by Dan Vigin Annual Convention 2008 Cancun Mexico

by Dan Vigin Annual Convention 2008 Cancun Mexico Part 1 1

TABLE OF CONTENTS Restoring Hammond X-66 Table of Contents. Description Nbr of Slides Level Part One. - Introduction - Power Supply Unit - Keyboards - Pedal Keyboard - Expression Pedal - Drawbars - Outlets panel - Mechanical works 5 4 6 14 6 3 6 5 Part 1 * *** ** 2

TABLE OF CONTENTS Restoring Hammond X-66 Table of Contents. Description Nbr of Slides Level Part Two. - Scanners - Reverb - Arpeggiator - Tab Controls - Tibia Flute Filters - Preamps - TWG / Dividers - Special Effects - Sforzando - Percussion Keyers 13 6 3 2 8 7 4 6 Part 1 ***** *** *** 3

TABLE OF CONTENTS Restoring Hammond X-66 Table of Contents. Description Nbr of Slides Level Part Three. - Tone Cabinet TC 12 -77 - Addons: X-Tal Generator 5 - Addons: Stand-by PSU - Addons: Leslie Preamp - Addons: Leslie Motor Contr. - Addons: Midi on Upper Kbd 7 3 4 4 *** Part 1 *** *** 4

INTRODUCTION Restoring Hammond X-66 DISCLAIMER This information is for educational purposes only and no claims are made that this information will lead to any successful repair or the like. Dan. Vigin assumes no reponsibility to its use. Part 1 5

INTRODUCTION Restoring Hammond X-66 The story began in an antique shop at Ostende in April ‘ 07. Only three X-66’s were sold in Belgium. Two of them disappeared in the nature, the last one was there. The X-66 was standing in the back store, dusty, simply awful and totally dead. Even so, after strong negociations on price with the vendor, I bought it for an acceptable price. That was seen from the outside. Part 1 6

INTRODUCTION Restoring Hammond X-66 The inside was even worst. Additional circuits to drive external synthesizer were integrated in the upper keyboard. Midi was not yet born at that time. The output preamp PCB needed for the Leslie was just fixed with foam ! Unbelievable. The switching relay for Leslie motor speed was left hanging nearby the supply panel without any safety precaution. Incredible ! Part 1 7

INTRODUCTION Restoring Hammond X-66 Those addon’s were really poorly mounted by unqualified technician. In addtion to that, the Tone Cabinet was also totally inoperative. All five built-in power amplifiers were burnt, dead. A dedicated chapter is dedicated to TC-1277 in Part 3. Four missing contacts on pedal keyboard. Fortunately, beside some heavy scratches on the cabinet and faulty connecting cable, the Leslie 145 delivered with was still in quite acceptable conditions. Part 1 8

INTRODUCTION Restoring Hammond X-66 HOW TO START RESTORING NOW ? 1. The first phase of operation was to remove all that junk: useless circuits, relays, associated cabling, etc. . and to put back the X-66 in its original state as ‘freshly’ delivered from factory. This includes the cosmetic aspect as well. 2. Then after achieving that, the next step is to switch ON the console and try to establish a diagnostic of all the problems encountered and there are… 3. Afterwards, after having restored both X-66 console and Tone Cabinet, it is now possible to « improve and personalize » some parts, adding Leslie preamps and motor controls circuits, X-Tal generator, Midi, etc… Part 1 9

INTRODUCTION Restoring Hammond X-66 WHERE TO START RESTORING NOW ? The sequence to start ‘refurbishing’ is not relevant since in this case, almost every section has to be carefully cleaned, rebuilt, controlled and properly re-installed. If one wants to get some sound out of an organ, it’s always better to rely on a working audio system behind it. That’s why, I started by this part which seemed the simplest one to my opinion. TC-1277 will be covered in Part 3. Part 1 10

