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.

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

~

CODE

LOCATION

FREQ.

U R OPERATION

~

0

Chain

~

& 1

<

m

~

-

~

[

m Train

=

~

(Mod.

3)

=

n

m

=

c

C 2 Ribbon Drive 2

~

Mtr.

m

sf

~

5 Ribbon 3

Reverse

~

0

~~

~a

~

Ribbon Drive

Unit

~

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

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

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

ficient

lubrication.

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.

~

~.

~

a

~.

~

e.

a

(t)

t:l

$l:>

t:l

n

(t)

~

§

g.

(t)

..-..

s;

~

......

....

o

~

-;:a

$l:>

::+

to

o

....,

~

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

Lock

Lever

Figure 4. Translator Frame Lock Lever

Manual Controls:

Adjustment

Translator Lock-Lever

The

lever

must

operate

with

a positive locking action

when

a force of four to seven pounds is applied

at

the

center of

the

knob

and

perpendicular to

the

handle.

Adjust as follows (Figure 4):

1.

Loosen

the

translating-frame gib locknut.

2.

Loosen

the

frame locking setscrew for gib-to-tie-bar

clearance.

3.

Lower

the

lock lever to

the

fully-locked position

and

recheck for gib-to-tie-bar clearance.

4.

Press

the

locking mechanism to

the

rear

of

the

machine while holding

the

locking roller squarely

against

the

tie bar.

5.

Turn

the

frame locking setscrew finger tight.

Note: Make sure

the

locknut

is

not against

the

lock block.

6.

Tighten

the

setscrew 900 to 1500•

7.

Tighten

the

locknut.

Translator Vernier Knob

Set

the

vernier to provide a movement of

~"

(±

J{l').

1.

Clamp

the

translator vernier knob against

the

shoulder of

the

vernier screw (Figure 5).

2.

Position

the

right retaining collar against

the

knob,

and

clamp

the

collar to

the

vernier screw.

3. Position

the

left retaining collar so

that

a total

end

play of .0005" to .002" exists

between

the

two col-

lars

and

the

translator-lock lever,

and

clamp

the

collar to

the

vernier screw.

Note:

On

late machines, the left collar

is

pinned. Adjust

this clearance

by

using

the

right collar.

4.

Tighten

the

setscrews in

the

translator-frame

bear-

ing to provide a slight

drag

on

the

vernier screw.

Locking

Roller

Tie

Bar

Setscrew

Gib

Apply Loctite* sealant to

the

setscrew threads if

this adjustment is made.

Vertical Print-Alignment Knob

1.

Position

the

eccentric shaft (Figure 6).

a.

The

slot in

the

right

end

should

be

parallel

with

the

slot

in

the

sector-gear hub, within

"44".

b.

Further

adjustments

may

require

that

this

be

altered.

2.

Position each ball-detent barrel to

the

periphery of

the

sector gear:

a.

For

clearance throughout full gear rotation.

b.

For

maximum clearance of .008".

Note:

When

installing a new ball-detent barrel, insert

the new barrel from the sector-gear side of the mounting

block. This method avoids stripping off too much locking

material on initial installation.

*Loctite

is

a product of the American Sealant Company

Translator

Frame

Figure 5. Translator Vemier

I •

'N

loOk

51.evo

Translato~((l;;)

Lock Lever

~~

R;ght Coilo,

/"

~

Translator

Vernier

Knob

11

Vertical Print

Alignment Knob

~r~--Clamp

Slot

Figure 6. Vertical Print-Alignment Knob

3. Lock

the

translator frame.

4.

Check

for a

bind

between

the

bottom

of

the

vernier

screw

and

the

lock sleeve of

the

translator vernier

(see

Figure

5).

a. Raise

the

translator frame to its

uppermost

po-

sition.

b.

Tum

the

translator vernier

knob

to

detect

a bind.

5.

If

a

bind

is

not

detected,

proceed

to

step

7.

6.

Remove

the

bind

between

the

bottom

of

the

vernier

screw

and

the

lock sleeve of

the

translator vernier.

a. Loosen

the

clamp screws in

the

sector-gear

hub.

b.

Tum

the

eccentric shaft counterclockwise

until

the

bind

is eliminated.

c.

Tighten

the

clamp screws.

