IBM 1402 User manual

,' " ,
il) g5 ~ Customer Engineering
Reference Manual
.I.
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. v
Card Read-Punch
8231-002-5
---- -

Customer Engineering
Reference Manual
~ ~ @ ~ Card Read-Punch

Preface
I
The maint.enance information in this manual pertains
to all models,
1, 2, 3, 4, 5, and 6, of the IBM 1402
Card Read Punch. The adjustments and procedures
affect all models unless specifically identified.
Sixth Edition
This is a reprint of 231-0002-4 incorporating changes released in the following FE Supplement.
Form Number
S31-0150
Pages affected
1-1, 3-2, 3-19, 3-38, 3-39, 3-41,
3-41.2, 3-41.3, 3-41.5, 4-2, 7-1,
7-2.
Date
4/28/67
Specifications contained herein are subject to change from time to time. Any such changes
will be reported in subsequent revisions or FE SupplementS.
Copies of this and other IBM publications can be obtained through
IBM Branch Offices. Address comments concerning the content
of this publication to:
IBM, Product Publications Department, Rochester, Minn. 55901.
o1960, 1961, 1962, 1964 by International Business Machines Corporation

SECTION 1. INTRODUCTION.
Installation Procedure
Specifications
Speed ••
1-1
1-1
1-1
1-1
SECTION 2. PREVENTIVE MAINTENANCE 2-1
SECTION 3. SERVICING PROCEDURES
Read Feed
Timing Belts
Clutched Feed Roll Drive Belt
Reader Clutch. •
Clutch Pulley Assembly.
Clutch Drive Assembly •
File Feed Clutch • •
File Feed Joggler. • •
Hopper and Picker Knives.
Card Weights
Card Guides
Brush Assembly •
Punch Feed
Timing Belts
Timing Belt Adjustments
Punch Feed Clutch •
Geneva
Hopper and Picker Knives.
Card Guides • •
Feed Rolls and Aligner Stations.
Brush Assemblies. •
Punch Unit •••
Cam Follower Assembly •
Interposer and Interposer Link
Interposer Guide Bar •
Interposer Setup Bail.
Latch. ••
MagDet Bar Assembly
Magnet Unit
Punch •• ••
Stripper Assembly.
Transport and Stackers
Chute Blade and Selector Magnet •
Transport Rolls.
Jam Bar •
Stacker
Stacker Joggler •
Electrical Components
Solar Cell CB •
Lamp Assembly.
Solar Assembly. •
Component Card Assembly
Permissive Make Relays
Circuit Breakers • •
PACB
••
MagDetic PA Emitter
Open Strap Contacts.
RT and PT Relay Model 3
Punch Emitter;Model 2.
Power Supplies,Model1
Power Supplies, Model 2
3-1
3-1
3-1
3-1
3-2
3-3
3-4
3-5
3-6
3-6
3-8
3-8
3-8
3-10
3-10
3-14
3-14
3-15
3-16
3-16
3-18
3-24
3-24
3-25
3-26
3-26
3-27
3-28
3-29
3-30
3-31
3-31
3-32
3-32
3-33
3-33
3-33
3-33
3-33
3-33
3-36
3-36
3-37
3-37
3-38
3-39
3-39
3-40
3-40
3-40
3-41
./. 3-41
Motors
Redesigned Punch Feed.
Card Guides
Feed Roll Timing Check •
Feed Roll Adjustments.
Aligner Station Timing Check •
Punch Feed Removals. •
SECTION
4. SERVICE AIDS
Customer Engineering Service Panel •
Punch
Service Switch Panel. •
SECTION
5. SPECIAL FEATURES
51-80 Column Device
Hopper •••
Pocket Selectors
Stackers
Punch Feed Read •
Brushes
Card Guides.
Early Read •
SECTION
6. SERVICE HINTS
Read Feed. •
Start and Run Data Flow •
Stop Data Flow
Reader Stop Lights •
Clutch Failures •
Reader Check Lights
Validity Lights •
Brush
Timing •
Circuit Breaker Timing
Punch Feed. • ••
Start and Run Data Flow •
Stop Data Flow •
Punch Stop Lights •
Punch Check Lights. •
Punch Check Brushes Out of Time
Faulty Punch Registration
Dropping Punches •• ••
Multiple Punches • •
Damaged Cards or Jams in Feed
Stacker. •• • • • • •
Faulty Stacking • •• •
Card Jamming, Transport Area
SECTION 7. LOCATIONS •
SECTION
8. SPECIAL TOOLS ••
Punch Timing Rod •
Timing Mark Gage. • •
Die Card Guide •• •
Interposer Setup Bail Gage
Stepped Feed Roll Assembly Gage
Punch Unit Adjusting Plates
Read Clutch Locating Plate Gage
Punch Unit Squareness Gage
CONTENTS
3-41
3-41
3-41
3-41.1
3-41.2
3-41.5
3-41.6
4-1
4-1
4-1
5-1
5-1
5-1
5-1
5-1
5-1
5-1
5-3
5-3
6-1
6-1
6-1
6-2
6-2
6-2
6-3
6-4
6-4
6-4
6-4
6-4
6-4
6-4
6-4
6-4
6-4
6-4
6-6
6-6
6-6
6-6
6-6
7-1
8-1
8-1
8-1
8-1
8-1
8-1
8-1
'~
8~1
,

