Index Everest-D User manual

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INDEXEVERESTSERVICEMANUAL
IndexBraillePrinterCompany
Table of contents
1. Mechanics 2
1.1 Disassembling 2
1.1.1 Backplate 2
1.1.2 Expose the main board 3
1.1.3 Open the front panel cover 3
1.1.4 Right casing 4
1.1.5 Left casing 4
1.1.6 Remove the main board 5
1.1.7 Loosen the front panel cover 5
1.1.8 Fan 6
1.1.9 Front panel cover indicator 6
1.1.10 Transformer 7
1.1.11 Roll bearing, left side. 7
1.1.12 Stepper motor, paper feeding 8
1.1.13 Driving belt 8
1.1.14 Pulleys 9
1.1.15 Right roll bearing 9
1.1.16 Roll axle 10
1.1.17 Printing head 10
1.1.18 Front panel board 11
1.1.19 Printing head board 11
1.1.20 Steering dowels 12
1.1.21 Plastic films 12
1.1.22 Hammers 13
1.1.23 Casing 13
1.1.24 Back bar 14
1.1.25 Rubber damper 14
1.1.26 Anvils 15
1.1.27 Axle 15
1.1.28 Gliding bearings 16
1.1.29 Stepper motor, printing head 16
1.1.30 Gear wheel, printinghead motor 17
1.1.31 Reference pulse sensor 17
1.1.32 Gear wheel, paper feeding 18
1.1.33 Sheet feeder 18
2. Service instructions 19
2.1 Adjust printing head
reference pulse offset 19
2.2 Internal printer test program 19
2.3 Front panel 19
2.4 Hammer configuration 20
2.5 Fault messages. 20
2.5.1 Failure "100" No reference-pulse 20
2.5.2 Failure "Front panel open". 20
2.5.3 Failure "Paper length fault". 20
2.5.4 Failure "Paper jam". 20
2.5.5 Failure "140". 20
2.5.6 Failure "150" 20
2.5.7 Failure "160" 20
2.5.8 Failure " 170" 21
2.6 Reference pulse offset. 21
2.7 Paper sensor adjustment 21
2.8 Voltage compensation. 21
2.8.1 Run Volt 21
2.8.2 Change parameters 22
2.8.3 Send file to Everest 22
3Printer modules 24
3.1 Screws nuts and glue 24
3.2 Printinghead 24
3.3 Chassis 24
3.4 Transmission 25
3.5 Shipping material 25
3.6 Electronics 25
3.7 Component locations 26
4Electronic components 31
4.1 Printinghead board 31
4.2 Main board 33
5Shematic descriptions 36
5.1 Mainboard layout 36
5.2 CPU 37
5.3 Memory map decoding 38
5.4 Dynamic Ram 39
5.5 EPROM & EEPROM 40
5.6 Stepper motor drivers -
printinghead interface 41
5.7 Keyboard Indterface &
Speech synthesis 42
5.8 Centronics interface 43
5.9 RS-232 44
5.10 Power supply 45
5.11 Printing head - paper indicator 46
5.12 Printing head - solenoid drivers 47
6Cables 48
6.1 Serial communication 48
6.1.1 RS232-C circuit summary. 48
6.1.2 Index RS232-C configuration 49
6.1.3 Cable INDEX IBM-PC 49
6.1.4 Cable INDEX-AT 49
6.1.5 Cable configuration
Index - Apple McIntosh 50
6.2 Centronics interface 50
6.2.1 Centronics inteface standard 50
7Disassembling flowchart 51

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1. Mechanics
1.1 Disassembling
Thismanualcontainsaflowchart,whichdescribestheeasiestwaytodisassembleandmakeserviceon
INDEXEverest-D.
Theflowchartislocatedinchapter6inthismanual.
TheflowchartfordisassemblingofINDEXEVEREST-Dwillbeusedinthefollowingway:
Lookforthedetailthatyouwanttodisassembleintheflowchart,forexampleanvils.
ByfollowingtheflowfromEVEREST-DtoANVILS.Youwillseethatyouhavetodothefollowing:
1.Openthefrontpanelcover.
2.Liftouttheprintinghead.
3.Removetheaxle.
4. Open the back bar.
5.Liftouttherubberdamper.
6.Removetheanvils.
1.1.1 Backplate
Figure 1.1.1 Disassembling of the back plate.
1.Unscrewthethreescrewsfromthefrontsideofthesheetfeeder.
2.Unscrewthefourscrewsonthebackplate.
3.Removethebackplate.
1.1.2 Expose the main board
Figure 1.1.2 Main board.