7. Adjust

the

sector-gear stop screw:

a.

For

a minimum clearance of

~"

between

the

translator frame

and

the

printer

casting.

b.

For

a minimum clearance of

~2"

between

the

lower

edge

of

the

sector gear

and

the

printer

casting.

Print-Timing Dial

(Models 1, 2, 4,

5,

and

6)

1. Place 4-part

paper

in

the

machine.

2.

Load

all H's, W's,

or

M's into storage for printing.

3.

Program

for

PRINT

AND

BRANCH.

4. Select 8-lines-per-inch carriage

mode

and

set

the

print-densitylever

at

C.

12

5. Set

the

print-timing dial at:

a. 20 for Models 1

and

2.

b. 15 for Models 4

and

5.

c.

11

for Model

6.

Assume 4-part

paper

is .012" thick.

If

a microme-

ter

is available,

it

is advisable to determine

the

exact thickness

and

set

the

timing dial

to

the

correct

number

as

determined

from

the

chart

on

the

ribbon

cover.

Note:

There

are three different

print

timing dial charts:

Timing chart decal (part 475644) for Models 1

and

2

Timing chart decal (part 865912) for Models 4

and

5

Timing

chart

decal (part 889623) for

the

Model 6.

6.

Run

the

machine for

ten

to

twenty

lines.

7.

Examine

the

fourth copy. A faint

smudge

will

be

visible showing

the

outline of

each

hammer.

The

relative position of

each

printed

character

to

the

hammer

can thus

be

examined

and

evaluated.

8.

Adjust

the

timing-dial screw (Figure 7) until

the

maximum

number

of

printed

characters is centered

on

the

hammer

impression marks. Maintain

the

dial

setting of:

a,

20

for Models 1 and

2,

b. 15 for Models 4

and

5.

c.

11

for Model 6.

9.

Individual positions

are

adjusted

for centering

by

the

hammer-magnet eccentric adjusting tool (part

451123).

Note:

It

may

be

necessary

to

compromise this adjust-

ment

to obtain acceptable print density.

If

the

correct ham-

mer

flight time

and

print density cannot·

be

obtained, a

new

hammer-magnet assembly should

be

installed.

Forms-Width Vernier

1.

Adjustment

procedure:

a.

~fove

the

translator frame to

the

left.

b. Remove knobs.

d. Remove

the

gear

guard.

e. Locate

the

left

forms tractors in

the

correspond-

ing extreme left slots

in

the

tractor mounting

bars.

f.

Locate

the

right

forms tractors

in

the

corre-

sponding extreme

right

holes in

the

face of

the

removable slides.

2.

Adjust

the

left

tractor-pinfeeds horizontally.

a. Place a straight

edge

along

the

feeds

to

check

alignment.

,.

Figure 7. Print-Timing Dial Adjustment

b. Shift the tractor mounting bars to align the pin

feeds within .005". There are two screws in each

end of each

bar

(Figure 8).

Figure 8. Tractors (T-Casting Removed)

c.

Keep the left horizontal surface of the lower

mounting

bar

against the corresponding horizon-

tal lip of the printer casting.

The

upper mount-

13

ing

bar

is positioned

up

and

down

by

an

eccentric

washer on

current

machines.

The

upper

and

lower

mounting

bars

must

be

paralle1.

3. Adjust

the

right

tractor

feeds.

a.

Orient

the

horizontal adjusting screws, horizon-

tal-drive collar,

and

gear

to align

the

right

feeds

within

.005", horizontally.

b. Place a

straight

edge

along

the

feeds to

check alignment.

c.

Reposition (if necessary)

the

horizontal adjusting

screws in relation to

the

conars

and

gears to ob-

tain

adjustment.

d. Position

the

collars

and

gears for a maximum

end

play of .002".

4.

Operate

the

forms-width vernier

with

light finger

force. Adjust

the

friction scre\v

and

block as re-

quired.

5.

After this

adjustment

has

been

made,

adjust

the

vertical position of

the

right

ends of

the

upper

and

lower tractor

mounting

bars

for free

movement

of

tractor

assemblies.

Manual-Clutch

and

Line-Selection Knob

1.

Preliminary

procedure:

a. Move

the

translator frame to

the

left.

b. Remove knobs.

c.

Remove

the

front inner cover.

d. Remove

the

gear

guard.

