IBM 1403 User manual

~) ~3 ~ Field Engineering
® Maintenance Manual
Printers

Maior Revision, November 1964
This manual, Form 225-6493-4, supersedes and obsoletes both
the previous edition, 225-6493-3; and Form 225-3282-0.
The information in both those publications is consolidated,
reorganized,
and updated to the latest engineering levels.
Np\lIT infnrmlltinn inl'ln(lps nrncpdllres for: new style ribbon-
shi~id 're~i~~;;~~t: h-yd;~~iic'" unit oil-seal replaceme~t, Model 3
train cartridge
gear replacement, and accumulative slug-to-slug
clearance adjustment, as well as a regrouping of related adjust-
ments
under Print Quality Adjusttnents.
New information is included for the Model 6, and some
Figures are
added to support the text where necessary.
Address comments concerning
the content of this publication to mM Product Publications, Endicott, New York 13764.
© 1960, 1961, 1962, 1963 by International Business Machines Corporation

Contents
IBM 1403 Printer Models 1, 2, 3, 4, 5, and 6 ........ 5
Introduction ............................................................................ 5
Safety ...................................................................................... 5
Preventive Maintenance ........................................................ 5
Installation Procedure ............................................................ 5
Service Procedures ............................................................ 10
Cover Removal........................................................................ 10
Manual Controls: Adjustment .............................................. 11
Forms Positioning .................................................................. 15
Base Adjustments and Removals ............................................ 21
Chain Cartridge ......
~.................... ........................................... 30
Hammer-Unit Assembly .......................................................... 37
Ribbon Unit ............................................................................
41
Tape-Controlled Hydraulic Carriage........................... 51
Hydraulic Unit ........................................................................ 51
Carriage Adjustments ............................................................ 57
Carriage Adjustment with
the Tachometer-
Generator ............................................................................ 63
Single Shots ............................................. ,. ............................. 65
Static Adjustment of the Carriage-Tape Brushes .. .............. 70
Dynamic Adjustment of the Carriage Tape Brushes ............ 71
Information Peculiar to the IBM 1403 Model 3 72
Service Procedures .................................................................. 72
Manual Controls -Adjustment ............................................ 72
Base Adjustments and Removals ............................................ 72
Train Motor Drive-Gear Adjustment .................................... 74
IBM 1416 Train Cartridge ...................................................... 75
Train Lubricator .................................................................... 81
Hammer-Unit Assembly ........................................................ .81
Ribbon Unit ............................................................................ 87
Print Quality Adjustments .................................................... 89
Impression Control Bar Adjustment .................................... 91
Timing Disk Transducer Adjustments ................................ 91
PCS Transducer Adjustment .................................................. 94
Print-Quality Concepts .................................................... 95
Printing Characteristics Defined ............................................ 95
Print-Quality Measuring Devices ........................................ 95
Printer Checks and Adjustments to Meet
Optical-Reader Requirements ............................................ 98
Specific Print Problems and Their Cure .............................. 98
Locations and Voltage Specifications .................... 102
Appendix ,........................................................................... 103
Oscilloscope Waveform Charts .:.......................................... 103
Print Troubleshooting Reference Chart ............................ 104
Index .................................................................................... 105