IBM 1402 Card Read-Punch

Installation Procedure
1. Remove shipping braces, tape, plastic cover from
relay
gate and blocks under feed shock mounts.
2. If lower magazine throat has two flat springs skip
to Step 3. If the lower magazine throat has a
mirror finish:
a. Remove front and rear covers from sides of
hopper casting.
b. Loosen screw
at bottom of each flat spring and
lift out file feed filler. See Figure I-I.
c. Remove clip from stud on each support plate.
d. Remove tape, holding pivot pins in upper
magazine. Move pins flush with upper maga-
zine slides.
e. Hold upper magazine in vertical position; set
into
lower magazine so pivot pins are under
fingers of lower magazine.
f. Place upper magazine struts on studs. Replace
clips.
g. Slide pivot pins into support plate holes.
h.
Tighten screws.
i. Replace file feed filler and covers.
j. Go on to Step 4.
3.
If the lower magazine throat has two flat springs:
a. Remove two covers from sides of hopper cast-
ing.
b. Loosen screw
at bottom of each flat spring and
lift out file feed filler. See Figure I-I.
c. Remove clip from stud on each support plate.
d. Hook magazine struts over studs
and replace
clips.
e. A split shaft,
held by a set screw, is located
just above file feed drive shaft. Slip both
halves of shaft to center, inside of castiI).g.
f. Put upper magazine in place and slide both
halves of shaft from center so they hold maga-
zine in place. Ends of split shaft should be
flush with end of magazine holes.
g.
Tighten set screw to secure split shaft.
Section 1. Introduction
h. Replace file feed filler.
i. Replace two covers.
4. Examine all relays (without removing) for dis-
placed armatures.
.5. Trip clutches and crank machine by hand, check-
ing for
binding conditions in feeds or card trans-
port.
6. Install shroud 609386 on cable junction box.
7. After installing main line cord through bottom of
machine, check
that cable clamp is fastened se-
curely to
bottom plate of machine.
8. Check power supply voltages at CE Panel.
9. Check covers for proper fit and appearance.
10. Check operation of file feed. Adjust file feed delay
resistor on relay
gate so approximately a two-inch
stack of cards enters
hopper before feeding be-
gins.
11. Run test decks to verify machine operation.
Specil1cations
Speed
READ FEED
Models 1 & 3: Adjust motor pulley for 800 + 3
20 cpm.
Model 2: Adjust motor pulley for 800 ± 15 cpm.
Models 4, 5, and 6: Adjust motor pulley for 450 +2
-15 cpm.
PUNCH FEED
Adjust motor pulley for 250 ± 3 cpm.
1402 CERM (4/67) 1-1

STRUT----~
CLIP--------+~.
SUPPORT- ______ ,.}.
PLATE
STRUJ----"\
CLlP-------;-'ti.
SUPPORT-----"\
PLATE
Figure 1-1. File Feed Tray Mounting
1-2
SET
SCREW
RETAINING SCREW
, ..... ___ FILE
FEED
FILLER
MOUNTING
SCREW
NEW STYLE
OLD. STYLE