2.

Check

the

adjustment

of

the

manual

clutch

and

the

line-selection-knob assembly

(Figure

9).

a.

Check

for clearance:

(1)

For

a minimum-end

piay

of

the

dentent

arms on

the

shaft.

(2)

For

a minimum of .025"

between

the

detent

roller

and

the

detent

wheel

when

the

detent

is inoperative.

(3)

Between

the

tines of

the

shift fork

and

the

shift-

gear

hub.

b.

Check

for alignment of

the:

(1)

Detent

arms to

the

slots in

the

camming plate.

(2)

Detent

wheels to the

detent

arms.

c.

Check for correct operation to

make

sure that:

(1)

The

clutch shifts from 6-line

neutral

to

6-line drive

and

from 8-line neutral to 8-line drive.

Figure

9. Manual-Clutch

and

Line-Selection Assembly (Lower

Tractor

Shaft Removed)

14

(2)

The

detent

ann

spring causes correct operation of

the

detent

anns

and

wheels (there should

be

a force of

4!1

to

6!1

pounds

on

the

detent

ann).

(3)

The

detent

arm

roller seats fully in

the

detent

wheel

when

the

detent

is operative.

3.

If the conditions in step 2 are met, no further ad-

justment

is

necessary. Proceed to step

11.

If

not:

a.

Unhook the detent-arm springs.

b. Loosen both the

detent

wheels.

c.

Slide the right detent wheel to

the

right.

d. Loosen the detent-arm collars.

e.

Slide the detent arms to

the

left.

f.

Loosen the camming plate on the shift fork so

that

the plate

is

justfree to slide.

g. Loosen the setscrew

that

holds the camming-

plate roller stop rod.

h. Wedge some

paper

between

the

shift-fork tines

and the hub of

the

shift gear to center the tines

around the shift-gear hub.

4.

Position

the

shift fork on

the

shift rack for gear

mesh and clearance.

a.

Detent the shift rack in 6-line drive

at

the right.

b. Position the shift fork on the shift rack

so

that

the shift gear meshes with the 6-line driving

and

driven gears

and

has clearance to the casting.

c.

Rotate the shift fork around the shift rack to

center

the

shift fork around the shift-gear hub.

d. Clamp the shift fork to the shift rack.

5.

Align the detent arms to the camming plate.

a.

Set the shift gear to 6-line drive position.

b. Align the detent arms with the left two slots in

the camming plate.

c.

Tighten the collars to hold the detent arms in

position.

6.

Adjust for a clearance between the detent wheels

and the detent arms of .025" with the manual

clutch in either

6-

or 8-line drive.

a.

Turn

the

6-

and

8-line gear idler to a position

where

it

does

not

move when the shift gear

is

shifted from the 6-line drive to the 8-line drive,

or vice versa.

b. Set the shift gear to the 8-line neutral position.

c.

Slide the right detent wheel opposite

the

right

detent arm.

d. Use a

rubber

band

to hold the right arm against

the detent.

e. Adjust the camming-plate roller stop rod to

provide a .025" clearance between

the

detent

arm

and

the

teeth of

the

right

detent

wheel.

f.

Tighten the setscrew to hold the camming-

plate roller stop rod.

g.

Rehook the springs on the detent arms.

h. Clamp the camming plate to the shift fork.

7.

Align the detentwheels to the detent arms.

a.

Set the manual clutch to 8-line neutral.

b. Align the left detent wheel to the left detent

arm.

c.

Clamp the left detent wheel to

the

tractor shaft.

d. Set the manual clutch to 6-line neutral.

e.

Align the right detent wheel to the right detent

arm.

f.

Clamp

the

right detent wheel to the tractor

shaft.

g.

Check the operation of the manual clutch for

four manually operated spaces.

h.

Readjust as necessary.

8.

Set the spring tension to provide

4!1

to

6!1

pounds

force on

the

detent arm when

it

is

engaged in the

detent wheel.

9.

Remove the

paper

from between the shift-fork

tines

and

the shift-gear hub.

10.

Position the clutch-interlock switch.

a.

The

switch must transfer before the plunger

completely clears all of the four grooves of the

shift rack.

Note:

The

switch operating

plunger

must

have a

minimum of .005" clearance to

the

rack grooves

when

detented.

b. Position the switch to obtain this adjustment.

