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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. Keep those plots as a reference.

Important: While performing the P.M., 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 800 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
  • Humidity
  
Door and upper cover interlocks Open each door and the upper cover. Ensure that the safety interlocks are operating correctly.  
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 800 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.    
Firmware Check firmware version The latest machine firmware is installed Release notes and firmware downloads
Settings Backup settings
  • For older machine versions, save table and record all NVM information.
  • For newer machine versions, save all tables on a rescue diskette
  
**Load film from each of the three cassettes**
Loading Watch and listen. Smooth, symmetrical and quiet movement in each cassette  
Drum Vacuum and spreader Watch. 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 system 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. related procedure

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
  • Run diagnostics to check laser graph and power.

OR

  • Calibrate laser for 5000.
  • Value should be >5000. "Normal" value is 10,000.

 

  • If laser calibration fails, replace static optic.

Replace the static optic unit if value is <5000.

 

D: Assemblies and components

Objectives:  Check everything, then go back and repair or adjust as required.
Time needed:  4-5 hours

  What to Do What to Look For Procedure

Parts
ECOs/FCOs Check that all mandatory FCOs are implemented on the Dolev 800.   FCO list
Standard controller - Board revision levels
  1. Remove boards.
  2. Record the revision levels.
  3. Clean electronic crate.
  4. Clean boards.
  5. Reinstall boards (Replace boards with latest revision, as required.)
  6. Run diagnostics
  • Relay driver 1
  • Relay driver 2
  • Stepper driver
  • Power converter
  • OMC
  • CRI
  • CPU
  • Strobe
  • Spinner driver
  • Fast LDR I/F

Boards and drivers comp level and ordering information
Data box (for Dolev 800 older models)
  1. Remove VLSI board.
  2. Clean data crate.
  3. Check comp level.
  4. Clean or replace board.
  5. Reinstall VLSI board.
 Check VLSI comp level. VLSI comp level
Detectors Run diagnostics to check detectors
  • Film detectors
  • Cassette detectors
  • Lever detectors
  • Door switches
  • Carriage HP/EP
  • Roller position home, end, and roller counter
  • Vacuum detectors A and B
  
Loading system
Loading cassettes Vacuum and clean. Loading shaft flanges should be in good condition, with no cracks and no magnets missing.  
Cassette detectors Remove and insert the cassettes. Confirm that the bar flag toggles between off and on.  
Cassette Rubber wheels
  1. Disassemble light-proof shelves to reach rubber wheels
  2. Clean with a lint-free cloth dampened with alcohol.
 Caution: Do not attempt to activate the rubber wheels while cleaning them. Your fingers could get caught in the system.  
Film-in detectors
  1. Run diagnostics.
  2. Manually activate film-in detectors and check signals.
 Make sure that the message "No Film" does not appear. Replacement procedure
Loading system Feeding rollers

Clean roller Dellerin wheels

   Cleaning procedure
Cutter
  1. Clean and then grease cutter guide with Mobilux #2.
  2. Run the cutter for 5 minutes via diagnostics.
  3. Examine cut edge of film.
  4. Check cutter chain tension.
  5. Lubricate cutter guide if required.
  • Cutter should operate smoothly.
  • Cut edge of film should be even.
 Cutter assembly procedures
Feeder wheels Run diagnostics. Activate and while wheels rotate, wipe them with a lint-free cloth dampened with alcohol. Check the force of 250 +/- 20 gr. for a pair of wheels on each film guide plate, using film and a weight gauge.  
Film transport guides Clean.    
Unloading cassette
  1. Vacuum and clean dust from the cassette and door 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 assembly

Spreader
  1. Check that wheels do not scratch film.
  2. Clean.
  3. Verify offsets parameters are condusive to proper spreader function.

 
  • With no film on drum, wheels do not rotate (in the up position)
  • With film on drum, wheels roll freely, lightly touching the film

Lock wheel pressure screw to press wheels out. Release to free wheels.
Rotate screw till wheels are in top position and release to 1 mm below top position.

Cleaning procedure

Spreader component replacement procedures
Film attachment to drum
  1. Insert a small piece of film between spreader rollers and drum.
  2. Adjust the tension of the pressure rollers if required.

There should be resistance; the film should not enter easily.

 Adjust roller tension
Drum cavity and central beam
  1. Vacuum dust and dirt from drum and beam.
  2. Wipe surfaces with a lint-free cloth.
   procedure
Drum vacuum holes Clean with medical needle (22G1.5 or similar).    
Vacuum leakage
  1. Run diagnostics and activate vacuum valves A and B.
  2. Operate vacuum pump.
  3. Optional check: connect pressure guage and check pressure level.
  • Check that film is attached to the drum
  • With a pressure guage, check the following:
    • without film: pressure max. 55 cm water
    • with film in full format: pressure min. 65 cm water
  
Feed detectors and counters Run diagnostics, and replace if required.   Replacement parts
Rubber wheels and sprockets (for spreader motor chain) Check chain tension, and check condition of rubber wheels and sprockets. Replace if required. Rubber wheels should be undamaged, and sprockets Replacement parts
Carriage - dynamic optic assembly

Lead screw		 Perform Leadscrew maintenance procedure.   maintenance procedure


Lead screw coupling (damper)

 Check pressure on damper and adjust if required.   procedure
Carriage beam Clean and oil carriage beam and felt.   Carriage beam maintenance
Dynamic optics
  1. Remove dynamic optic.
  2. Clean.
  3. Reinstall dynamic optic.
  

Cleaning dynamic optics

Assemble/dis-assemble dynamic optic assembly
Spinner
  1. Clean spinner encoder according to cleaning procedure.
  2. Adjust bow and linearity, if required.
  3. Run quality test procedure.
 Important: If spinner is under warranty, do not clean it! The warranty expire date is located on a label on the spinner.

cleaning procedure

Adjustment procedure

Test procedure
Shutter
  1. Pull out and examine.
  2. Wipe surface of reflector and solar cell with lens tissue and alcohol.
  3. Run diagnostics.

Shutter solenoid should function correctly.

 Cleaning the shutter
Penta prism / cube Clean.    
Fiber connectors
  1. Disconnect optical connectors.
  2. Clean surface with rice paper and alcohol.
  3. With a small, special brush clean the adaptor.
  4. Put a new coupling optic gel on the connectors, and then return them to their position.
    
Punch assembly
Punch (if installed) Remove slugs and clean container.    
Air supply
  1. Check connection and leakage.
  2. Check input pressure.
 Input pressure should be 5 bar.  
Punch assys Operate punches to verify smooth, successful operation.    
Power supply
Power unit voltage Run dignostics to check voltage levels, and adjust 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 800 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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