The prime objective of any maintenance activity is to
provide maximum machine availability to the cus-
tomer however; adjustments should not be made un-
less necessary.
Section 2. Preventive Maintenance
cracks, burnt contacts, loose connections and clogged
filters.
The three basic steps of preventive maintenance are
to clean, lubricate, and inspect. Figure 2-1 shows rec-
ommended preventive maintenance routine.
Be visually alert for trouble indications any time
you service tbe machine. Look for corrosion, wear, Apply lubrication only in
the quantity necessary to
supply the immediate area involved. Wipe off excess.
CODE
LOCATION
FREQ.
LUBRICATE -CLEAN
OBSERVE
U R
OPERATION
MO.
PUNCH
CLEAN AND VACUUM FEED. LUBRICATE CONTACT AND
BRUSH.fS FOR WEAR AND DAMAGE
FEED
FEED ROLL HANGER PIVOTS, ALL CLUTCH PIVOTS ••• • *9 HUSH TIMING
LOWERING FRAME SLIDING SURFACES AND CAMS
...
•*17
PUNCH REGISTRATION
LUBRICATE GEARS, ALIGNER CAMS. FEED ROLL OPENING
BELT WEAR
CAMS, PICKER KNIFE CAMS, PUNCH CLUTCH LATCH
CAM, EXTENSION SPRING ENDS, PUNCH CLUTCH
4
ARMA TURE LATCH PIVOT. . • • . • . • • • • • • • . . •. '17
STACKER
CLEAN AND VACUUM TRANSPORT. LUBRICATE CARD
BELT WEAR
TRANS-
PUSHER SLIDE CAM FOLLOWERS •••••••••••••.
'9
PORT
LUBRICATE CARD PUSHER SLIDE SPRING ENDS AND CAMS. '17
LUBRICATE STACKER JOGGLER CLUTCH SPRING GREASE
FITTING .•..•••....•.••..••...••••. *20
FILTER
REPLACE IF DIRT IS VISIBLE FROM
INSIDE
0 MUFFIN
MODEL 1: -20V SUPPLY; EARLY
FANS
STAGE 2, 3V SUPPLY
MODEL 2: -20V, +12V SUPPLIES
(ONE FAN), -12V SUPPLY
3
MODEL 3: PUNCH MAGNET
DRIVERS (SMS GATE)
READ
LUBRICATE ARMATURE PIVOT AND LINK .....•.•..•
#6
DETENT PAWL, KEEPER, LATCH,
CLUTCH
LUBRICATE LATCH, KEEPER, LOAD PAWL, DETENT PAWL,
AND RATCHET FOR WEAR
AND INTERMEDIATE ARM PIVOTS ..•••.•..•... #17
EXCESSIVE CLUTCH BACKLASH
LUBRICATE ARM, KEEPER, LATCH, AND CLUTCH RATCHET
WHILE ENGAGED
WORKING SURFACES .•.••••
............
#17
CLUTCH PULLEY SHOCK MOUNT
1
LUBRICATE CLUTCH NEEDLE BEARING AND REVERSE LOCK FOR LOOSENESS
GREASE FITTINGS ..•.....• . ...... .....
#17
READ
CLEAN AND VACUUM FEED.
LUBRICATE FEED ROLL
FEED
HANGER PIVOTS AND ALL OTHER PIVOTS .•..•...
#6
BRUSHES FOR WEAR AND DAMAGE
LUBRICATE GEARS, PICKER KNIFE CAM, EXTENSION
BRUSH TIMING
SPRING ENDS •..•.....••.•••••••• , •.
#17
BELT WEAR
FILE
LUBRICATE CAM FOLLOWER ARM JOGGLER PIVOTS .•..
#9
CLUTCH OVERTHROW
FEED LUBRICA TE ALL OTHER PIVOTS
............. ..
#6
BELT WEAR
LUBRICATE FRONT JOGGLER SPRING ENDS, GEAR FEED ROLLS FOR GLAZE
2 JOGGLER, CAMS, ADJUSTING
SCREW SURFACES,
CLUTCH LATCH CAM SURFACE, SIDE JOGGLER
SIDE RETURN SPRING •.••••.••..•..••...
#17
CLUTCH GREASE FITTING ••••.•••••••••••••
'120
Figure 2-1. 1402 Preventive Maintenance Routine Chart
2-1

LUBRICATE -CLEAN
3
CB'S
LUBRICA TE CB ARM PIVOTS AND ROLLERS .••••••..
PUNCH
SEE NOTE I. REMOVE FELT WICK AT TOP OF PUNCH
UNIT AND LUBRICATE SIX OIL LINES •.•••...•
LUBRICATE LATCH WICK, LINK PIVOTS ••.•••••.
LUBRICATE STRIPPER CAVITY (SEE NOTE 2), LATCH
SPRING, HOOKS, ARMATURE PIVOTS, SETUP BAIL
6 3 CHANNEL,
CAM SURFACES ••.•.••••..•••
LUBRICATE NEEDLE BEARING GREASE FITTINGS, DIE
LOCATING STUDS ..•.•••..••.••..••.
GENEVA FILL GENEVA HOUSING TO LINE IF OIL WINDOW IS
RIGHT OF DRIVE PULLEY ••••.•..••...••.
FILL GENEVA HOUSING TO 1/16" ABOVE LINE IF OIL
WINDOW
IS LEFT OF DRIVE PULLEY .•••••.•••
5 DRIVE GEARS .•.•••.•.•.••••.•••..••.
7
DRIVE FILL DRIVE MOTOR OIL CUPS .••••••.•••••..
MOTORS 6
8 GENEVA
REPLACE GENEVA OIL. •.••••.•.•.•••.•••
12
BASE LUBRICATE COVER LATCHES AND OPERATING SURFACES
NOTE I: WITH THE REDESIGNED PUNCH FEED IT IS NOT NECESSARY TO REMOVE
PUNCH UNIT TO LUBRICATE. HOLES HAVE BEEN PROVIDED IN THE SIDE FRAME SO
ALL GREASE FITTINGS ARE ACCESSIBLE.
NOTE 2: BE SURE GREASE COMES OUT AROUND 1ST AND 80TH PUNCHES.
Figure 2-1. 1402 Preventive Maintenance Routine Chart (Cont.)
2-2
..
OBSERVE
#9
CONTACT CONDITION AND
MOVEMENT
CHECK TIMING OF CB'S CONNEC-
\"
TED TO CE SERVICE PANEL
CHECK CAM FOLLOWER
#9
ADJUSTMENTS
#9
CHECK PUNCH BAIL AND SETUP BAIL
FOR EXCESSIVE WINK. (SHOULD
\ ~
NOT EXCEED .010" IN VERTICAL
11]7
PLANE WHEN CAM FOLLOWERS
ARE HELD TIGHT AGAINST CAM.)
'#20
CHECK TOP OF 80-MAGNET CORES
FOR DIRT OR RUST
CLEAN IF NECESSARY
CHECK GEAR WINK CLEARANCE
#9
CHECK FOR EXCESSIVE INTERNAL
BACKLASH IN THE GENEVA
#9
MECHANISM ON AT LEAST TWO
#17
INTERMITTENT CYCLES BY HOLD-
ING THE INPUT PULLEY AND
ROCKING INTERMITTENT ROLLS
BACK AND FORTH. CHECK FOR
LOOSE PINS
#9
#9
#17