11.

Replace the remaining parts in reverse order.

Forms Positioning

Tractor Shafts

and

Tractor Mounting Bars Removal

This procedure is given for the removal of

the

upper

and

lower tractors,

the

tractor mounting bars,

and

the

drive shafts.

If

only one set

is

to

be

removed, do only

as much of each step

as

will allow the desired set to

be removed.

1.

Remove the forms.

2.

Remove the clip-on

paper

guides from

the

tractor

mounting bars.

3.

Remove the inner front cover.

4.

Remove the

upper

and

lower forms-guide bars with

the jam bars attached (early machines only).

15

5. Remove

the

jam

contact mountings from

the

tractor

mounting bars (early machines only).

6.

Remove

the

wires from

the

form-stop contacts

at

the

terminal block.

7. Shift

the

T-casting to

the

left.

8. Remove

the

gear guard.

Separate

the

vertical shaft of the forms-width vernier

by

loosening

the

setscrews in

the

vertical coupling of

the

forms-width vernier. Move

the

vertical coupling

up

onto

the

upper

shaft

and

lock

it

to

the

shaft.

Remove the bearing retaining castings. See Figure

8.

l.

Loosen

the

screws

that

prevent

bearing

end

shake

(at

the

right).

2.

Remove

the

two bearing-holding screws (at

the

right) for each

bearing

retaining casting.

3. Shift

the

T-casting to

the

right.

4. Remove

the

two holding screws (at

the

left) for

each bearing retaining casting (one screw is a

dowel).

5. Remove

both

bearing retaining castings.

Remove the tractor mounting

bar

and

the

tractor

shaft.

l.

Remove

the

two screws

and

the

slide-retainer

plate

at

the left

end

of one of

the

tractor mounting bars.

2.

Remove

the

two holding screws

at

the

right

end

of

the

same tractor mounting bar.

3. Lift

the

tractors,

the

mounting bar,

and

the

shaft

out

and

to

the

left to clear

the

T-casting.

Repeat step 5 for

the

other assembly.

Individual

Pin-Feed

Removal

l.

Open

the

T-casting.

2.

Remove

the

forms.

3.

Open

the

tractor door.

Remove

the

tractor

paper

guides.

l.

Remove

the

tractor

paper

guide farthest from

the

hinge of

the

door.

2.

Remove

the

tractor guide on

the

other side of

the

feeds.

16

Align

the

pin-feed holding pins

with

the

slot in

the

frame spacer plate (the

end

nearest

the

drive shaft)

Figure 10).

l.

Turn

the

tractor shaft until one holding

aligns

with

the

slot.

2.

Use a similar

to

push

the

installed

toward

the

center of

the

machine

(part

804671).

3. Repeat step 2 for

the

second holding pin.

Remo\rc

the

feed

by

lifting.

Insert

the

ne,:l,'

feed.

Replace

the

pin-feed holding pins.

1.

Insert

the

second pin.

2.

Tum

the

tractor shaft until

the

first holding-pin

hole is aligned

with

the

slot.

3. Insert

the

first pin.

Note: Pins

are

to

be

flush

or

slightly recessed.

Replace

the

tractor

paper

guides in reverse order

(see

Forms-Tractor Adiustment).

Forms-Tractor

Adiustment

Adjust

the

belt

tension.

1.

Maintain parallelism

between

the axes of rotation

of the drive sprocket

and

of the movable sprocket

(Figure 11).

2.

Position the movable-sprocket

stud

for a minimum

slack

at

the

point of tightest engagement.

a.

Ensure

that

belt

tension

is

not excessive.

b. Tighten

the

sprocket stud.

Position

the

beveled

ramps.

1.

The

point

of

the

ramp

must point in

the

direction

opposite to the

belt

motion.

2.

Position

the

ramp

for a clearance of .002" to .007"

to

the

respective sprocket hub,

3.

Clamp in position.

Position the tractor

paper

guides.

l.

Align

the

edge of

the

paper

guide nearest

the

door

pivot

plate

Hush to

the

pivot plate.

2.

Position

the

under

side of

the

paper

guide

Hush

against

the

edge of

the

spacer plate.

Figure 10. Tractor (Upper Left)

3.

