index drive shaft and.,turnthe index to 315 .
4. Tighten the
clamped hub.
5.
If the timer index is moved, the brush timing
and CB timing will have to be checked.
Clutch
Pulley Assembly Removal (Figure 2-6)
The
clutch pulley includes the dogs wd arms that
operate them. Remove the pulley as follows:
1. If the same clutch assembly is to be used, spot
mark the clutch pulley and'the picker knife cam shaft
pulley to the belt. (This is to retain RLCB's, Solar
CB, and picker knife timing.)
2-4
2. Remove file feed drive belt.
3. Loosen idler for clutch pulley belt.
4. Remove grease fittingon ends of clutch shaft.
5.
Loosen retaining clamp and remove clamp and
file feed
drive pulley together.
6. Remove clutch pulley drive belt.
7. Remove clutch pulley assembly. It may be
necessary to loosen V-belt input pulley and move it
towards the end of its shaft.
Clutch Pulley Assembly Installation
When a new clutch pulley assembly is installed, the
entire procedure listed under Clutch Adjustment
should be
performed after the following steps have
been completed:
1. Be
certain that two thrust bearings (washers)
are on shaft against clutch ratchet.
2. Install clutchpulley, operating the arms so that
the detent and dogfitintohighdwellof ratchet.
3. Place two thrust bearings against clutch
pulley.
4.
Install clutch retaining clamp (and file feed
pulley), allowing no end play
of pulley.
5.
Install clutch pulley belt with spot marks
lined up and adjust idler.
6. Install grease fitting and file feed drive belt.
7. Reposition V-belt inputpulley, if moved.
8. Check
picker knife timing. RLCB's timing. and
solar CB timing.
Clutch
Drive Removal (Figure 2-6)
1.
Scribe lines along one end and side of unit to
maintain'front io.,l!ear,and side to side location.
2. Remove dynamic
timer index as follows:
a. Remove screw from hand crank.
b. Remove two screws from index base.
c. Loosen clamped hub on index shaft.
d. Unplug index cable.
3. RemoVe four drive belts.
a. Contact roll drive (front).
b.
File feed drive (rear).
c. Motor drive (rear).
d. Clutched feed roll drive. Loosen belt take-
up pulley bracket (idler)~:, ;." ... ,...., ~ .
4. Remove
clutch magti.etIeads at terminal block.
5. Remove four
hex-head clutch drive assembly
mounting screws.
6. Remove assembly through rear.
Clutch Drive Installation
1. Set drive assembly in position from rear.
2. Install four drive assembly mounting screws;
do not tighten.
3.
Position clutch drive assembly -on scribed
lines. Tighten mounting screws.
4. Install dynamic timer index (leave clamped hub
loose). 0 0 . '
5. Set index to 315 ± 1 •block armature and turn

REVERSE LOCK
CLUTCH PULLEY ASSEMBL ·Y
'----DRiVE PULLEY
Figure 2-6. Clutch Drive Assembly
machine until detent keeper falls behind drive arm .
Tighten clamping hub.
6. Install clutch drive belt and adjust idler pulley .
At this time loosen the picker knife camshaft pulley
locking screws .
7. Timing the picker knife camshaft can be
accomplished by tripping the read clutch and setting
the timer at 2160 for a 2 group brush machine or
o
212 for a 3 group brush machine . Place a card in
the hopper up against the first feed rolls . Turn the
cam shaft in the normal machine direction until the
feed knives touch the card. Tighten the pulley lock
screws . This is a starting point for brush timing.
Refer to wiring diagram for the final brush timing.
Change the picker knife camshaft for the proper
brush timing by slipping the drive pulley on the cam
shaft.
8. Time RC CB's, using the set screw retained
gear on the RC CB shaft.
9. Install the other three belts and unblock the
clutch armature.
10. Check the following timings : o 0
a. Clutch engagement time (315 ± 1 ).
b.
Brush impulse CB timing.
c. RC CB timing.
d. RL CB timing.
TIMER INDEX SHAFT ·
MAGNET ASSEMBLY
FILE FEED
Principle of Operation (Figure 2-7)
The file feed consists of two basic units:
1. Upper magazine.
2. Lower magazine.
The upper magazine is the tray which holds up to
3600 cards to be fed into the hopper. This tray is
hinged and can be locked at an angle to make the
brush area of the machine more accessible.
The lower magazine contains clutch contr01led
feed rolls that feed the cards into the hopper. Opera-
tion of the helical spring-type feed roll clutch is
controlled by the level of the cards in the hopper.
Under spring tension, tlJ-e front joggler applies pres · ':'
sure on the joggler operating lever, causing the lever
to follow the contour of the front joggler cam . As
the front joggler cam rotates, the front j<;>ggler
oscillates, joggling the cards into position. If there
are sufficient cards in the hopper to cover the sensing
pads, the inward travel of the joggler is limited and
the joggler control lever is not allowed to follow the
low dwell of the front joggler cam . There will be no
clutch action or cards fed down into the hopper at
this time.
2-5

