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Planned Maintenance Procedure

Strictly confidential. Do not leave at a customer site.

Planned maintenance (PM) is to be performed only by Creo service personnel or by trained and certified operators.

To print out the PM instructions below, click on the print icon at the top of the page.

Planned maintenance is performed every six months.

Before going to the site:

Before you begin:

Plot the grid and ATP test in the resolution that the customer usually works with. Look for any patterns or effects, overall screen quality, and registration. Keep those plots as a reference.

Important: While performing maintenance, do not take apart or dismantle any part not specified for checking, cleaning or greasing.

A:  Safety and Exterior

Objectives:  Check safety first!  Determine that all Dolev 4Press components are safe to operate and to work on. Walk around the entire device to examine the exterior and surroundings for damage and any issues that may require further investigation or repair.
Time needed:  20 minutes  (Device can be returned to customer any time.)

Safety and Exterior Evaluation What to Do What to Look For Procedure

Parts
Site conditions Check that the site conditions are within the specifications, and inform operator of any unfit conditions.
  • Temperature
  • Relative humidity
  
Door and side interlocks Open each door. Ensure that the safety interlocks are operating correctly. Panel operation
Detectors status
Panels, doors and covers Visually inspect the overall condition of all surfaces, hinges. Smooth opening and closing, good condition Ordering information
Operating panel and keys Visually inspect and activate all four keys and buttons    

B:  System Operation

Objectives:  Determine that the Dolev 4Press is operating correctly. Watch and listen. Note irregularities for further investigation.
Time needed:  20 minutes  (Device can be returned to customer any time.)

System Operation What to Do What to Look For Procedure

Parts
Operator feedback Speak with the operators and prepress manager.
  • Smooth imaging
  • Imaging quality
  • Smooth communication with workflow station
  
Operator training Make sure the operators understand how to operate the device safely. Use customer training check list.  
Firmware Check firmware version The latest machine firmware is installed Release notes and firmware downloads
Settings Backup settings

Save all tables on a rescue diskette

 501V50331A - S/W rescue diskette
**Load film into the drum.**
Rocker assy Watch and listen. When loading drawer is closed, rocker assy closes without touching optomech side flanges.  
Loading rollers and guides Watch and listen. Smooth, symmetrical and quiet movement of film.  
Drum air release grooves Watch, and use a flashlight to see. Film should be smoothly spread in the drum with no visible air bubbles.  
Cutter Watch and listen. Smooth quite operation and even cut edge of film.  
Unload rollers and guides Watch and listen. Smooth quite operation.  
**Move carriage from HP to EP**
Carriage Listen. Listen for any irregular noises.  
Dynamic optic chain assembly Watch and listen. Dynamic optic chain opens and rewinds smoothly.  

C:  Imaging

Note:  To properly assess image quality, the processor should have been serviced and filled with fresh chemistry within the last 24 to 48 hours.

  What to Do What to Look For Procedure

Parts
**Expose a large gray scale in three of the client's favorite formats.**
Static Optic
Laser From the service utility, run ND filter graph. Value should be >40,000. "Normal" value is 60,000. Replace the static optic unit if value is <40,000.

 

D: Assemblies and components

Objectives:  Check everything, then go back and repair or adjust as required.
Time needed:  3-4 hours

  What to Do What to Look For Procedure

Parts
ECOs/FCOs Check that all mandatory FCOs are implemented on the Dolev 4press.   FCO list
E-box and P-box board revision levels

 

  1. Remove E-box and P-box unit.
  2. Remove boards.
  3. Record the revision levels.
  4. Clean E-box interior.
  5. Clean boards.
  6. Reinstall boards (Replace boards with latest revision, as required.)
  7. Separate P-box from E-box, and then clean P-box.
  8. Reassemble P-box, and E box.
  9. Run diagnostics
  • OMC
  • CRI
  • Strobe
  • CPU 486 + SDOC
  • Floppy drive
  • Spinner driver
  • Stepper driver
  • DC motor controller

Boards and drivers comp level and ordering information
Data box (if exists)
  1. Remove VLSI board.
  2. Clean data crate.
  3. Check comp level.
  4. Clean or replace VLSI board.
 Check VLSI comp level. VLSI comp level
Machine parameters
  1. Make sure that all parameters are according to customer requirements.
  2. Save all parameters
  • Res/Int table
  • Motor settings
  • Machine offsets
  • Punch settings
 Rescue diskette
Detectors Run diagnostics to check detectors.
  • Film detectors
  • Cassette detectors
  • Punch detectors
  • Load/unload drawers
  • Door interlock
  • Carriage HP/EP
  • Processor selector signals
  
Loading system
Loading cassette
  1. Vacuum and clean dust from the cassette and drawer area.
  2. Check the shaft clutch.
  3. Check film tension.
  • Loading shaft flanges should be in good condition, with no cracks.
  • Shaft clutch should turn easily.
  • Pressure = 800 gr. +/- 100 gr.
  