Read Feed
Timing Belts
All read feed belts, except the clutched feed roll drive
belt, captive on some machines, are easily replaced
and require no timing.
ADJUSTMENT
Belt, pulley, bearing, and shaft life will be increased
if correct belt tension is maintained.
The one pound
(450 grams) pressure indicated in Figure 3-1 can be
measured by using gram gage 450459 and X10 blade.
When using the gram gage, the pointer must be as
Section 3. Servicing Procedures
near the midpoint of belt width as possible.
Clutched Feed Roll Drive Belt
This procedure is necessary only if the belt is captive.
REPLACEMENT
1. Remove solar cell unit.
a. Remove plastic cover, disk mounting screw,
and disk.
b. Loosen three set screws in solar cell mounting
plate. These screws retain the mounting plate
to three spacer studs mounted in machine side
frame. Carefully remove solar cell unit,
and
allow it to swing out of working area.
FILE FEED DRIVE
3" 111
~±~
CONTACT
ROLL
MODEL 2 ONLY
1 LB.
DRIVER
1 LB.
CONTACT
ROLL
Figure 3-1. Reader Timing Belt Adjustmeri~
111 1"
-±-
8 32
DRIVER
~
1" ,"
-±-
4 32
JOGGLER DRIVE
3 If 1"
16±'32
3-1

2. Loosen idler pulley. Install belt and tighten with
idler pulley.
3. Loosen picker knife camshaft drive pulley.
4. Trip clutch by hand and turn index to 2160 for
three-group brushes, or 2120 for two-group
brushes. Place card against first feed rolls, and
manually turn picker camshaft in normal machine
direction until feed knives touch card. Tighten
pulley locking screws. This
is a reference point.
Check brush timing with timer index, .and shaft
picker camshaft to get proper timing.
NOTE: Any change in picker knife timing will
directly affect RLCBs and solar CB.
5. After brushes are in time, reinstall solar cell unit.
a. Remount solar cell mounting plate
Hush
against shoulder of three studs and tighten
three set screws, located in mounting plate.
b. Reinstall disk, and slightly tighten mounting·
screw. Be sure disk is located in center of solar
cell mounting block.
If care has been taken in
removing
and reinstalling cell unit and'disk,
it will be located in same place (in reference
to cell mounting block)
as it was originally.
See Figure 3-2. .
6. To retime solar cell, refer to Electrical Compon-
ents, Solar Cell CB, Timing Procedure.
7. At this point, it may be advisable to time RLCB~s
to ensure proper tolerance.
Reader Clutch
Adjustments of the reader clutch are the sam~on all
models.
Modell, with Early Read special fea-
ture, uses a six.-tooth ratchet clutch. The Early Read
feature
is standard on the Model 3, 4, 5, and 6. A
two-tooth ratchet
is used (standard) on other models.
Caution: Be sure the clutch is latched up when you
finish working on it. Nipping and possible machine
damage will result
if the clutch is not latched.
The reader clutch can be adjusted either in machine
or when clutch drive unit
is removed. Steps 1-4 should
CELL MOUNTING
BLOCK
'---tt- ........ _-- CENTERED
IN SLOT
Figure 3-2. Disk Centering
3-2 (4/67)
be performed only when a new clutch assembly is in-
stalled, or when complete adjustment is to be made
to center plate assembly
and clutch magnet assembly.
When a complete adjustment
is to be made, the read
clutch locating plate gage 610147 must be used.
NOTE: Use of this gage will ensure a parallel con-
dition, at latch-up time, between drive arm latch sur-
face and latch. If adjustments are to be made only to
the armature, latch,
and magnet, begin at Step 5.
ADJUSTMENTS
1. Remove clutch pulley assembly. See Clutch Pul-
ley Assembly, Removal.
2. Remove latch keeper and latch from center plate
assembly. See Figure 3-3.
3. Position locating gage on center plate assem-
bly studs and clutch pulley shaft with posi-
tioning block loose. See Figure 3-4. Secure posi-
tioning block against bottom of center plate as-
sembly as far to left as possible (Figure 3-3). Re-
move gage.
4. Reinstall latch keeper, spring, and latch. Follow
Clutch Pulley Assembly, Installation for re-
assembly of clutch p.~.liIey assembly. See Figure
3-3.
5. Adjust armature pivot bracket to maintain .002"
to .005" clearance between armature and core. See
Figure 3-~. .
6. There should:- be .020" to .022" Clearance be-
tween armature and yoke with latch agai~st back-
stop. See Figure 3-3B ..
7. Hold armature attracted, and remove slack from
linkage
by pushing latch toward drive arm (Fig-
ure 3-3B). Position center plate assembly on posi-
tioning block to get slight drag on .OOS" feeler
gage between latch
and clutch drive arm. Tighten
center plate assembly mounting screws. There
should be
at least 75% of latch in contact with
driv.e arm assembly in latched condition.
NOTE: Be sure to keep center plate against
positioning block.
S. Loosen positioning block mounting screws and
position block as
far right (ear of locating block
against
plate) as possible. Lock mounting screws.
9. Adjust center eccentric keeper stop stud to obtain
.000" to .020" between clutch drive arm and latch
keeper
at latch time. See Figure 3-3C.
10. Check for ro2" clearance between step on ratchet
and detent (backlash) with clutch engaged. If
there is more than .002" clearance, install a longer
detent.
NOTE: Seven new detents, 609737 through
609743, are available in .002" progressions. These
detents are etched 1 thtough
7.