HELICAL
SPRING
CLUTCH
Figure 2-7. File Feed
JOGGLER
OPERATING
LEVER
When the card level drops below the sensing pads,
the additional travel of the joggler forces the joggIer
operating lever to follow the low dwell of the front
joggler cam. At this time, thetab on the joggler op-
erating lever will cause the clutch operating lever to
rotate counterclockwise, pivoting the clutch latch out
of the step in the clutch sleeve. The helical spring
grips the shaft, and the feed rolls are driven. Cards
feed until card level in the hopper again reaches the
sensing pads and then the clutchlatches.
Cards are automatically front-and-side-joggled
in the hopper. Correct operating jogglers produce a
deck with almost perfectly straight sides. The front
joggler· can be opened for insertion or removal of
either cards or card weight.
The card weight is designed to pass through the
lower magazine into the hopper and must be used to
feed the last cards.
The front joggler interlock, mounted under the
read hopper, renders the machine inoperative unless
the front joggler is closed.
Clutch Adjustments
With the clutch latch against the latch step on the
sleeve, loosen the split collar and rotate the collar
2-6
o /\ /~
I
'~' . "v. \
CLUTCH
SENSING
LEVER ~
JOGGLER
CONTROL
LEVER
LOWER MAGAZINE
backwards (opposite normal direction) until stopped
by the spring fully uncoiled inside the sleeve. While
holding the split collar in this pOSition, rotate the
detent gear to 1/16" past detent position. This should
result in 1/16" overthrow (Figure 2-8).
Clutch Removal
1. Remove covers and upper and lower maga-
zines.
2. Remove drive unit from machine.
3. Remove. rear pulley and front and rear joggler
cams.
NOTE: Mark cams and shaft to maintain relation-
ship.
CLUTCH LATCH
CLUTCH 0 ETEN T
Figure 2-8. File Feed Clutch Adjustments