POWER SUPPLY Restoring Hammond X-66 REBUILDING THE POWER SUPPLY UNIT Feeding all circuits with the adequate resources (i. e. correct voltages while supplying the needed currents) is basic and self-evident. That’s the function of the PSU. Technically spoken, this part is rather elementary. The weakest components are the filter capacitors. After more than 40 years, those ‘ Elco’s ‘ become dry, leaky, out of specs… I even found one elco that was totally ‘opened’, that means totally useless ! Part 1 11

POWER SUPPLY Restoring Hammond X-66 REBUILDING THE POWER SUPPLY UNIT Throw all those caps out and replace by new filter caps providing so a better long term stability. Power resistors installed outside the PSU need some attention too. Values have to be checked and replaced if needed. Take this opportunity to also check the rectifier diodes. Forward resistance should be similar, if not replace them as well. Rescrew thoroughly all GND points. Very important ! Part 1 12

POWER SUPPLY Restoring Hammond X-66 REBUILDING THE POWER SUPPLY UNIT Safety: the way the Hammond’s and Leslie’s were manufactured in the 60’s was not at all in line with the safety regulations, at least for the European market. In combination with the output panel, all safety improvements were implemented to comply with EU Class I safety regulations. Important ! Attached picture exhibits the PSU with new filter caps (for PCB mounting) installed on a bakelite panel since original filter caps are no more available. Part 1 13

POWER SUPPLY Restoring Hammond X-66 REBUILDING THE POWER SUPPLY UNIT After crosscheck with the schematic diagram, connect the PSU via a variable auto-transformer. Slowly increase the voltage and monitor the current. When the nominal AC mains voltage is reached, let it like warm up for several hours, the time needed to ‘reformat’ the new Elco’s. Part 1 14

POWER SUPPLY Restoring Hammond X-66 REBUILDING THE POWER SUPPLY UNIT Everything looks fine now. Check all the DC output voltages at the PSU voltage receptacle and resistor panel. Measurements will indicate values slightly higher than when under operation. Quite normal, don’t worry about that now. PSU is now completed and ready for use. Part 1 15

KEYBOARDS Restoring Hammond X-66 RENOVATING THE KEYBOARDS Keyboards are the interfaces between the core of the instrument and the player. We are permanently touching those parts with hands, that's why keyboards must be as perfect as possible. Before After Part 1 16

KEYBOARDS Restoring Hammond X-66 RENOVATING THE KEYBOARDS Keyboards must be attractive : I mean by that: pleasing and identical pressure on all keys, well damped, noise-free when releasing, perfect alignments, no lateral slack generating 'clicks' side noise on gliding, identical contacts activation and of course perfectly cleaned, free of scratches, 'super-polished up' keys. “Everything to render the organist envious to touch keyboards sit down on the bench and start playing. Evidently, this elementary principle is not peculiar to X 66 consoles but applicable as well to most of keyboards instruments”. Part 1 17

KEYBOARDS Restoring Hammond X-66 DISMOUNTING KEYBOARDS & CLEANING All the keys can be easily dismounted and should be numbered. Keys can be easily scratched with the springs. After removal, it’s now great time to remove dust and various foreign objects with vacuum cleaner and start cleaning with alcohol, spray’s … BEFORE AFTER Part 1 18

KEYBOARDS Restoring Hammond X-66 REPAIRING BROKEN KEYS Many black and white keys were found broken on my X-66. Evidently, the simplest way is to replace them by new ones if you can still find them. Mechanically, it’s certainly the best way to go but the shades of white keys will not match anymore ! So, whenever possible, try to fix and re-use the original keys, at least for the white ones. Part 1 19

KEYBOARDS Restoring Hammond X-66 REPAIRING BROKEN KEYS Most of the time, the rear plastic holder is broken. Re-glue it with cyanolit glue in its initial position. Each fixation screw is equipped with a crimped lockwasher that has to be removed (not so easy without damaging threats). Grease both screws and gently rescrew them. By doing so, the threat has gained about 2 mm in length in the non-broken part of the holder which is sufficient to restore the mechanical fixation. Afterwards, for better reinforcing purpose, epoxy glue can be applied on the rear side. Part 1 20

