IBM 1402 User manual

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il) g5 ~ Customer Engineering
Reference Manual
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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