Lotem 800 Family planned maintenance procedures

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Lotem 800 Family Planned Maintenance (PM) Procedures

Important: Strictly confidential. Do not leave this document at a customer site
Planned maintenance (PM) must only be performed by Kodak 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.

Note:

Many of the instructions below contain links to more detailed descriptions.
Planned maintenance should be performed every six months.
During maintenance, list all the parts that you replace on your Lotem 800 Family Planned Maintenance Checklist.

PM and jigs part lists:

Lotem 800 II basic PM kit (510K1R551A) (22 Mar 05)
Lotem 800 basic PM kit (510K1P003A) (23 Oct 07)
Regional jig kit (510J6L042) (22 Mar 05)
Qntm preventive maintenance kit II (510K1R551B) (23 Oct 07)
Customer PM parts (22 Mar 05)

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.
Check for any mandatory FCOs or upgrades, and arrange to have the parts available on site.
Make sure the relevant PM and jig kits are available on site. Order jigs from regional offices.
Make sure to take the following to the site:
- Cotton swabs
- Rice paper
- Alcohol
- SAE 30 motor oil
- Mobil Mobilux #2
- Grease gun
- Silicon oil
- Non-alcoholic press blanket cleaner (rubber rejuvenator)

Important:
During the PM, do not dismantle any part which has not been specified for checking, cleaning or lubrication.

Imaging

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

Expose a Creo Plate Test Target (CPTT) in the client’s favorite format. This will serve as your reference plate.

Imaging	Do the following...	Reference
Imaging quality, position and size	Inspect the exposed CPTT reference file.
Laser (Fiberhead)	Check maximum laser calibration (300 mW). Compare the results with the results of the last PM.	View Laser Group dialog box
Laser (Quantum)	Check laser graph and power. Compare the results with the results of the last PM.	Procedure

Objectives: Check safety first! Determine that all Lotem 800 Q / II Family 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.

Safety and Exterior Evaluation	Do the following...	Reference
Site conditions	Verify that the site conditions, including humidity and temperature, are within the specifications. Record the humidity and temperature readings on the PM report, and inform the operator of any unfit conditions.	Lotem 800 II Family Site Preparation Guide
Doors, panels, and interlocks	Visually inspect the overall condition of all surfaces. Open each door and panel. In Lotem Controller, check safety interlocks and verify that they function correctly.
Debris cabinet hose	Verify that the exterior hose is not impeded or broken.
Drum vacuum pump and cooling fluid leaks	Check the floor at the side of the platesetter and verify that there are no external fluid leaks.

Backup Settings

Objectives: Determine that the Lotem 800 II is operating correctly. Note any irregularities for further investigation.

System Operation	Do the following...	Reference
Backup settings	Back up the registry, database folder, FCOs, laser uniformity and MCKey plate counter: (HKey_Local_Machine/Software/MCkey)	Lotem backup and restore utility
Backup settings (Quantum)	In addition to the registry and the database folder, back up the following: List version—compare to latest controlled release NVS dump diff Save flash.bin Save ram.bin	Procedure
Firmware (Quantum)	Update to the current controlled release version.	Head TMCE Xilinx Post Boot

System Operation

Do the following...

Reference

Backup settings

Back up the registry, database folder, FCOs, laser uniformity and MCKey plate counter:
(HKey_Local_Machine/Software/MCkey)

Lotem backup and restore utility

Backup settings
(Quantum)

In addition to the registry and the database folder, back up the following:

List version—compare to latest controlled release
NVS dump diff
Save flash.bin
Save ram.bin

Procedure

Firmware
(Quantum)

Update to the current controlled release version.

Assemblies and Components

Objectives: Check all the assemblies and components, then go back and repair or adjust as required.
Important: Before opening any doors and panels, send the carriage to its 500 mm position.

Load and unload at least three plates of different sizes. Verify that the loading and unloading sequences progress successfully.
Successful loading and unloading verifies that the drum gripper rollers and drum balance systems are working properly.