TIMING
This adjustment ensures that read feed dynamic timer
is in time with clutch at engaging time.
1. Block the clutch armature attracted.
2. Crank machine and listen or feel for latch keeper
to fall behind drive arm. This should happen at
315° ±1°.
3. If index is not at 315° ± 1° when latch keeper
falls behind drive arm, loosen clamped hub on in-
dex drive shaft and turn index to 315°.
4. Tighten clamped hub.
NOTE: If timer index is moved, brush and CB
timing will have to be 'Checked.
Clutch Pulley Assembly
The clutch pulley includes the dogs and arms.
REMOYAL
1. If same clutch assembly is to be used, spot mark
clutch pulley and picker knife cam shaft pulley
to belt to retain RLCB's, solar CB, and picker
knife timing.
2. Remove file feed drive belt.
3. Loosen clutch pulley belt idler.
4. Remove grease fItting on end of clutch shaft.
5. Loosen retaining clamp and remove clamp and
file feed drive pulley together.
6. Remove clutch pulley drive belt.
SLIGHT DRAG 75%
OR MORE
LA TCH SURFACE
LA TCH KEEPER
Figure 3-:3". Reader Clutch Adjustments
NOTE:
ADJUST SCREWS
FOR .020" TO
.022" CLEARANCE
HERE
CHECK .002"
.008"
UNLATCHING CLEARANCE
SHOULD GIVE 75% (OR MORE)
LA TCH SURFACE CONTACT (SEE 8)
POSITIONING BLOCK
3-3

CENTER PLATE ASM
Figure 3-4. Latch Assembly Plate Alignment
7. Remove clutch pulley assembly. It may be neces-
sary to loosen V-belt
input pulley and move it
towards the end of its shaft. See Figure 3-5.
CLUTCH PULLEY ASSEMBLY
'---- DRI VE~ULLEY
Figure 3-5. Clutch Drive Assembly
3-4
INSTALLATION
When a new clutch pulley assembly is installed, the
procedure listed under Reader Clutch, Adiustment
should be performed.
1. Be certain that two thrust bearings (washers)
are on shaft against clutch ratchet.
2. Install clutch pulley and operate the arms so that
detent and dog fit into high dwell of ratchet .
3. Place
two thrust bearings against clutch pulley.
4. Install clutch retaining clamp (and file feed pul-
ley) allowing no end play of pulley.
5.
I~stall clutch pulley belt with spot marks lined
up; adjust idler.
6. Install grease fitting and file feed drive belt.
7. Reposition V-belt input pulley, if moved.
8. Check picker knife, RLCB's and solar CB timing.
Clutch Drive Assembly
REMOVAL
1. Inscribe lines along one end and side of unit to
maintain front-to-rear
and side-to-side location.
2. Remove dynamic timer index.
a. Remove screw from
hand crank.
b. Remove two screws from index base.
TIMER INDEX SHAFT
CLUTCH MAGNET ASSEMBLY

