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PART IV

MAINTENANCE

401. ROUTINE MAINTENANCE.

(a) The following policy of routine inspection and overhaul has been established:

Whenever possible and according to circumstances:

(1) A routine inspection of the ECM at a regularly established ECM Repair Facility, every 30 days.

(2) A routine complete overhaul of the ECM at a regularly established ECM Repair Facility every twelve months.

(b) Between these inspections and overhauls there are certain operations which must be performed by the operator. This section of these instructions is designed as a guide for the operator of the ECM, who must necessarily be responsible for the daily maintenance and up-keep of the ECM. Only a small amount of time is necessary to insure that the machine is properly maintained. Some maintenance duties must be performed daily, others require only a few minutes each week. A machine which is properly maintained will give a minimum of trouble.

402. LUBRICATION.

(a) The Spare Parts Box (ENG 109) issued with each machine supplies oil, grease and a one drop oil can.

(b) (1) Plates 3 and 4 are included to assist in locating the oil holes of the various units. It will be noted that, in many of the parts, felt wicks have been provided to receive the oil rather than the bearing surfaces of the parts themselves.

(2) CARE SHOULD BE TAKEN TO PREVENT OIL OR GREASE FROM GETTING ON THE CODE WHEELS, INDEX WHEELS, CIPHER UNIT, SEPARATORS, CONTROLLER AND KEYLEVER CONTACTS AND WIRING.

(c) Oil the following points sparingly, once every two weeks.

See Plate
(1) Stepping Pawls and Stepping Pawl latches - one drop. 3(c)
(2) Stepping drive bars - felt wick in rear guide and forward pivot points. 3(c)
4(a)
(3) Stepping bell crank, several drops in oil holes at pivot points. 4(c)
(4) Tape feed drive; rear bearing - fill oil cup. Front bearing - few
drops. 4(d)
(5) Friction drive felt washers, several drops on each. 4(b)
4(d)
(6) Clutch magnet armature pivot and clutch stop lever pivot - one drop. 3(b)
(7) Printer stop pins, one drop on tip of each stop pin. 4(b)
(8) Print hammer pivot screw - one drop. --
(9) Clutch mechanism - several drops. Ball bearings (two) - few drops. 3(a)
(10) Motor - ball oilers (two). --
 
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Drawing of main shaft will call outs for parts.
PLATE 3A - MAIN SHAFT
Drawing of right end view of main shaft.
PLATE 3B - MAIN SHAFT
(Right End View)
Drawing of CODE WHEEL STEPPING MECHANISM
PLATE 3C - CODE WHEEL STEPPING MECHANISM

PLATE 3

 
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Drawing of CIPHER UNIT CAVITY
PLATE 4A - CIPHER UNIT CAVITY
Drawing of PRINTER
PLATE 4B - PRINTER
Drawing of the BELL CRANK, (Stepping Mechanism)
PLATE 4C - BELL CRANK
(Stepping Mechanism)
Drawing of the TAPE FEED DRIVE, (Right Side of Printer)
PLATE 4D - TAPE FEED DRIVE
(Right Side of Printer)

PLATE 4

 
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(d) Apply grease sparingly to the following points, once every two weeks when the machine is in constant use:
See Plate
(1) Channel cam- inner surface in contact with roller. 3(c)
(2) Stepping pawl, point of contact with reset screw. 3(c)
(3) Tape feed shaft gear. 4(d)
(4) Typewheel shaft gear, reset bail groove. 4(b)
(5) Printer reset cam, timing cams, print hammer cam, tape feed cam, counter cam, clutch stop lever cam. 3(a)
(6) Printer drive gear, tape feed drive gear, and main shaft drive gear. 3(a)
(7) Motor pinion (on motor shaft). ---
(8) Controller detent roller and cam surface. ---
CAUTION: Rub the grease in and clean up any surplus grease which may drop from the parts after the machine has run a few minutes.

(e) At the time of oiling, (and more often if necessary) wipe the Code Wheel spindles with an oily cloth. The Code Wheels must not run on a dry spindle.