KEYBOARDS Restoring Hammond X-66 CRADLE ADJUSTMENT With aging, the tension spring was too weak and had insufficient pressure to bring the rod back in its correct position. Preset keys were inoperative. Small hole Coil spring A small hole was drilled in the stop felt bracket and coil spring installed. Easy and effective ! Part 1 21

KEYBOARDS Restoring Hammond X-66 CONTACTS & BUSBARS CLEANING This section only pertains to the Upper keyboard. This operation requires a certain skill and …. a lot of patience. Firstly, unscrew the fasteners located at the rear side of the keyboard and disengage the whole row of keying modules as shown on picture. Part 1 22

KEYBOARDS Restoring Hammond X-66 CONTACTS & BUSBARS CLEANING Start by removing the Presets busbars and clean carefully each busbar with alcohol. contacts are so rendered free. Presets First cleaning with air-pressure (6 bars) of each keying module in order to remove dust and others. Afterwards, clean with alcohol each contact and visually check them with a small mirror. Busbar anchor block Part 1 23

KEYBOARDS Restoring Hammond X-66 CONTACTS & BUSBARS CLEANING Contacts of eack keying module have to be cleaned one by one exactly at that level. This operation takes a lot of time and is rather delicate but there is no other way. Patience is a must and perfect lighting is required. No rush, take it easy…. Keying module Part 1 24

KEYBOARDS Restoring Hammond X-66 CONTACTS & BUSBARS CLEANING When Presets contacts are done, it's time now to clean the keys-contacts. There is no other alternative than cutting the wires connecting each busbar. Otherwise, it's impossible to remove the busbars out of the console. Be sure to take note of the initial position of each lead and busbar ! Cut buss bars wires at that level. Similarly to Presets contacts, start by cleaning each busbar and contacts as done for the Presets ones. Part 1 25

KEYBOARDS Restoring Hammond X-66 CONTACTS & BUSBARS CLEANING When completed re-install busbars in their original position. This operation is not easy specially for the first ones. Be careful, you have no right to mistake for this operation ! Re-solder each busbar lead and don't forget to isolate them with schrink tubes. The last action consists in re-installing the whole row of contacts in its initial position. Not easy at all. If you can be helped by two additional hands, don't hesitate to claim for help, you will save a lot of time (it took me half-a-day just to do this). Now, when all contacts are correctly re-positioned, start re-inserting each key as originally. Keyboard is now completed Part 1 Upper 26

KEYBOARDS Restoring Hammond X-66 CONTACTS & BUSBARS CLEANING The Lower keyboard is less accessible than the upper one and entails huge dismounting. So, I decided not to do it and find another way. Based on B 3's maintenance tips, bus anchor block located at both ends of the keyboard were unscrewed. Then gently move back and forth those buss anchor block while depressing the keys at the same time, it is also possible to get 'some ways' of refinding good contacts. Part 1 27

KEYBOARDS Restoring Hammond X-66 RE-INSTALLING KEYS To eliminate the lateral slack of keys, here again, the easiest way is to replace all the old key-combs by new ones. After several decades of operation, the paddings maintaining the keys in correct position are somewhat worn out and keys become 'clanky'. A special small vice system has been handcrafted. (refer to Annex_1 for details). The idea is to flatten out the rivet fixing the padding. By doing so, the padding enlarges by about 0. 5 mm on both sides eliminating so this unpleasant lateral slack. Part 1 28

KEYBOARDS Restoring Hammond X-66 RE-INSTALLING KEYS If the adjacent rivets are also tightened, lateral slack on the entire keyboard entirely disappears. Again it takes time but the improvement involved is really noticeable. If tightening of paddings is exagerated, it is easy to reduce the excess with a sandpaper lime. Before re-positioning each key, check the angle of the small clamp activating the contact bracket on each key module. This clamp should have the same angle. A dot of white grease is put on this portion of the clamp pushing the contact bracket. Part 1 29

PEDAL KEYBOARD Restoring Hammond X-66 RENOVATING PEDAL KEYBOARD Pedal board was also in poor conditions and needed some actions. It is composed of two major elements: Pedal switch assembly, integral part of the console. Pedal keyboard, removable. Before Part 1 30