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.
4. Remove clutch magnet leads at terminal block.
5. Remove four hex-head clutch drive assembly
mounting screws.
6. Remove assembly through rear of machine.
INSTALLATION
1. Set drive assembly into position from rear of ma-
chine.
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.
5. Set index to 315' ± 1°. Block armature and crank
machine until detent keeper falls behind drive
arm. Tighten clamping hub.
6. Install clutch drive belt and adjust idler pulley.
Loosen picker knife camshaft pulley locking
screws.
7. Time picker knife camshaft by tripping read
clutch and setting timer at 216° for a 3-group
brush, or 212° for a 2-group brush.
a. Place a card in the hopper and against first
feed rolls.
b. Turn camshaft in normal maehine direction
until feed knives touch the card.
c. Tighten pulley lock screws. (This is a starting
point for brush timing; refer to wiring diagram
for final brush timing. )
d. Change picker knife camshaft for proper brush
timing by slipping drive pulley on camshaft.
8. Time RCCB's by using set screw-retained gear on
the RCCB shaft.
9. Install the other three belts and unblock clutch
armature.
10. Check timings.
a. Clutch engagement time (315° ± 1°).
b. Brush impulse CB timing.
c. RCCB timing.
d. RLCB timing.
File Feed Clutch
ADJUSTMENTS
1. With clutch latch against latch step on sleeve,
loosen split collar and rotate collar backwards
until stopped by spring, fully uncoiled, inside of
sleeve.
2. Hold split collar in this position and rotate detent
gear to 1/16" past detent position. Tighten screws
in split collar. This adjustment should result in
1/16" overthrow. See Figure 3-6.
REMOVAL
1. Remove covers, and upper and lower magazines.
2. Remove drive unit from machine.
3. Mark cams and shaft to maintain relationship. Re-
move rear pulley and front and rear joggler cams.
4. Remove rear bearing retainer plate.
5. Mark side joggler cam and shaft to maintain re-
lationship.
6. Loosen side joggler cam, clutch hub (with grease
fitting), and clutch drive gear on joggler cam
shaft. (The set screws are seated in undercuts
on shaft and must be loosened a full turn.) Slide
shaft opt rear of unit.
7. Remove clutch assembly through bottom of unit.
The clutch can now be disassembled and spring
can be r~rng,ved.
INSTALLATION
Follow removal steps in reverse order. Be certain
clutch latch and detent are in correct positions, and
grease fitting is over slot in shaft. The clutch drive
sleeve and side joggler cam should hold clutch to-
gether, with clutch in full mesh. The sleeve and side
joggler cam. should not, squeeze clutch so tightly as
to cause binding when' clutch is latched. Check all
drive unit adjustments after unit is replaced in ma-
chine.
CLUTCH LATCH
1/16'~~AT FULL
OVERTHROW
CLUTCH DETENT
Figure 3-6. File Feed Clutch Adjustments
3-5

SERVICE CHECKS
1. The front joggler interlocking arm should have
approximately 1/16" travel before contact makes.
2. Upper card deck support must be centered be-
tween side frames.
3. Front joggler operating levers must be free of
binds between side plates
and lower magazine.
4. Hopper bed plate springs must be 3/8" ± 1/16"
above hopper bed plate.
5. Speed nuts should not interfere with helical spring
clutch. Use shims, PIN 603544, to shim lower
magazine.
6. If flat springs are used, the lower magazine throat
should
be .020" to .040" above an imaginary plane
determined by
the tops of feed rolls. If throat is
formed from mirror plate it should be set at .055"
to .065" above feed rolls. See Figure 3-7.
7. File feed delay must allow three to five seconds
for cards to feed from file into hopper before
reader-clutching begins. A variable resistor,
R-2,
on left bottom corner of the relay gate, is pro-
vided for this adjustment.
File Feed Joggler
FRONT JOGGLER ADJUSTMENT
1. Crank file feed drive unit until front joggler cam
followers are on low dwell. See Figure
3-8. Fill
hopper to just below sensing pads on front joggler,
and close joggler. Set adjusting screws on joggler
TO .065" IF MIRROR THROAr
.020" TO .040" IF SPRING THROAT
.'
Figure 3-7. Lower Magazine Throat Adjustments
3-6
to just touch operating arms.
Under these conditions there should be .003" to
.010" clearance between cards and lower end of
joggling surfaces (lower
end of joggling surfaces
are in line with top of card feed knife posts).
a. On some machines, this clearance is obtained
by adjusting hopper post mounting
bar by
means of set screw. Then, hopper posts have
to
be adjusted also. Refer to Hopper Adfust-
ments.
b. On other machines, hopper post mounting bar
is pinned in position. The .003" to .010" clear-
ance
is obtained by shimming between pivot
blocks
and mounting bar.
2. Crank file feed drive until front joggler cam fol-
lowers are on high dwell of cams. Fill hopper
with cards until cards are level with top of sensing
pads; close joggler. Hold rear cam follower
against cam,
and continue to operate unit. Stop
when .005" to
.008" clearance appears between
cam follower arm
and adjusting screws. Lo~sen
clutch operating lever on its pivot shaft and fully
seat clutch latch.
With cam follower against cam,
position clutch operating lever
so it just touches
turned-over ear on cam follower arm. Tighten
set screws in clutch operating lever to secure
it to
shaft.
SIDE JOGGLER ADJUSTMENT
1. With a two-inch stack of cards in hopper, crank
file feed drive until hopper joggler cam follower
is on high dwell of cam. Set adjusting screw for
.000" to .005" clearance between the top of deck
and joggler arm. See Figure 3-9.
2. With hopper empty, crank machine until side
joggler
is fully extended.
Caution: There must be enough clearance to
allow movement between joggler arm
and hop-
per side plate, or joggler will break.
3. Lift side joggler arm at operating arm. See Figure
3-9.
If interference exists, check distance between
hopper side plates. See Hopper and Picker Knives,
Adfustment.
Hopper and Picker Knives
Each picker knife block is fixed on its arm. Two
hardened pieces are inserted
in the block surface to
resist wear.
The inserts are ground to specifications.
Replacement of picker block is required when insert
becomes worn.
ADJUSTMENTS
1. Position picker knife cam followers for a minimum
clearance (without binds} over entire periphery