With

the

conditions

in

steps 1

and

2 established,

secure

both

paper

guide

and

mounting block with

their front surfaces

Hush

to the front edge of

the

spacer plate.

4.

Position

the

lower edge of

the

adjacent

paper

guide

against the lower edge of

the

paper

guide nearest

the door pivot, maintaining the

upper

edges par-

allel. Check

that

the

inner edges of the guides are

clear of the pins.

5.

Fasten

the

adjacent

paper

guide to

the

tractor

frame.

Position

the

tractor door for a clearance of

paper

guide plates to the door runners of .048" to .056"

(Figure 12).

1.

Loosen the pivot plate.

Note:

The

Loctite sealant must

be

used on

the

threads

of

the

holding screws if this adjustment

is

made.)

2.

Screw

the

door stop in below

the

correct door

setting.

3.

Insert two sets of feeler gages

with

the

correct

setting.

17

Figure 11. Tractor Assembly

4.

Force

the

door against

the

feeler gages.

5.

Tighten

the

pivot plate.

6.

Set

the

door stop to hold

the

door

at

the

correct

clearance.

Pivot Plate

Mounting Screws

Figure 12. Tractor Door Clearance

18

Cover Stop

Set Screw

form-stop lever

is

within

~l'

of

the

front surface of

the

paper

guide.

Tractor-Mounted Jam-Detection Device Adiustment

Some additional adjustments

are

applicable to forms

tractors

that

have

tractor-mounted jam-detection de-

vices.

1.

Adjust

the

jam-detection setscrew so

that

the

jam-

detection switch breaks

when

the

door is opened a

total of .095" to .118" (Figure 13).

2.

Adjust

the

slide

support

plate

to

limit

the

tractor

door

open

position. Place a straight

edge

against

the

belt-guide

step

perpendicular

to

the

tractor

guide

plate

as shown in

Figure

14. Adjust

the

slide

support

plate

to

obtain

~"

±

~"

clearance

between

the

door

and

the

straight edge. Be sure

to

maintain

proper

belt

tension

when

tightening

the

plate

hold-

ing nut.

Upper and Lower Tractor Drive-Shaft Positions

First, check

the

forms-width vernier.

Prepare

to adjust

the

drive shafts.

1.

Position

the

left forms tractors

in

the

corresponding

slots in

the

tractor mounting

bar.

()

.095"-

.118"

Door Opening

Figure 13. Jam-Detection Switch Adjustment

2.

Position

the

right fonns tractors

in

the

correspond-

ing holes

in

the

face of

the

movable slides.

3.

Place a

fonn

in

the

fonns tractors.

Check

the

position of

the

upper

drive shaft to

the

lower tractor drive shaft.

The

fonn

must fit in

the

trac-

Straightedge

b

~h

3/32"

~

1/32"

C.~_

.....

~~'./

Figure 14. Tractor Door Opening Limit

tors with a minimum slack in paper.

Feed

the

forms

manually

and

check for no elongation of

the

pin-feed

holes (this may occur

under

power).

The

upper

tractor pins should touch

the

upper

edge

of

the

feed holes in

the

form.

The

lower tractor.

pins should touch

the

lower edge of

the

feed holes

in the form.

If

fonns are tighter

on

one side

than

the

other, ad-

just

the

left

end

of

the

upper

mounting

bar

by

means

of

the

eccentric washer (on current machines). See

Figure 8.

If

necessary, adjust

the

upper

tractor shaft drive in

relation to

the

lower tractor drive shaft.

1.

Loosen

the

upper

tractor shaft drive gear.

2.

Manually rotate

the

shaft to remove slack.

3.

Clamp

the

drive gear to

the

shaft.

Replace any remaining parts in reverse order.

Tractor Installation

This procedure refers to

both

the

upper

and

the

lower

assembly. Place

the

tractor shaft

and

the

mounting

bar

in

relative positions on a flat surface.

Install

the

tractors on

the

drive shaft.

1.

Slide

the

drive shaft through

the

square drive

hub

on

the

right tractor.

2.

Turn

the

left tractor drive until

the

pins line

up

with

those on

the

right tractor and,

at

the

same

time,

the

drive

hub

lines

up

with

the

drive shaft.

Note: These pins line

up

at

only one point during one

revolution of the drive shaft.