This maintenance manual is a companion-piece to Cus-
tomer Engineering Jvfanual of Instruction: IBM 140a
Printers,
Form 225-6492. It includes information neces-
sary for the correct servicing of
the 1403 printers. The
manual is arranged in three sections.
The first section (Alodels 1, 2, 3, 4, 5 and 6) contains
information common to all 1403 models except for
those differences peculiar to
the Model 3. Special tim-
ings or adjustments required for the single-speed
Model 6 are noted,
as required.
The second section contains additional Information
Peculiar to the Afodel 3. The great differences in the
printing mechanisms of
the Model 3 warrant placing
this information in a separate section more readily
available to the reader.
The third section contains general information on
Print Quality Concepts, and applies equally to all
models.
Safety
Personal safety cannot be overemphasized. To insure
your own safety, make it
an everyday practice to fol-
low all safety precautions at all times. Become familiar
with
and use the safety practices outlined in Form
229-1264, a pocket-sized card issued to all customer
engineers.
The 1403 mainline CE switch turns off all ac power
except 115V ac at the convenience outlet.
It does not
affect the dc voltages. Use this switch only when sys-
tem power is
off.
Caution: Remember if ac power is on, opening the T-casting
removes two phases from the chain/train drive motor. The
other phase remains present on this motor. All three phases re-
main on the hammer unit blower and the hydraulic drive motor,
which continue to run regardless of the gate interlock switch.
Preventive Maintenance
The prime objective of maintenance is to provide maxi-
mum machine availability to the customer. Unless a
preventive maintenance operation reduces machine
downtime,
it is unnecessary.
Do not adjust or disassemble a unit that is working
properly, even if tolerances vary from specifications.
IBM 1403 Printer
Models 1, 2, 3, 4, 5, and 6
Be visually alert for trouble indications any time
you service the machine. Look for corrosion, wear,
cracks,
burned contacts, and loose connections. Watch
for filters clogged with dirt.
The three basic steps of preventive maintenance are:
clean, lubricate,
and inspect. Do not do more than the
preventive maintenance scheduled on equipment
that
is operating satisfactorily. Figure 1 shows the recom-
mended preventive maintenance for single-shift opera-
tion.
When used by more than one shift daily, increase
the maintenance frequency accordingly.
Apply lubrication only in
the quantity necessary to
supply
the immediate area involved. Wipe off excess.
On the 1403, take special care to keep lubricants away
from:
Ribbon Cover seals
Paper path Rubber dampers
Electrical wiring Grommets
Ribbon
drag brakes
The process meter should be checked every six
months as prescribed
under Installation Procedure.
Installation Procedure
Base Installation
l. Remove protective wrappings, tape, etc., and the
wooden block used to prevent the translator frame
from shifting during shipment.
2. Make a visual check for parts broken or damaged
in transit.
3. Check manual knobs, levers, and covers for correct
operation.
4. Check for oil as follows:
a.
On Models 3 and N-1. See that the clear plastic
train lubricator beneath
the lower right end of
the T-casting contains special lubricant (part
856381). Prime the
pump (see Train Lubricator,
steps 2 and 5).
b.
On all other models. See that the reservoir be-
hind the clear plastic window in the right end
of the T-casting contains IBM 6 oil.
5

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CODE
LOCATION
FREQ.
U R OPERATION
~
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0 Chain
~
& 1
<
m
~
-
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[
m Train
=
~
(Mod. 3)
=
n
m
=
c
C 2 Ribbon Drive 2
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Mtr.
m
sf
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5 Ribbon 3
Reverse
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0
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~a
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Ribbon Drive
Unit
~
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c
-
~~
Ribbon Drive
Gear Reduction
Housing
Aux. Ribbon
Correction
Device (Opt) or
Skew Device
(Mod. 3)
3 Chain Drive
Train Drive
(Mod. 3)
Troin
{Mod.
3)
Forms Cart
-
~.
).M. ROUTINE 2 I
LUBRICATION
Fill right oil reservoir in T-ca
!"ing IBM fl6
Bearing oil CI ps (2 oil cups) IB
M #6
(8 drops each
Toggle plate
anchor IBM #
All gears Lu~
All bearings,
IBM fl6. Fri(
ball IBM fl6.
Without oil-I
to cup on top
cup). With (
to oil-level f
light film of
and gears.
light film of
1. light filn
pinion, jl
2. Add #22
(see lubri'
light fi 1m Lli
Fill oi I reser',
P/N 856381
cup).
pivot IBM #6. R
24. Skew roller
riplate *70 greas
pivots, <:md c lut
tion-disk interpo
evel hole: 1/80
(may have screw
ii-level hole: F
ole. Replace sc
'verse togg
Ie
)ivot IBM f6.
! (light filrn).
;h shafts
;er stud and
mce IBM 1'16
instead of
II with IBM fl6
ew.
Lubriplate #700
"I eccentrici
Lubriplare #70 on
I eccentrici
Lubriplclte #70:
termediClte, and
o bevel
gear uni
cating Bevel Gea
briplate #70 on d
oir with special
drive key"
drum geanl.
r Unit)
rive
key.
ubricant,
CLEAN
Clean type with vacuum
cleaner as required.
Clean typeface wi th IBM
cleaner, P/N 451529
Wipe excessive oil and
grease from all areas to
prevent contaminating
ribbon"
Keep friction reverse-drag
surfaces clil free. Wipe
excessive oi I and grease
from all surfaces to pre-
vent ccmtamination of
ribbon ..
OBSERVE
I
I
Check that reservoir never runs dry. Check
that oi I reaches the chain. Check for
chain binds.
If bind is detected, perform
off-c:artridge cleani ng.
Check that oil is available at end of wick
I
I
in m'Jvable base.
Check by pressing a
whit,e
piece of paper against the wick.
A
light oil film on the paper indicates suf-
I
I
ficient lubrication.
I
I
I
Check for wear and correct ribbon reverse
and skew operation.
I
Check for wear and binds.
Check for
I
corn~ct operation.
I
~
Check accumulated slug to slug clearance.
Free, train movement with .001" between
butts of two type slugs.
Slight binds in
train with .003" gage.
Check for proper grounding. Check ground-
ing strips for foreign material.