Film-in detectors

Manually activate film-in detectors.

 Detector arm should be free.  
Load/unload rollers
  1. Clean rollers with a clean cloth and alcohol or super rubber rejuvenator.
  2. Check and adjust roller pressure, if required.
  • Load roller back pressure should be equal on both sides and center.
  • Unload roller pressure = 1000 gr +/- 100gr.
 Adjusting load/unload roller tension
Cutter
  1. Clean and then oil cutter guide with Silicon oil.
  2. Run the cutter for 3 minutes via diagnostics.
  3. Examine cut edge of film.
  4. Check cutter chain tension.
  • Cutter should operate smoothly.
  • Cut edge of film should be even.
  
Film transport guides Clean the guides with a clean cloth dampened with alcohol.
  • Inner and outer guides
  • Front and rear guides
  • Rocker guide
  • In-line processor guides
  
Unloading cassette
  1. Vacuum and clean dust from the cassette and drawer area.
  2. Insert undeveloped film in the cassette.
  3. Expose the cassette to strong light for a few minutes.
  4. Develop film in dark room and inspect results.
 Check for light leakage. Totally clear film indicates no light leakage.  
Drum cavity and guide beam
  1. Vacuum dust and dirt from drum and beam.
  2. Wipe surfaces with a lint-free cloth.
  3. Use anti-static spray protection for dry environments.
    
Drum air release grooves Clean with medical needle (22G1.5 or similar).    
Film attachment to drum
  1. Perform Advance Film to 600 mm.
  2. Perform Attach Sequence.
  3. Use a flashlight to check.

There should be no air bubbles between the film and drum.

 Adjusting load/unload roller tension
Film feed counters

Run diagnostics, and check.
  • Load
  • Take
  • Unload
  • Cassette encoders
 Replace if required.
Carriage - dynamic optic assembly

Leadscrew
  1. Check visually.
  2. Check that the end bearing is clean and not damaged.
  3. Clean with alcohol.
  4. Grease with Mobilux #2.
 Thread should not be bent, screw should be in good condition. Use ball nut greaser (507B26966)


Leadscrew coupling (damper)

 Check pressure on blue coupling and adjust if required. Measurement of coupling compression is <1.5 mm Adjust coupling pressure
Dynamic optics
  1. Remove dynamic optic assembly.
  2. Clean guide beam with a clean cloth dampened with alcohol.
  3. Clean rulon pads under the dynamic optic assembly.
  4. Clean lenses first with a blower brush or can of compressed air, and then with a proper cleaning tool and alcohol only (not acetone). Do not scratch lenses.
  5. Disconnect optical connectors. Clean fiber optic tips with lens cleaning tissue and alcohol.
  6. With a small, special brush clean the adaptor.
  7. Clean spinner encoder, see procedure (see Important).
  8. Reinstall dynamic optic assembly.
  9. Check bow and linearity, and replace dynamic optic if required, or adjust linearity using strobe correction table, see procedure.
  10. Run quality test procedure.
  • Clean spinner encoder once a year after its warranty has expired.

    • Important: If spinner is under warranty, do not clean it! The warranty expire date is located on a label on the spinner.

  • Bow = 30 micron
  • Linearity = 50 micron
 Installing/uninstalling dynamic optics

 

Cleaning procedure

Linearity procedure
Penta prism / cube Clean.    
Fiber connectors
  1. Disconnect optical connectors.
  2. Clean surface with lens cleaning tissue and alcohol.
  3. With a small, special brush clean the adaptor.
    
Punch assembly
Punch (if installed) Remove slugs and clean container.    
Punch assy
  1. Oil the punch pin with silicon oil.
  2. Operate punches to verify smooth, successful operation.
    
Power supply
Power unit voltage Run dignostics to check voltage levels, and replace power box, if required.    
**Expose a large gray scale in three of the client's favorite formats. Check for patterns and uniformity, and compare to reference.**

 

E:  Service Comments

  1. Record PM call information.
  2. Complete the "Service Comments" section of the Dolev 4press Planned Maintenance checklist. For the customer's information, make a note of:
    • All FCOs that were installed
    • Any firmware that was installed
    • All parts that were replaced
    • Any operating environment issues

F:  Customer Acceptance

To complete the PM, the check list must be signed off by the customer and returned to Creo.

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