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1.Unscrewthemarkedscrewsintheupperrawofthemainboard.
2.Turndownthemainboard.
1.1.3 Open the front panel cover
Figure 1.1.3 Opening the front panel cover.
1.Toopenthecover,grabthehandleandtheplasticcasing.
2.Openthefrontpanelcover.
1.1.4 Right casing

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Figure 1.1.4 Right casing.
1.Unscrewthemarkedscrews.
2.Slideoutthecasing.
1.1.5 Left casing
Figure 1.1.5 The left casing.
1.Unscrewthemarkedscrews.
2.Slideoutthecasing.

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1.1.6 Remove the main board
Figure 1.1.6 Main board.
1.Loosentheflatcables.
2.Unscrewtheboard.
3.Takeoutthemainboard.
1.1.7 Loosen the front panel cover
Figure 1.1.7 Disassembling of the front panel cover.
1.Loosentheflatcablefromtheswitchpanel.
2.Unscrewthescrewsfromthesideplates.

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1.1.8 Fan
Figure 1.1.8 Location of the fan.
1.Loosentheconnectioncablestothefan.
2.Unscrewthefan.
3.Removethefan.
1.1.9 Front panel cover indicator
Figure 1.1.9 Front panel cover indicator.
1.Loosentheconnectioncablestothefrontpanelcoverindicator.
2.Slideouttheboard
.
3.Loosentheindicatorwithasolderingiron.

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1.1.10 Transformer
Figure 1.1.10 Transformer.
1.Loosentheconnectioncablestothetransformer.
2.Unscrewthetransformer.
1.1.11 Roll bearing, left side.
Figure 1.1.11 Roll bearing.
1.Unscrewthethreescrewsontheupperrollbearing.
2.Carefullyremovetherollbearing.
Dothesameoperationfortheotherbearing.

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1.1.12 Stepper motor, paper feeding
Figure 1.1.12 Stepper motor, paper feeding.
1.Loosentheconnectioncablestothesteppermotor.
2.Loosenthefourscrewandremovethemotor.
1.1.13 Driving belt
Figure1.1.13 Locationofthedrivingbelt.
1.Pulloffthedrivingbeltfromthepulleys.

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1.1.14 Pulleys
Figure1.1.14 Pulleys.
1.Removethepulleyswithapuller.
1.1.15 Right roll bearing
Figure 1.1.15 The right roll bearing.
1.Unscrewtheupperrollbearing.
2.Carefullyremovetherollbearing.
Dothesameoperationfortheotherbearing.

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1.1.16 Roll axle
Figure 1.1.16 Roll axles.
1.Whentherollbearingisremoved,carefullyslideouttherollaxles.
1.1.17 Printing head
Figure 1.1.17 Printinghead.
1.Unscrewthefournutsonthescrewsholdingtheprintinghead.
2.Carefullypullouttheprintinghead.
3.Loosenthetwoflatcablesandthegroundconnectioncable.

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1.1.18 Front panel board
Figure 1.1.18 Front panel board.
1.Loosenthecableconnectionstothefrontpanelboard.
2.Slideouttheboardfromtheprofile.
1.1.19 Printing head board
Figure 1.1.19 Driving board.
1.Unscrewtheboard.
2.Removetheboard.

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1.1.20 Steering dowels
Figure 1.1.20 Steering dowels.
1.Loosensteeringdowelsfromtheanvilprofile.
2.Loosensteeringdowelsfromthehammerprofile.
1.1.21 Plastic films
Figure 1.1.21 Plastic films.
1.Pullofftheplasticfilms.