PEDAL KEYBOARD Restoring Hammond X-66 RENOVATING PEDAL KEYBOARD 1. Pedal switch assembly was in need of serious repairs. Pedal strip had to be removed from the console. Several switches were missing ! and no more foundable. By chance, I found switches of Hammond R-100 series that are compatible with some minor adaptations. All switches were dismounted, cleaned, realigned. The metal strip repainted and adequate insulation material reinstalled. Beside finding the switches, no major problem. Part 1 31

PEDAL KEYBOARD Restoring Hammond X-66 RENOVATING PEDAL KEYBOARD 2. Pedal board was in an horrible state and had to be totally dismounted, each wooden part sanded, re-painting. Rust of springs removed with sanding machine. Mostly, wooden and mechanical works. Nothing really exciting indeed! Pedal frame Repainting pedal keys Part 1 32

PEDAL KEYBOARD Restoring Hammond X-66 RENOVATING PEDAL KEYBOARD 2. Pedal board - Felt pads Since the pedal keyboard is dismounted, it’s a good practice to remove the original felt strips, clean and replace them in the opposite way (flip vertical in computer jargon). Original felt pads avoiding lateral slacks of pedal keys were replaced by new ones (a must). Part 1 33

PEDAL KEYBOARD Restoring Hammond X-66 RENOVATING PEDAL KEYBOARD Re-adjustment of tension springs is compulsory. Re-install pedal keys in their initial position and screw down with a locking ratchet to a position that pedal key stays « in balance » between the rest position and the upper one. Locking ratchet At that moment, make a CW (*)rotation by one turn to restore appropriate tension. One turn clockwise 3/4 turn will provide less tension while 11/2 turn will increase the tension. It’s important to align all tension springs by the same amount. * Clockwise rotation After Part 1 34

PEDAL KEYBOARD Restoring Hammond X-66 RENOVATING PEDAL KEYBOARD Pedal board - Final All pedal switches are tested and resoldered as original. Part 1 Pedal keyboard completed and ready for use 35

EXPRESSION PEDAL Restoring Hammond X-66 EXPRESSION PEDAL Beside ‘grand’ cleaning, some improvements can be implemented on the expression pedal. This part can be removed quite easily from the console. Firstly, unscrew (2) and remove the photo cell adapter from the assembly and open it. Remove dust, foreign debris and start cleaning. Part 1 36

EXPRESSION PEDAL Restoring Hammond X-66 EXPRESSION PEDAL Replace the light bulb. Use alcohol-soaked cotton buds to clean the photo cells thoroughly. Then, it’s a good opportunity to check each of the four photocells with ohmeter. In dark condition, the resistance should be in the range of 4. 0 MΩ to 4. 5 MΩ. In full lighting condition, the resistance value should drop in the range of 200 Ω to 400 Ω. Part 1 37

EXPRESSION PEDAL Restoring Hammond X-66 EXPRESSION PEDAL: Leslie motor speed control. When playing, it’s more convenient to control Leslie motor speed with the right foot than using the original Leslie half-moon switches. One micro-switch has been installed on a metal square just to provide a short ‘pulse’ needed to reverse the motor speed. Rear view Full details of this control circuit will be provided in Part 3. This completes the expression pedal section. Front view Part 1 38

DRAWBARS Restoring Hammond X-66 DRAWBARS Maintenance. Basically, X-66 drawbars are identical to other Hammond’ series. Nothing specific but some maintenance was needed since moisture, dust, oxydation… are really harmful to proper drawbars operation. Before Part 1 39

DRAWBARS Restoring Hammond X-66 DRAWBARS Maintenance. To attain the drawbars, the tab control panel has to be removed (7 ) and flipped vertically in order to get proper access to the drawbars blocks. When laid down on the bench, then you realize the importance of removing all foreign debris, excesses of grease, oxydation, accumulation of dust. . Dismount and clean up with alcohol. After cleaning During cleaning Part 1 40