Assemblies and components	Do the following...	Reference
Lotem 800 II and Quantum Family
FCOs	Check that all next visit FCOs are implemented on the platesetter. Install FCO Updater utility for existing FCOs, as required.	FCOs, FCO Updater utility
Board diagnostics	Run diagnostics on the boards.
Overall system	Check for rust and paint damage every six months.
Punch system
Punch slugs	Every six months, clean punch slugs in both platesetter and slug box.
Loading system
Detectors	Verify proper performance of the punch HP detectors, and tighten the screws if necessary. Clean the following detectors with cotton swabs/rice paper and alcohol: Paper/plate on disposal detector Paper bin detector Centering short pins Punch short pins detector
Loading rollers	Clean using a clean cloth and a press blanket cleaner (such as Rubber Rejuvenator). Do not use an alcohol based cleaner.
XY rails	Clean, and then lubricate tunnels with grease.
XY loading bar	Check parallelism. Clean. Adjust, if required.
Loading system vacuum pump	Check the blades and filter	Procedure
Paper disposal rollers and paper disposal tweezers	Remove and throw away pieces of paper stuck inside. Clean with a clean cloth and a press blanket cleaner (such as Rubber Rejuvenator). Do not use an alcohol based cleaner. Replace the paper disposal tweezers every six months.
Suction cups	Check for wear. If worn or fractured, replace.	FCO 512-00213A
Internal fans	Clean every six months.
E-box fans	Clean every six months.
Unloading system
Unloading rollers	Clean using a clean cloth and a press blanket cleaner (such as Rubber Rejuvenator). Do not use an alcohol based cleaner.
Unloading conveyor	Visually inspect the belts for any wear or tear.
Drum system
Head/tail grippers	Check and tighten all screws every six months	FCO 512-00133A
Vacuum pump air filter	Replace every 6 months.	Procedure
Drum vacuum holes	Using the cleaning jig (part number 510K1R593), with vacuum turned on, use the 0.8 mm drill to clean the drum vacuum holes.	Procedure
Vacuum hoses	Verify that the exterior vacuum hose is not worn, crushed or broken and replace if required.
Drum detectors	Clean the following detectors with a cotton swab/rice paper and alcohol: Load gripper enable detector Unload gripper enable detector Left balance enable detector Right balance enable detector
Edge detection strip	Clean with alcohol.
Swivel	Lubricate the swivel rotation unit with 4-5 drops of SAE 30 motor oil.	Procedure
Vacuum pressure	Make sure the vacuum is working correctly.	Procedure
Light detector (applicable only to FH platesetters)
Light detector	Clean with a cotton swab (dipped in alcohol).	Procedure
Carriage system
Leadscrew	Clean and lubricate.
V-blocks: Oil pads Carriage	Clean every six months.	Procedure
Debris internal hose	Verify that the internal hose is not impeded or broken.
Lotem 800 Quantum
Loading pump air filter	Replace every six months.	Procedure
Water pump	Oil the pump’s motor on an annual basis.	Cooling system planned maintenance
Internal fans	Clean every six months.
UDRC particulate filter	Replace, as required, every six months, or every 10,000 m² of plate.	UDRC-B particulate filter
Cooling system	Check every 6 months. Cooling water pump Pressure test Strainer Draining cooling liquid	Cooling system planned maintenance
L-box fans, ventilator openings and air paths (applicable only to FH)	Use a damp cloth to clean the fans and ventilator openings.

Service Comments

Record PM call information.
Perform fine machine calibration after PM:
1. Perform a minimum of two loading sequences with different plate sizes and thicknesses. Adjust the parameters, if required.
2. Perform the following Lotem 800 calibrations (if necessary):
  - Focus
  - Wpower
  - Slop
  - Curve
3. Expose the final CPTT; check and obtain approval for machine calibration quality.
4. Back up the registry and the database to a floppy disk, using the Lotem backup and restore utility.
Complete the Service Comments section of the Lotem 800 II Family Planned Maintenance Checklist.
For the customer’s information, make a note of the following:

Test the Remote Support and ensure the site is configured on the RSS.
All FCOs that were installed.
All firmware updates that were installed.
Any safety features that were disabled or bypassed.
Any operating environment issues, such as room temperature, humidity, etc.

Customer Acceptance

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