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1.1.22 Hammers
Figure 1.1.22 Hammers.
1.Loosenthecablesfromtheprintingheadboardsockets.
2.Unscrewthehammers.
1.1.23 Casing
Figure 1.1.23 Casing.
1.Unscrewthecasing.

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1.1.24 Back bar
Figure 1.1.24 Back bar.
1.Unscrewthemarkedallenscrewsholdingthebackbar.
2. Remove the back bar.
1.1.25 Rubber damper
Figure 1.1.25 Rubber damper.
1.Removetherubberdamper,locatedunderthebackbar.

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1.1.26 Anvils
Figure 1.1.26 Location of the anvils.
1.Takeouttheanvils.
1.1.27 Axle
Figure 1.1.27 Axle.
1.Carefullypullouttheaxlefromtheglidingbearings.

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1.1.28 Gliding bearings
Figure 1.1.28 Gliding bearings.
1.Carefullyknockouttheglidingbearingsfromthebearinghousing.
1.1.29 Stepper motor, printing head
Figure 1.1.29 Stepper motor.
1.Loosenthecabletothesteppermotor.
2.Unscrewthemotor.
3.Pulloutthemotor.

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1.1.30 Gear wheel, printinghead motor
Figure 1.1.30 Gear wheel.
1.Pulloutthegearwheelwithapuller.
1.1.31 Reference pulse sensor
Figure 1.1.31 Printinghead reference pulse sensor.
1.Loosenthesensorwithasolderingiron.

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1.1.32 Gear wheel, paper feeding
Figure 1.1.32 Gear wheels.
1.Pulloutthegearwheelswithapuller.
1.1.33 Sheet feeder
Figure 1.1.33 Sheet feeder
1.Unscrewthethreescrews.
2..Liftoffthesheetfeeder

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2. Service instructions
2.1 Adjust printing head reference pulse offset
1. Press VALUE simultaneously while power on. Everest will echo a beeping sound.
2. Press VALUE until several times until the distance between the printing head and the
sideplate is 2-3 mm.
3. Press ”Setup” to store the new reference pulse offset.
2.2 Internal printer test program
An integrated test program enables sequence testing of the different hardware modules in Everest.
The modules that the program test are: RAM, PROM, FAN, Sheet feeder, Stepper motor paper-
feed, stepper motor + reference pulse on the printing head, front panel + front panel decoding,
Centronics port, RS 232-C port, paper indicator and front panel indicator.
In the user manual, chapter 5.10, you will find the complete instructions for the test program.
2.3 Front panel
Use the following schematic description to solve connection problems with the front panel.

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2.4 Hammer configuration
The hammers is working in the following order:
Male hammers (prints page 1, down page in document stack.)
No 1 character 1-3
No 3 character 4-10
No 5 character 11-17
No 7 character 18-24
No 9 character 25-31
No 11 character 32-38
No 13 character 39-42
Female hammers (prints page 2, upper page in document stack.)
No 2 character 1-7
No 4 character 8-14
No 6 character 15-21
No 8 character 22-28
No 10 character 29-35
No 12 character 36-42
2.5 Fault messages.
2.5.1 Failure “100” - No reference-pulse.
Major fault. Turn the printer off/on. If you still get the same message, check the reference-pulse
sensor on the printinghead board and the magnet on the centre plate and the fuses on the
mainboard.
2.5.2 Failure “Front panel open”.
Close the front panel cover and give ON LINE.
2.5.3 Failure “Paper length fault”.
This fault appears when the paper is to short comparing to the measured paper length. If the
paper is dark, for example with a dark picture, this fault can appear. Give ON LINE to continue
printout on the current page. Give REPEAT to continue printing a new copy of the current page
2.5.4 Failure “Paper jam”.
This fault appears when the paper is to long comparing to the measured paper length. Give ON
LINE to continue printing with the current page. Give REPEAT to continue printing a new copy
the next page.
2.5.5 Failure “140”.
Not valid command when selecting A,B or C from computer.
2.5.6 Failure “150”.
Fault in setup file, a non numeric value.
2.5.7 Failure “160”
Major fault. The EEPROM is not receiving or writing information in a correct way.
Try to do a "SUPER-SYSTEM RESET".