3.

Slide

the

drive shaft through

the

square

drive

hub

on

the

left tractor.

Install

the

tractors

on

the

mounting bar. Slide

the

mounting

bar

through right

and

left tractors.

Tractor-Shaft

and

Mounting-Bar Replacement

Place

the

tractors,

the

mounting bar,

and

the

tractor

shaft in

the

machine.

1.

Set

the

assembly in

the

machine.

2.

Insert

the

screws in

the

slide retainer

plate

and

the

mounting

bar

at

the

left

and

turn

the

screws in a

few turns.

3.

Insert

the

holding screws

at

the

right

end

of

the

mounting

bar

and

turn

in

until nearly snug.

19

Repeat for

the

other assembly.

Install

the

bearing retaining castings.

1.

Slide

the

bearing and bearing retainer ring in posi-

tion.

New

machines do not have

the

bearing re-

tainer ring.

2.

Place the bearing retaining casting in position.

3.

Insert

the

two right holding screws

and

tighten un-

til almost snug.

4.

Insert

the

two left holding screws

and

tighten.

5.

Snug

up

the bearing-end screws.

6.

Tighten the right bearing-retaining casting-holding

screws.

7.

Tighten

the

bearing-end screws.

Repeat this step for

the

other assembly.

Position

the

tractor mounting bars.

1.

Slide

the

tractors

apart

to extreme positions.

2.

Position

the

tractor mounting bars against

the

lip

and

eccentric washer on the printer casting

at

the

left.

3.

Shift

the

mounting bars horizontally to vertically

position

the

left tractor pins on the

upper

mountLl1g

bar

within .005" of the left tractor pins on

the

lower

mounting bar. Use a straightedge laid along

the

tractor pins for determining vertical alignment.

Connect the vertical shaft of

the

forms-width ver-

nier.

1.

Loosen

the

setscrews

in

the

vertical coupling

and

slide into engagement with

the

upper

and

lower

shaft.

2.

Clamp

the

coupling to

both

shafts.

Perform the following adjustments:

1.

Adjust

the

forms-width vernier.

2.

Position the

upper

and

lower tractor drive shafts.

Replace

the

remaining parts in reverse order.

Tractor Jam-Detection Device Adiustment (Old Style)

This applies to

both

upper

and

lower detection de-

vices of machines

that

are

not

equipped

with

tractor-

mounted jam-detection devices.

20

Check the jam-detection device.

l.

The

jam bail must rest against

both

the

left

and

right tractor doors.

2.

The

rear of the bail mounting brackets must

be

flush to

the

rear of the forms support bar.

3.

When

applied

at

the operating edge of

the

bail, the

bail movement must

be

free.

4.

A force of

~

pound

(225 grams)

must

move the

bail away from

the

tractor door.

5.

The

switch plunger must

be

.010" to .015" past

the toggle point

when

the

bail is resting against the

tractor doors.

6.

The

switch plunger must

be

free of

the

bail when

the tractor doors are opened against

the

forms-

guide support bar.

If

these conditions in step 2 are met, no further

adjustment

is

necessary.

Adjust

the

jam-detection bail.

l.

Loosen

the

bail mounting brackets.

2.

Rest

the

bail against

both

forms-tractors.

3.

Position the

rear

edge of the mounting bracket flush

to

the

real' side of

the

forms-guide support

bar

within .005".

4.

Tighten the mounting bracket in position.

Adjust

the

bail torsion spring.

l.

Loosen the locknut on

the

spring stud.

2.

Turn

the

screw

and

tighten

the

locknut.

3.

Check for a

~

pound

force to move

the

bail away

from

the

tractors.

4.

Readjust as necessary.

Position

the

bail switch.

1.

Loosen the holding screws.

2.

Be sure

the

jam

bar

is against

the

tractor cover.

3.

Locate

the

switch so

that

the switch plunger is

moved

.010"

to .015" past

the

toggle point.

4.

Tighten

the

ho!dLTlg

screws.

Forms-Stacker Assembly Adiustment

For

the gravity-stacking device

and

single-speed

stacker, disregard

the

adjustments

that

are not ap-

plicable.

l.

Stacker tension springs are to

be

adjusted to the

feed rolls to a point of tangency without compress-

IBM 1403 User manual

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