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4 Hammer Unit 6 Use IBM 116 on hammer-magnet armature
pivots. Use light film IBM #6 on armature
backstops
and hammer surfaces that contact
armatures. Do not atomize.
Hammer Unit
No lubrication required
{Mod. 3)
Strip Residual
Hammer Unit
Blower
6
Chain
Drum
Timing Disk
{Mod. 3)
Train Drive Fill
train drive gear housing with IBM 1117
{Mod. 3)
to just over the bottom of the gears.
1 Tractor Feed Light film Lubriplate 1170 on tractor drive
pulleys, tractor shafts, and operating
surface of tractor be I t.
Stacker Light film Lubriplate #70 on bevel drive
gears and drive belt. Use IBM #6 on
friction drive shaft.
Carriage
Contact roll bearings IBM #6.
Tape-Read
8 Hydraulic Unit Blower Motor
(2 oil cups) IBM 116.
6-8 line Drive Apply
light fi 1m Lubriplate '70 on active
surfaces of all gears, shiff fork, camming
plate, and detent wheels.
Apply IBM #6 on
the detent arm pivots and rollers.
Lubricate
whenever this area is entered on a service
call.
7 Frame T-Casting Use I ight film Lubriplate
'70 on active
Phenolic Support surfaces
of gears, sl ides, guides, and levers.
Chock Use
IBM 116 on bearings, bushings, and
pivots.
* Lubriplate is a Trademark of Fiske Bros. Refining Company
Clean armature backstops
Check for loose hammers and magnet coils.
before applying IBM 116.
Check for worn hammer-magnet residuals
and worn armature pivots.
Check that pushrods are free and straight.
Check that armatures, hammers, and forms
compressors
are free to pivot.
Replace Do not allow strip to wear through.
Replace blower air-filter
as necessary •
Perform off-cartridge
Check for correct chain tension.
chain cleaning
Scope drum head output (ground to one side
of read head) • Should be 50-150 mv.
Adjust
head-to-drum clearance as necessary.
Mod 6 - 40-150 mv •
Scope disk
head output for 50-150 mv. (on
leg to ground).
Adjust head to disk gap
to .001" to .002". (Do not go more than
.002").
Check that grease is lubricating all gears.
Check tractor adjustments as required.
Clean as necessary
Check for broken friction springs.
Check
for wear on friction drive roll.
Clean contact rolls Check tape brushes for bent or broken
strands. Check brush tracking and all
stop brush timings to E-l •
Check timing belt tension. When leakage
is apparent, check for correct hydraulic
fluid level (approximately to bottom of
coils).
Check 6-8 line detent retaining collars
for loose setscrews.
Check for wear and binds.
Check
adjustments.