403. CLEANING CONTACTS.

(a) Experience has shown that the major cause of unreliable operation is dirty contacts of the Cipher Unit. Clean contacts are absolutely necessary for proper functioning of the machine. The only reliable method of maintaining clean contacts, except where an approved Code Wheel lubricant is used, is to follow a daily cleaning schedule. This will not only insure the removal of any dirt which may have been deposited but also will remove any "carried over" metal which may have been ground off the contacts.

(b) The lid should be removed only as required for changing Code Wheels, making Index Settings, lubrications, etc. It should be kept in place at all other times.

(c) (1) The plunger-contacts of the Cipher Unit must be inspected and cleaned DAILY, except where an approved Code Wheel lubricant is used. The Spare Parts Box (ENG 109) contains a canvas paddle which is especially designed to fit between the Cipher Unit Separators. The outside plunger contacts should be rubbed with one side of the canvas paddle.

(2) When the canvas becomes soiled, it should be removed and cleaned. If cleaning solutions are used it must be rinsed several times in water to insure all cleaning solution is removed. The canvas should be stretched tightly when re-assembled on the wooden form.

(d) To clean the contacts of the Code Wheels, place a piece of canvas on a smooth flat surface and rub the Code Wheel and Index Wheel contacts against the canvas until they have become clean and bright. If in some cases the hub of the Code Wheel will not permit the Code Wheel to lay completely flat, two blocks should be laid side by side with a space between them, forming a depression in which the hub of the Code Wheel will ride, permitting the Code Wheel Contacts to lay flat on the canvas,

(e) If, because of infrequent cleaning, the contacts cannot be cleaned with the canvas paddle, a pencil (not ink) eraser may be used. The standard flat type, about two inches long is a convenient size. It must be clean and free from abrasive material. The use of the eraser must always be followed by cleaning with the canvas paddle.

 
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404. CODE WHEEL LUBRICANT.

(a) A special Code Wheel Lubricant is being made available to all holders. Initially small quantities will be forwarded to the Registered Publication Issuing Offices, as a matter of convenience in distribution, but regular distribution will be through the ECM Repair Facilities.

(b) Until the lubricant is available, or if the supply is temporarily exhausted, the standard method of cleaning Code Wheels should be followed.

(c) The use of the Code Wheel lubricant requires the cleaning of the Cipher Unit and Code Wheel contacts at intervals of two four weeks instead of daily.

(d) The approved lubricant is commercially known as "Lubriplate" formula 105.

NOTE: "Lubriplate" is extensively used throughout the Navy In connection with other equipment, but in most cases It is not formula 105, which is the only type "Lubriplate" authorized for a Code Wheel lubricant.

(e) "Lubriplate" is light cream in color and has a viscosity similar to petroleum jelly.

(f) To apply "Lubriplate":

(1) Clean the contacts of the Code Wheel, Index Wheel and Cipher Unit in accordance with paragraph 403. Wipe the contacts with a clean cloth to insure that all dust is removed.

(2) Place a very small quantity of "Lubriplate" 105 on the contact surfaces of the Code Wheels and Index Wheels. Rub the lubricant into the surface of the contacts.

NOTE: Do not lubricate the contacts of the Cipher Unit.

(3) Polish the faces of the Code Wheels and Index Wheels with a lint-free cloth. Remove any excess lubricant.

(g) "Lubriplate" should be applied at intervals of two to four weeks, depending upon use and local conditions.

(h) THE USE OF ANY OTHER LUBRICANT, OR OF "LUBRIPLATE" IN ANY FORMULA OTHER THAN "105" IS NOT AUTHORIZED.

INFREQUENT OPERATIONS

405. PRINTER RIBBON.

(a) A standard 1/2 inch typewriter carbon ribbon (such as used on an Underwood typewriter) is used on the Printer. A Hectograph ribbon may be used if preferred.

(b) The ribbon feed Is reversed by moving the ribbon reverse lever towards the spool upon which the ribbon is to be wound.

(c) Only one-half of the ribbon is used at a time, and after one-half fails to print clearly, the ribbon should be inverted to use the other half. This is accomplished by reversing the respective positions of the spools (i.e., the left spool to the right position and the right spool to the left position) and replacing the ribbon in the ribbon guide. When replacing the spools on the shafts be sure the small pin on the hub of the shaft engages the spool, thus preventing the spool from slipping on the shaft.