4. Remove rear bearing retainer plate.
5. Loosen
side joggler cam, clutch hub (with
grease fitting), and clutch drive gear on joggler cam
shaft. These set screws are seated in undercuts on
shaft and must be looseneda full turn. Slide shaft out
of
rear of unit.
6. Remove clutch assembly through bottom of
unit. The
clutch can now be dis-assembled and the
spring removed.
7. Re-assemble in reverse order. Be careful to
have the clutch latch and the detent in their correct
positions, and the grease fittings over the slotin the
shaft. The
clutch drive sleeve and the side joggler
cam should hold the clutch together, with the clutch
in full mesh. The sleeve and the side joggler cam
should hold the clutch together, withthe clutch in full
mesh. The sleeve and the side joggler cam should
not squeeze
the clutch so tightly as to cause binding
when the
clutch is latched. Check all drive unit ad-
justments after the unit is replaced in the machines.
Service Checks
1. The
front joggler interlocking arm shouldhave
approximately 1/16" travel before contact makes.
2. The upper card deck support must be centered
between the side frames.
3. The front joggler operating levers must be
free of binds between the side plates and the lower
magazine.
4. Hopper bed
plate springs must be 3/8" ± 1/16"
above hopper bed plate.
5. Shims
are available to shim the lower maga-
zine if the speed nuts interfere withthe helical spring
clutch.
6. The
lower magazine throat should be .020" to
.040" above the imaginary plane determined by the
tops of the feed
rolls (Figure 2- 9) .
Joggler Adjustments
Front Joggler
1. Turn the file feed drive unit until the front
joggler cam followers are on the low dwells of the
camS.
Fill the hopper to just below the sensing pads
on the front joggler and close joggler. Set the ad-
justing screws on the joggler to just touch the
operating arms (Figure 2-10). Undertheseconditions
there should be .003" to .010" clearance between the
cards and the lower end of the joggling surfaces (the
lower end of the joggling surfaces is in line with the
top of the card feed knife posts). This clearance is
obtained by adjusting the hopper post mounting bar
with the set screw (Figure 2-10). The hopper posts
will now have to be adjusted (Refer to Hopper Adjust-
ments).
2. Turn the file feed drive until the frontjoggler
cam followers are on the highdwellofthe cams. Fill
the hopper with cards to a level even with the top of
the sensing pads and close the joggler. Hold the rear
.020 TO .040
Figure 2-9. File Feed Adjustments
cam follower against the cam, andcontinue to operate
the unit. Stop when .005" to .008" clearance appears
between the cam follower arm and the adjusting
screws. Loosen the clutch operating lever on its
pivot shaft and fully seat the clutch latch. With the
cam follower against the cam, position the clutch
operating lever so that it just touchesthe turned 'over
ear on the cam follower arm (Figure 2-10). Tighten
the
set screws in the clutch operating lever, securing
it to its shaft.
Side Joggler
1. With a two inch column of cards in the hopper,
turn the file feed drive until the hopper joggler cam
follower is on the high dwell of the cam. Set the
adjusting screw for .000" to .005" clearance between
the top ofthe deck andthe joggler arm (Figure 2-10A).
NOTE:
There is no timing relationship between the
side and front joggler cams, nor between the cams
and the feed knives. The front joggler cams should
however,
be even with each other.
HOPPER AND PICKER KNIVES
Principles of Operation Figure 2-11.
After cards go from the file feed to the hopper, the
picker knives provide the means of moving the cards
from the hopper into the first set of feed rolls. A
picker knife cam assembly is located ona shaft driven
under clutch control. Two cam follower arms are
clamped to an adjacent shaft that causes it to oscil-
late. Two picker knife arms, also clamped to this
shaft, move the picker knife blocks.
2-7

Figure 2-10. Lower Magazine Throat
II------SIDE JOGGLER
•000" to •005"
CLEARANCE
2" CARD DECK
Figure 2-10A. Side Joggler Adjustments
2-8
LATCH
CLUTCH OPERATING LEVER
III~I+--- ELONGATED HOLE
The picker knives travel in an arc and not in a
flat plane parallel to the card line. For this reason,
to obtain the best possible feeding conditions, the
knife blocks
must travel evenlythroughthe same arc.
The knife blocks are factoryadjustedandshould never
be changed. ~.
Each picker knife block is fixed on its arm~~ITwo
carballoy pieces are inserted in the block surface to
resist wear. The inserts are groundtospecifications
for knife projection and replacement of the picker
block is required when the insert becomes worn.
Adjustments
1.
Position picker knife cam followers for a
maximum of .004"
clearance over the entire pe-
riphery of the cams, without binding.
2. Shim hopper posts on mounting
bar for a
clearance of .010" to .015" betweenhopper posts and
a pack of
cards restingagainstthethroatknife. (The
file feed
front joggler must be adjusted first.)