5. Check for fluid in the hydraulic reservoir (1 gallon,
part 477567).
6. Install the signal cable shoe-connectors (SC-1 and
SC-2) in the proper receptacles. Connector SC-1
has gold-plated contacts and should be inserted
into the front receptacle.
On the Model 3, remove the cartridge blower
hose to permit insertion of SC-1, after which you
must reconnect the hose.
7. Install two antiwalk feet.
8. Assemble the forms-cart right- and left-grounding
guide assemblies.
9. Check all terminal-block safety shields for warp-
age before turning machine power on.
10. To insure correct machine performance, it is most
important to check the .100" spacing between the
cartridge and the hammer unit on the Model 3
printer (Figure 2). This is a critical dimension. If
it has shifted during shipment, print quality can be
drastically affected. Check this adjustment care-
fully
at both ends and readjust if necessary. (Refer
to Figure 18 for other models.)
Line Voltage Wiring Check
Before connecting the power plug to the printer:
!. Determine actual customer line voltage being sup-
plied. If a
change is necessary, proceed with steps
2 and 3.
2. For line voltages nearest to 208 volts:
a. Place
the chain-drive-motor machine cable on
terminals TB-7-1, 7-2, and 7-3. (TB-7 is on the
T-casting, to the right of the chain-drive motor,
under the chain cartridge and under the ribbon.)
Train Type Slug
Locating Block
. 100"
Figure 2. Train-to-Hammer Unit Positioning
8
b. Place one ac lead for the elapsed time meter on
terminal
4. The other ac lead will remain on ter-
minal!. The ac terminal block is inside the meter
cover. To check or change these ac line connec-
tions requires a
retainer (part 740489).
3. For line voltages nearest to 230 volts:
a. Place the chain-drive-motor machine cable on
terminals TB-7-4, 7-5,
and 7-6.
b. Place one ac lead for the elapsed time meter on
terminal
5. The other ac lead will remain on ter-
minal1.
Three-Phase Motor Rotation Check
1. \Vhen the system is ready, turn on the system
power,
with the T-casting open.
2. Check carriage-motor rotation by observing the ro-
tation of the forms stacker rolls. Correct rotation
causes paper to stack properly. An mM card placed
between the rolls before power is turned on will
give an immediate indication of stacker roll rotation.
The card should eject downward.
3. Close the T-casting and check the direction of the
rotation of the type-train drive motor. The motor
rotation is correct if the train moves counterclock-
wise
when viewed from the top.
4. :Make sure the hammer unit blower is blowing air
normally into the hammer unit. Some air flow will
be felt even if the blower is turning in the wrong
direction. Also, make sure the type-train blower is
blowing air.
5. Turn off the system power. Do not use the mainline
CE switch on the 1403 (toggle switch inside rear
cover). This switch should be used only if the sys-
tem
power is off.
6. If all three-phase motors are rotating in the correct
direction,
proceed to System Check-Out. If one
motor is rotating incorrectly, go to step 7. If all
motors are rotating incorrectly, proceed as follows:
a.
Turn off the system power.
b.
Tum off the power to the wall receptacle.
c. Reverse any two leads at the wall plug, or at the
system power-input circuit breaker .
d.
Tum on the system power and recheck the motor
direction.