of cams. Maximum clearance must not exceed
.006" at any point.
2. Be sure file feed front joggler is adjusted, then
shim hopper posts on mounting bar for clearance
of .010" to .015" between posts and cards resting
against throat knife.
3. With a clearance of .062" ± .005" between rear
hopper side plate and rear side frame, adjust front
side plate for .016" to .021" over length of card.
NOTE: This adjustment must center cards be-
tween rails in transport area (5/16" ± 1/32" from
front rail).
4. Adjust hopper back plate card guide fingers for
.020" to .050" clearance to hopper bed plate
fingers. See Figure 3-10.
5. Position feed knife arms. evenly on shaft so that
LATCH
Figure 3-8. File Feed Adjustments
feed edge of picker knife block travels .020" to
.030" beyond trailing edge of card when card is
held against hopper posts.
6. Position throat roller so step, indicating center
line of roller, is lined up with throat knife face.
7. The throat opening should be .0095" go, and
.0105" no-go.
8. Time picker knife cams to feed card so the trailing
edge of card aligns with face of throat knife at
approximately 72° for 2-group brushes, and 75°
for 3-group brushes.
NOTE: The preceding is only a reference point
for making brush timings. When brushes are on
scribed line (refer to Brush Assembly Adjust-
.ment), retime picker knife cam to obtain
proper
brush timing. See Brush Assembly Timing.
CLUTCH OPERATING LEVER
3-7

FilSUre 3-9. Side Joggler Adjustments
·0095" to .
01
05"
THROAT
CLEARANCE
Figure 3-10. HopPer Adjustments
3-8
Card \Veisihfs
Th~ re~u~nship be ....
een the
'hree SMngs on card
W"'gh, " ""Portan, in eJ;m;nating card "tisfeea'
caused by a bouncing card We;g&, If the -'e ~g
is at hi h d' . h . T sprIng
. g. -~"on., e ....0 end springs mus, be set
to b'gb d""eu.,on. See F;gu", 8.11.
AD]{JSl'ME;NTS
1. Set -..,. 'Pring 15/64 '0 17/64'below bolt I
card Weight. om 0
2. Se' end. sPringS 7/82 '0 15/64 below bo ..... oJ
card Welght.
Card GUides
Reier to F;gu", 3-12for card /Mde 'PeciBcaticns,
Brush ASSeftl&ly
AD]tJSl'ME;Nl'S
1. IUsert brush assembly into"'''cbiue and cbeck f
.015" to ·040" clearanCe between brusb s"Para,::
and ':'nm", ron w;th end '0 end VoriaUo
n
.DIS".
See FlgUres 8-12 and 8..18.
•. Loosen lonr s"Para'or hOlding screWs,
HOPPER BAC/( PLA. TE
ADJUSTING SCREWS
'----+---.020" to .030"

ev
ZZ
? 22 ZZZZZZZZZZ? lZ? ZZZ ZZ ?~~
~::'
CC::==:::;;::;::;;~;:::====::::JI;,L 15"
CENTER SPRING
n-
TO
b4
I
END SPRINGS
NOTE:
IF ONE SPRING IS SET TO LOW DIMENSION,
SET ALL SPRINGS TO LOW DIMENSION; IF
ONE IS HIGH, ALL MUST BE HIGH.
Figure 3-11. Card Weight Adjustments
b. Place brush assembly in operating position.
c. Place .025" feeler gages between ends of sepa-
rator
and contact roll.
d. Hold brush separator down to feeler gages
and
tighten screws.
2. The scribed line (Figure 3-14) shows the best
brush-to;~ontact-roll relationship. Four combina-
tions of brushes
and brush separators are in use.
a. Three group brushes; one scribed ~ine: These
are used on Model 2 machines
and some
. 015" TO .050"
CARD
"h_
.015" TO .040"
Figure 3-12. Reader Feed Adjustments
·Trade Name of Allen Manufacturing Company, Hartford,
Connecticut.
Model 1's. Set heel of shortest brush group
on scribed line + .030"
-.020".
NOTE: + is toward the stacker, -is toward
the hopper.
b. Three group brushes; two scribed lines: These
are used on Model 2 machines
and some
Model 1's. Set heel of shortest
brush group on
scribed line nearest
hopper + .030"-.020".
c. Two group brushes; one scribed line: These
are used on Model 3 machines
and some
Model 1's. Set heel of shortest
brush group
.050" + .030"-.020" beyond scribed line.
d. Two-group brushes; two scribed lines: These
brushes are used on Models 3
and 4, and on
some
Modell machines. Set heel of shortest
brush group on scribed line nearest stacker
+.030" -.020".
3. Adjust brush assembly for correct lateral track-
ing of brushes.
Caution: Do not tighten set screws to a point
where they
bind the retractable frames.
a. Center brushes in separator with two \) Allen-
Head setscrews in brush assembly frames.
b. With brush assembly in place, adjust screws
in machine side frames for correct
brush track-
ing.
FIRST LOWER
CARD GUIDE
3-9