 
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(d) To insert a new ribbon:

(1) Allow the ribbon to accumulate on either spool. Disengage the ribbon from the ribbon guide. Remove the spools from the shaft by pulling straight out (the spools are mounted on split shafts).

(2) Disengage the ribbon from the empty spool, discarding the ribbon and the spool on which it is wound.

(3) Engage the new ribbon to the center of the empty spool.

(4) Replace the spools on the shafts so the ribbon runs to the outside of both spools.

(5) Replace the ribbon in the ribbon guide.

406. PAPER TAPE REPLACEMENT.

(a) Paper tape is a "supply" Item and is not normally procurable from ECM Repair Facilities or Registered Publication Issuing Offices. In some cases, a small supply of tape is carried in stock at these places, but only as an emergency supply. Each ship or station should anticipate its needs and order an adequate stock well in advance of actual needs. Activities from whom paper-tape can be obtained are as follows:

Stock Maintenance List
Navy Type - 10055
Paper Tape

Navy Yard or Base Maximum Stock
(Rolls)
Minimum Stock
(Rolls)
New York 40,000 5,000
Mare Island 40,000 5,000
Boston 2,000 500
Portsmouth (N.H.) 500 250
Sub-base, New London 2,000 500
Philadelphia 1,000 250
NYD, Norfolk 500 250
NOB, Norfolk 10,000 5,000
Washington 5,000 2,000
Charleston 2,000 500
NS, Key West 2,000 500
NSD, San Juan 2,000 500
NS, Guantanamo 500 250
NSD San Diego 2,000 500
Puget Sound 10,000 5,000
Pearl Harbor 10,000 5,000
NS, Balboa 1,000 250
NS, New Orleans 1,000 250
Sub-base, Coco Solo 1,000 250

(b) The paper tape used in the ECM Mark 2 is a special gummed tape made according to U.S. Navy specifications. It is not affected by high humidity and will not become loosened from the message blank with age. Ordinary 3/8 Inch paper tape (plain or gummed) may be used in an emergency, but it is not recommended. Two types of special ECM tape are available:

Navy Type No. Width Layers Length Groups Price Rolls to Box
CPM 10055 3/8" 1 1100 ft. 18,000 $0.15 ea. 10
CPM 10056 3/8" 1 plus carbon 500 ft. 8,000 $0.25 ea. 10
 
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(c) To replace the paper tape:

(1) Raise the tape retainer arm and remove the wooden spool.

(2) Unwind about two turns from the new roll of tape, place the spool of the tape on the spindle so the tape roll will turn clockwise when unrolling and replace the tape retainer into position.

(3) Thread the end of the paper tape through the tape roller (gummed side up) and into the cover tape channel with the gummed side out.

(4) Press the tape release tab and push the paper tapes (gummed side down) between the tape feed rollers and through the printer tape channel. Release the tape release tab.

(5) Thread the paper tape around the idler roller.

(6) Examine the "mesh" of the feed rollers; the paper tape should be held tightly.

407. CAUTIONS.

(a) Throughout this publication, several "Cautions" have been Inserted. Those which affect the maintenance and upkeep are summarized as follows:

(1) The lid should be removed only as required, such as changing Code Wheels, making Index Settings, etc. It should be kept in place at all other times.

(2) Code Wheels must be handled carefully, and kept in the box when not in use. Fingers should be kept from the contacts as much as possible. The Code Wheels should be carefully inserted into the Cipher Unit - the cam-lobe (the "bump" between "U" and "V") is easily broken off, rendering the use of the Code Wheel dangerous when used in certain positions.

(3) Both hands must be used when inserting the Cipher Unit into and removing it from the machine, otherwise the Cipher Unit, its frame, or the zeroizing contacts may be damaged. All four thumbscrews should be securely tightened.

(4) The pawl and channel ring must be adjusted so the hand drive lever is free to move up and down except when actually using emergency power.

(5) The contacts of the Cipher Unit, Code Wheels and machine must be kept scrupulously clean.

(6) Lubrication instructions must be faithfully followed.

(7) Keep the lamp in the Type 8 Safe Locker on continuously.

(8) The ribbon feed must be reversed by hand.

 
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