Lotem 800 - Planned Maintenance Procedure

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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.

Before going to the site:

Run an activity report to list all calls and dispatches for the device since the last PM (or install date if this is the first PM ever). Review the report for outstanding issues to help you prepare for the PM.
Find out when the processor chemistry will be changed. To properly assess image quality, the processor should be serviced and filled with fresh chemistry 24 to 48 hours before the PM visit.
Obtain permission from the customer to perform maintenance on the system. Inform the customer how long it will take.
If possible, arrange to work with an operator or maintenance person while performing maintenance. Explain proper system maintenance to that person, and point out any lack of maintenance that you notice.
Check for any mandatory FCOs or upgrades, and arrange to have the parts available on site.
Make sure the relevant PM and Add On kits are on site.
Make sure that the version and updated registry are available. If not, save Reg+DataBase.

Notes:

Many of the instructions below contain links to more detailed descriptions. For your convenience, most of these instructions appear in one document, which can also be printed out. The Drum Vacuum and Cooling System procedures are individual documents.
Planned maintenance is performed on a bi-annual basis, although some of the procedures should be performed every three months.
During maintenance, list all parts that you replace on your Lotem 800 Planned Maintenance Checklist.

PM and Add On spare parts lists:

PM - Basic Kit (510K1P003)
PM - Add On

Important: While performing the PM, 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 Lotem 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
Site conditions	Check that the site conditions are within the specifications, and inform operator of any unfit conditions.	Temperature Humidity
Doors, panels, and interlocks	Visually inspect the overall condition of all surfaces. Open each door and panel. From the PC Controller, check safety interlocks.	Safety interlocks should operate correctly.
Vacuum hoses	Check exterior hose.	Ensure that it is not being crushed or broken.
Debris cabinet hose	Check exterior hose.	Ensure that it is not being crushed or broken.

B: System Operation

Objectives: Determine that the Lotem 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.
Operator training	Make sure the operators understand how to operate the device safely.		Lotem 800 Customer Training (for Brisque ver 4 + Translations)
Backup settings #1	Backup the following info: Database folder Registry
Expose a large gray scale in three of the client's favorite formats.
Loading	Watch and listen.	Smooth, symmetrical and quiet movement; loading sequence progresses without problems.
Paper disposal	Watch and listen.	Paper is disposed of smoothly.
Drum vacuum	Watch.	Plate is held firmly to drum.
Head/tail grippers	Listen.	Listen for any irregular noises.
Carriage operation	Listen.	Listen for any irregular noises.
Edge detection	Listen and watch monitor.	Finds edge quickly, on first try.	Only if installed
Expose operation	Listen and watch monitor.	Listen for retraces and any irregular noises.
Plate unload from drum	Watch and listen.
Unload system	Watch and listen.	Smooth quiet operation, plate unloads without problems.

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
Laser	Check laser calibration.	Compare the results with the results of the last PM.

D: Assemblies and components

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

Lotem 800	What to Do	What to Look For	Procedure Parts
ECOs/FCOs	Check that all mandatory FCOs are implemented on the Lotem 800.		FCOs list
Board revision levels	Record the revision levels. Run diagnostics. Update, if required.	DSM DSM 2 MCF NUC Strobe 5 Strobe 7 DDB 1 N LDD 2 TEC 24 L box MB MB local 3 Local controller 3 Local 2 Punch board Interlock CTP power Interlock 2 (omron) E box MB
Detectors	Clean detectors with rice paper and alcohol.	Load gripper enable Unload gripper enable Balance Light detector window Paper/plate on disposal Paper/metal Centering short pins Punch short pins Paper bin Plate out of drum Plate out of machine Unload tray Conveyor HP/EP
Actuator pistons	Adjust air pressure regulators.
Fans Machine lower fans and inside L-box fans E-box fans	Clean every 6 months.
Loading/unloading system
Loading/unloading tray rollers	Clean with a clean cloth and alcohol super rubber rejuvenator.
XY rails	Clean; then lubricate tunnels with white grease.
X and Y belts	Check tension.		Adjust according to the small belt tension adjustment procedure, if required.
XY bar	Check parallelism. Clean.		Adjust according to the align the x-y bar to be parallel to the drum procedure, if required.
Suction cups	Check for wear.	Replace every 6 months (p/n 295C2M500).
Head/tail grippers	Check and tighten screws.		Adjust according to the tail grippers assy adjustment, if required.
External conveyor	Oil ball bearings every 6 months.
Paper disposal rollers	Clean with a clean cloth and alcohol super rubber rejuvenator.
Paper arm springs	Check for wear.	Replace every 6 months (p/n 280A4L952)
Unload rollers	Clean with a clean cloth and alcohol super rubber rejuvenator.
XY loading pump (Model 0523-101Q-G181D)	Replace filter every 6 months. Vacuum internal area. Measure vacuum blades with a caliber.	The width of the vacuum blades should be greater than 22 mm.	Gast XY loading vacuum pump PM procedure
XY loading pump Becker DT 4.8	Replace filter every 6 months. Vacuum internal area. Measure vacuum blades with a caliber.	The width of the vacuum blades should be greater than 12.5 mm.	Becker XY vacuum pump DT 4.8 procedure
Vacuum level	Check the XY vacuum level.		Loading (XY-system) vacuum pump check procedure
Drum system
Drum	Check the drum screws.	Drum screws should be secured with red paint, and the paint should not be removed.
Drum vacuum	Clean vacuum holes. Check drum vacuum. Replace pump air filter. Replace pump oil separator. Change pump oil.	Use drill 0.8 mm accessory kit (p/n 510K1R593).	U 3.40 Drum vacuum checking procedure
Dry vacuum pump	Replace filter every 6 months. Vacuum internal area. Measure vacuum blades with a caliber.	The width of the vacuum blades should be greater than 27 mm.	VT 4.40 vacuum pump maintenance procedure
Dry vacuum level	Check the drum vacuum level.		Drum vacuum checking procedure
Vacuum hoses	Visually check.	Wear or damage	Replace, if required.
Edge detection strip	Clean.		Only if installed
Swivel	Lubricate with 4-5 drops of SAE 30 motor oil.		Accessing swivel
Carriage system
Leadscrew	Clean and lubricate every 6 months.
Leadscrew HP fine detector	Calibrate.
Lens protector	Clean lens protector with rice paper and alcohol.	If Kodak plates are used, perform this procedure more frequently.	Lens protector access and cleaning procedure
Light detector	Remove and clean every 6 months.
Optic air supply (fufu)	Replace filter every 6 months.	p/n 432A10305	See part number and location
Oil bracket	Lubricate V block felt every 3 months. Replace every 6 months.	p/n 291A2N300B	Replace oil bracket
Punch system
Punch slugs	Remove from machine and from slugs box.
Punch HP	Check performance, and tighten screws.

E: Workstation

Objectives: Test the system thoroughly before leaving the site!
Time needed: 2 hours

Refer to Brisque & Timna Server Preventative Maintenance for details.

Workstation	What to Do	What to Look For	Procedure Parts
Disk usage	Check that usage capacity is less than 95%.
Desktop	Rebuild weekly.
Desktop trash	Empty weekly.
File system	Check monthly.

F: Service Comments

Record PM call information.
Complete the "Service Comments" section of the Lotem 800 Planned Maintenance Checklist. For the customer's information, make a note of:

All FCOs that were installed
All parts that were replaced
Any safety features that were disabled or bypassed
Any operating environment issues

G: Customer Acceptance

To complete the PM, the Lotem 800 Planned Maintenance Checklist must be signed off by the customer and returned to Creo.