CENTERING
SETSCREW
BRUSH
TIMING
ADJUSTING
SCREWS (2)
BRUSH
ASSEMBLY
PIVOT
PIVOT
OPERATING
SPRING (2)
. BRUSH SEPARATOR
MOUNTING BAR
Figure 3-13. Brush Assembly
c. Allow .003" clearance to prevent binding when
brush assembly is removed or replaced.
4. Adjust brush assembly card guide for .015" to
.050" clearance to lower card guide . See Figure
3-12.
TIMING " '..
Proper timing establishes the prop er relationship of
brush to contact roll, punched card hole to brush , and
TO STACKER
SINGLE
SCRIBED LINE
--- ____ --:~ DOUBLE
SCRIBED LINES
Figure 3-14. Brush Timing
3-10
CB impulse to punched card hole.
1. Check that brushes are on scribed line. See Brush
Assembly, Adjustment.
2. Dynamically check that first and se cond re ad
stations are 360° apart. If not, correct brush block
on which brushes are furthest from scribed line.
3. Dynamically
time brushes to wiring diagram by
shifting picker knife timing. Do not time brushes
by shifting them off scribed-line limits. .
a. All brushes must make, dynamically, within
± 2 .°
b. Loosen clamp on input pulley to time brushes;
12° brush at 5-time: M-BO °, B-92°; 16° brush
at 5-time: M-77°, B-93°.
c. Check and correct RLCB's and SCCB's (if
used ).
Punch Feecl
Timing Belts
""I~
The synchronous tooth of_ the punch clutch should be
used as a reference poi . henever units pertaining to
the punch clutch are ' r ' ed. Unless this tooth is
used , timing will be off by 90 °, 180°, or 270 °.
The synchronous tooth is that tooth whose driving
face is opposite the centerline of one of the three
tapped holes on the outside collar.
Refer to Figures 3-15 and 3-16 for belt locations and
units that must be removed in the event of belt break-
age .

MAIN DRIVE REPLACEMENT
1. Trip clutch between 230' and 300', and turn input
idler pulley, manually, until dog engages in clutch
ratchet.
2. While holding armature in tripped position, con-
tinue turning machine until latching surfaces of
clutch latch ann and dog carrier coincide. See
Figure 3-21F. Punch feed index should be
3150 ± W.
3. Set timer index at 315'.
4. Slip input drive belt on geneva pulley and, while
keeping
the relationship between lower pulley and
input idler pulley (315' at the clutch and 315' at
the timer), slip belt onto both pulleys. Adjust
tension
and recheck timing relationship. Refer to
Timing Belt Adjustment.
5. Time the geneva.
NDTE
a. Loosen geneva pulley lock screws.
b. Set timer index
and puncn index to 0'.
c. Depress geneva lock pin into timing slot and
tighten geneva pulley lock screws.
NOTE: At 315', if everything is in time,
geneva pin will detent
and punch clutch will
line up as described in Step
2.
FI RST STEPPED FEED
ROLL DRI VE BELT
DARKENED BELTS ARE UNDER CONTROL
OF PUNCH FEED CLUTCH
HOTOR PULLEY
Figure 3-15. Punch Feed·fi~g Belts
,,~,,:
DRIVE MOTOR BELT REPLACEMENT
1. Mark CR idler belt (3) and pulleys to maintain
timing.
2. Loosen CR idler belt (3) and slip it off.
3. Install drive motor belt and tighten.
4. Install CR idler belt (3), line up reference marks,
and tighten
with idler pulley.
CR IDLER BELT REPLACEMENT
1. If there is enough room to work belt between
the index pulley
and cross-over shaft pulley, the
index timer unit does not have to be removed
from base.
If removal is necessary, loosen three
base mounting screws on timer index.
2. Install new belt; tighten idler pulley and, if nec-
essary, tighten three base screw on timer index
unit.
3. Retime index timer.
a. Loosen timer index set screws (Figure 3-15).
b. Unlatch
punch clutch between 230' and 300'
and, while holding armature in tripped posi-
tion, continue turning machine until latching
surface of clutch arm
and dog carrier coincide
(See Figure 3-21F).
CR I DLER SHAFT
DRI VE TO
TRANSPORT
MECHANI SH