7. If one of the three-phase motors is turning in a di-
rection of rotation
that is incorrect:
a.
Tum off the system power. (Pull the power-plug
out of the printer.)
b. Interchange any
two of the three leads of the
motor.
c. Turn on system power and recheck motor rota-
tion.
Carriage Control-Tape Brush Timing
Check the dynamic adjustment of the carriage tape
brushes using a tape punched on the customer's tape
punch. Refer to Dynamic Adiustment of the Carriage-
Tape Brushes.
System Check-Out
1. Check for the correct operation of all printer inter-
locks:
Gate (T-casting)
Brush
Shift (6-8 line)
End of fonns
Fonns check
Thennal
Observe lights on both printer indicator panels
while actuating interlock switches.
2. Check and record the read-head output on one of
the oscilloscope waveform charts (see Figure 110 in
the Appendix). It can then be retained for future
reference.
The output should be 50-150 millivolts
for
each leg.
Scope between dc ground (pin J) and pins B and
D of SA-1 for this reading (see Figure 92). The
phasing of the PSS pulses to the differential ampli-
fier in the system is extremely important. This can
be checked by syncing internal-plus on the output
of the differential amplifier, and observing several
pulses.
The phasing of the PSS pulse is correct if the
differential-amplifier output pulse is stable and has
a rise time of less
than .5 microseconds. A waterfall
effect is permissible
at the trailing edge of this out-
put. (Refer to Timing Disk Transducer Adiust-
ments.)
Note: Reversal of the transducer leads will alter the
length of the output pulse.
3. If the printer is being installed with an existing sys-
tem, or is a field merge, or field interchange,
the
carriage control circuits for single-, double-, and
triple-spacing must be adjusted. (Refer to section on
Single-Shots.)
4. Give the printer a complete operational test, using
test decks 2000, 2010) 2012
and 2020.
Process ~eter Test
All printers are equipped with a process meter. This
meter will record time if the system processing unit
meter is recording, and if a first print instruction has
been received by the printer from the system. A stop
condition
is established when the printer space key or
restore key
is manually operated and released, or when
the system processing meter stops recording. However,
as long as
the space or restore key is held down, the
meter will record time, provided the system processing
unit meter is also recording time. The printer meter
stops when the space or restore key is released.
Once started, the printer meter starts and stops with
the system start and stop keys, regardless of the pro-
gram function, provided no printer stop condition
occurs.
Check
the printer process meter to see whether it
is functioning properly. Use the following test pro-
cedure:
1. Enter at address 444 the instruction 2B449H445_.
This will print one line and branch to a loop, which
will keep
the process M (- U) line active, although
the printer will not continue to print.
2. Operate the system start and stop keys. Note that
the printer meter starts and stops under control of
the system start and stop keys although no printing
is taking place.
3. With the printer meter running (because the pro-
gram is operating in a branch loop), press the space
key
and hold it down. The printer meter should not
stop recording.
4. Release the space key, and the printer meter should
stop.
5. Restart the program at address 444, and make sure
the restore key, when operated and released, stops
the printer meter while the system meter continues
to run.
9

Service Procedures
Cover Removal
Top Cover
1. Remove the front cover.
2. Remove
the rear cover.
3. Loosen,
but do not remove the mounting screws at
the rear of the top cover.
4. Tilt the cover down until the left and right stay
arms can be unhooked.
5.
Unhook the stay arms.
6. Lift the cover, and free it from the rear mounting
screws.
7. Replace in reverse order.
Top Forms Guide
1. Lift the front cover.
2.
Snap the top forms guide out of the front plastic
supports.
3. Raise
the front end of the guide.
5.
Unhook the rear end of the guide at the right.
6. Slide
the guide off the left rear stud.
7. Remove the guide.
8.
Replace in reverse order.
Front Cover
1. Raise the cover.
2. Compress
the spring on the stay-arm stud and move
the stud to the right.
"" ,....., -1. .1 • -1.1 ., 1 .1 •
v. .lIn: {ue cover up unn1 Ine sma Clears tne sray-arm.
4. Remove the retaining clip and slide out the hinge
pin.
5. Slide the cover to the right and off the left pivot.
6. Reinstall
the cover in reverse order.
Left Front Cover Panel
(Model 3 and Numeric Printers Only)
Pull the bottom of the panel (Figure 3) forward until
it clears its snap latch, then pull downward until the
10
top of the cover clears the two locating pins that go
through the holes in the top of the panel.
To replace, slide the cover upwards, guiding the lo-
cating pins through the holes in the top of the panel.
When the panel is up all the way, push the bottom to-
wards the rear of the machine until it snaps into place.
Inner Front Cover
1. Remove the following knobs:
a. Manual-clutch
and line-selection knob.
b.
Forms-width vernier knob.
c. Manual-advance knob.
2. Remove the CE indicator panel on the inner front
cover.
3. Remove
the inner-front-cover holding screws.
4. Remove the cover.
5. Replace in reverse order.
Top Cover Adiustment
(Printers without Torsion Bars)
Adjust the spanner-type nut on the stay arms for cor-
rect spring tension. The tension is correct if the cover
just closes by its own weight to a point where it aligns
with the shelf on the upper-left cover assembly. The
,"~~n:~~ nh~ •• l...l _nn •• __ L1..._L L1... _ L___ _ ___ _ '11 •
I.C;U.3.lVU .3UVU.lU i:l::>::>Ule:; Uli:lL LHe:; lUJ:.' cuyer Wlli remam
open in the raised position.
Figure 3. Left Front Cover Panel Removal/Replacement