DRAWBARS Restoring Hammond X-66 DRAWBARS Maintenance. Check for correct operation and 'feeling'. the proper excursion. If needed, slightly bend the contact spring to render Before remounting the drawbars, you like to see all the drawbar knobs in perfect horizontal alignment, then it's the right time also to check if all brass guide rods are straight. Part 1 41

DRAWBARS Restoring Hammond X-66 DRAWBARS Maintenance. Generally, a little curve is noticed at the level of the thrust. When completed, it is now time to grease again. One dot of grease is applied on each bus bar where the contacts are touching. In this case, special lubricant (*) was used but pure vaseline would do also the job. Lubricant (*) Tunerlub – Cat. 26 -01 – HF Lubricant made by GC Electronics (USA). Part 1 42

DRAWBARS Restoring Hammond X-66 DRAWBARS Maintenance. Some tips to re-solder drawbars leads. - cut the end of the lead, strip it by about 10 mm, twist the wires and solder it vertically. - by doing so the solder will flow inside the sheath and will so reinforce greatly the whole mechanical strength. The ultimate in luxury is to insert thermo-shrink tube. Part 1 43

DRAWBARS Restoring Hammond X-66 DRAWBARS Maintenance. After cleaning After re-installation Re-install the drawbars blocks as original, re-solder the leads, confirm properation and feeling. Re-install the tab control panel. Drawbars maintenance is completed and look like fresh from factory ! Part 1 44

OUTLETS Restoring Hammond X-66 OUTLETS The oulet receptacle has been reworked in order to comply more with EU safety regulations. 2 -pin UL inlet and socket were removed. A new approved 3 -pin inlet with earth connection was fixed. The original 2 -pin socket to feed external device was also removed and replaced by a 6 -pin socket. After modification Rear view Before Part 1 45

OUTLETS Restoring Hammond X-66 OUTLETS The oulet receptacle has been reworked in order to meet the EU safety regulations. After 2 -pin UL inlet and socket were removed. A new EU approved 3 -pin inlet with earth connection was fixed. The wiring diagram is provided on the next slide. Front view The original 2 -pin socket to feed external devices was also removed and replaced by a 6 -pin socket for Leslie 147. Part 1 46

OUTLETS Restoring Hammond X-66 OUTLETS Wiring diagram of X-66 outlet receptacle. Part 1 47

OUTLETS Restoring Hammond X-66 OUTLETS Since the rear panel was dismounted, 6 additional output sockets were incorporated to drive an external audio mixer. A small board was assuring the interface between the 4 outputs from output stage of the X-66 console. The diagram of this interface board is provided here-after. After Part 1 48

OUTLETS Restoring Hammond X-66 OUTLETS Schematic diagram of interface board between the console output and external audio mixer. filter as found in TC-series. Part 1 Same 49

MECHANICAL Restoring Hammond X-66 MECHANICAL WORKS Restoring also includes the mechanical part or the body of the organ. Moisture, dust, carelessness of the former owner entailed serious damages that did merit some actions. Bad luck, all chrome sleeves exhibited severe rust stains. No other choice to dismount those tubes and send them outside for chrome-plating process. Part 1 50

MECHANICAL Restoring Hammond X-66 MECHANICAL WORKS No other choice than to remove cabling between the upper section and the base in order to separate them later on in two apart units. say than to do ! Easier to Here is the X-33 console ! Part 1 51

MECHANICAL Restoring Hammond X-66 MECHANICAL WORKS All the mechanical parts composing the base unit were so dismounted, cleaned and entirely re-painted. Not really funny! Original pedal lighting has been replaced by new ‘economic’ lamps providing a wide-angle lighting, long-life and no heat dissipation inside the console. Part 1 52

MECHANICAL Restoring Hammond X-66 MECHANICAL WORKS Upon receipt the chrome sleeves, the base has been re-mounted and upper and base units re-assembled. Afterwards, re-cabling was done as initially. Similar treatment was applied to the bench (re-chroming the tubes). Removable wooden panels were also entirely refurbished by a cabinet-maker. The mechanical part is now completed. Part 1 53