PICKER KNIFE BLOCK
HOPPER BED
Figure 2-11. Picker Knife
3. With a clearance of .062" ± .005" betweenthe
rear hopper side plate andthe rear side frame. adjust
the front side plate for .016" to .021" over the length
of
the card.
NOTE: This adjustment should result in cards
centered between the rails in the transport area
(5/16" ± 1/32" from the front rail).
4. Adjust the hopper back plate card guide fingers
.020" to .050" clearance to the hopper bed plate
fingerS, (Figure 2-12).
5.
~osition the feedknife arms evenly on the shaft
so that the feed edge ofthe picker knife block travels
.020" to .030" beyond the trailing edge of a card.
when the card is held against the hopper posts.
6. The throat roller must be positioned so that
the step indicating the center line of the roller is
lined up with the throat knife face.
7.
The throat opening should be .0095" go and
.0105" no-go. Time the picker knife cams to feed a
card so that the trailing edge of a card aligns witg
:: ~a:o:; ::s:~o:~ ~~~ ~!ra~p;:a=h:!.
NOTE: This is just a referenoe point for making
brush timings. When the brushes are on the soribed
line (refer to Brush Assembly Adjustment). retime
the pioker knife oamshaft to obtain proper timing.
To adjust proceed as follows: ..
a. Loosen clamped hub on pioker knife oarA"
Place a card against the first feed rolls and
manually turn the picker camshaft machine di-
rection until the feed knives touch the card.
Tighten pulley locking screws.
NOTE: Any change in picker knife timing will
directly affect RC CB and solar CB (if on
machine).
Be. sure to check brush timings
and adjustments .carefully before making these
timings.
CARD GUIDES
Adjustments
1.
Position the first lower card guide for .005"
to .015" below the careltline. Position the second
lower card guide for .015" tcr .025" below the card
line. Adjust by loosenihg the mounting screws in the
side frames.
2. Position.the removable upper card guide for
.020" to .050" clearance to the first lower card guide
assembly.
CARD LEVERS
Adjustments
1. Make
sure all card levers are free of binds.
shaft pulley .\';.
• 0 """,''-
for~' ;:!~ ~~~:e=Yo~:6~X:;U::r~:;~~~~!. 'Figure 2-12. Hopper
Back Plate Clearance
2-9

2. Position all card lever contacts to give a mini-
mum contact travel of 1/16" when the card lever is
being operated by a card.
3. Position card levers and contacts to provide
a minimum of 1/64" rise of the N/O contact strap
off it support.
4. Adjust the contacts for 1/32" minimum air
gap.
5.
Time according to timing charts (dynami-
cally).
BRUSH ASSEMBLY
Adjustments (Figure 2-13)
1.
Insert brush assembly into machine and check
for .012" minimum clearance between brush sepa-
rator and contact roll with an end to end variation of
. 015" maximum. To adjust proceed as follows:
a. Loosen four separator holding screws.
b. Place brush assembly on flat surface.
c. Adjust separator to flat surface.
d. Tighten the four screws .
e. Check assembly in machine for correct
clearance.
SPRI NG (2)
BRUSH SEPARATOR MOUNTING
BRUSH TIMING ADJUSTING SCREWS
Figure 2-13. Brush Assembly
2-10
f. If clearance is incorrect, remove assembly
and shift separator in proper direction.
2. Loosen locking screws at either end of brush
assembly and shift block , so that the heels of the
brushes are .050" + .030" - .020" off the scribed line
on separator toward the stacker (left in read feed)
(Figure 2-14).
NOTE: This setting is for the 2 grouped brushes, if
the 3 grouped brushes are used, set them on the
scribed line + .030" - .020" .
3. Adjust the brush assembly for correct lateral
tracking of the brushes.
a. Center the brushes in the separatorbyuse
of the two Allen-head set screws in the brush
assembly frames.
NOTE: Do not tighten the set screws to a point
where they bind the retractable frames.
b. With the brush holder in place, adjust the
screws in the machine side frames for correct
brush tracking.
c. Allow .003" clearance to prevent binding,
when
removing or replacing the brush assembly.
4. Adjust brush assembly card guide for a mini-
mum of .025" clearance to the lower card guide.
CENTERING SETSCREW

Timing
1. Dynamically check brush to be sure that the
first and second read stations are a complete machine
cycle apart (360°) and within the scribed line settings
listed above.
2.
Dynamically time the brushes as per wiring
diagram by shifting the picker knife timing. Do not
accomplish brush timings by shifting brushes off
scribed line.
NOTE: The RL CB's and Solar CB (ifused) will have
to be retimed after this adjustment.
3 GROUP BRUSH 2 GROUP----/
BRUSH
Figure 2-14. Brush Timing
2-11