Lotem 800 II - 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 Jigs 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, Cooling System and UDRC detailed PM 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 Q / II Family Planned Maintenance Checklist.

PM and Jigs parts lists:

Lotem 800 Q / II Family - PM Basic Kit (510K1R551)
Lotem 800 Q / II Family - Regional Jigs Kit (510J6L042)

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 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.
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 II 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
Operator feedback	Speak with the operators and prepress manager.
Operator training	Make sure the operators understand how to operate the device safely.
Backup settings #1	Backup the following info: Database folder Registry Flash.bin file Ram.bin file
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.
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
Quantum
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 Q / II Family	What to Do	What to Look For	Procedure Parts
ECOs/FCOs	Check that all mandatory FCOs are implemented on the Lotem 800 Q / II Family.		Lotem 800 II FCOs
Board revision levels	Record the revision levels. Run diagnostics. Update, if required.	NUC (for Quantum only) MB local 3 Local 3 CTP power Interlock 2 (omron) E box MB TMCE CA
Detectors	Clean detectors with rice paper and alcohol.	Load gripper enable Unload gripper enable Balance Centering pins Punch short pins Unload tray Conveyor detector
Air flow regulators	Adjust for smooth operation every 3 months.
Actuator pistons	Adjust for smooth operation every 3 months.
E-box fans	Clean every 6 months.
Overall system	Check for rust and paint damage every 6 months.
Loading/unloading system
Loading/unloading rollers	Clean with a clean cloth and alcohol super rubber rejuvenator every 3 months.
XY rails	Clean and lubricate every 6 months.
X and Y belts	Check tension and adjust, if required.
XY loading bar	Check parallelism. Clean. Adjust, if required.
Suction cups	Check for wear every 3 months and replace, if required.
Head/tail grippers	Check and tighten all screws every 6 months.
External conveyor ball bearings	Lubricate ball bearings every 6 months.
Paper disposal rollers	Clean with a clean cloth and alcohol super rubber rejuvenator.
Loading pump air filter	Check loading pump air filter every 6 months.		Procedure
Internal fans	Check every 6 months.		Procedure
Drum system
Drum vacuum pump air filter	Replace every 6 months.		Procedure
Drum vacuum holes	Clean every 3 months.
Vacuum hoses	Visually check every 3 months.	Wear or damage
Edge detection strip	Clean.
Intake air filter	Clean every 6 months.		Procedure
Spring spoilers	Replace every 6 months.
Swivel rotation unit	Lubricate every 6 months.		Procedure
Carriage system
Leadscrew	Clean and lubricate every 6 months.
Oil pads for V block	Clean and lubricate every 3 months.
V block and carriage	Clean every 3 months.
Punch system
Punch slugs	Clean punch slugs in both machine and Slugs box every 3 months.
Punch HP	Check performance, and tighten screws every 3 months.
Lotem 800 w/MCU
Lotem 800 Quantum
Water pump	Oil the pump's motor on an annual basis.		Cooling system preventive maintenance
UDRC particulate filter	Replace, as required, every 6 months, or every 10,000 ^M2 of plate.		See Chapter 4, page 32
Cooling system	Check every 6 months.	Cooling water pump Pressure test Strainer Draining cooling liquid	Cooling system preventive maintenance

E: Workstation

Objectives: Test the system thoroughly before leaving the site! Update any/all firmware. Note updates under Service Commands on the customer's PM Checklist.
Time needed: 2 hours

Refer to the Control-Settings page for details of controlled releases.

Workstation	What to Do	Procedure Parts
Quantum
SCSI cable	Visually inspect the overall condition of the SCSI cable and connections. Replace as required.
TSP cable	Visually inspect the overall condition of the TSP cable and connections. Replace as required.
Head firmware	Update to the current Controlled Release version.	Procedure
TMCE firmware	Update to the current Controlled Release version.	Procedure
Xilinx	Update to the current Controlled Release version.	Procedure
Post	Update to the current Controlled Release version.	Procedure
Boot	Update to the current Controlled Release version.	Procedure
	Test operation.

F: 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:
  - Focus
  - Wpower
  - Slop
  - Curve
3. Expose the final ATP, and check the machine calibration quality.
4. Expose a job, and obtain approval for machine quality.
5. Back up the registry and the database to a floppy disk.
Complete the "Service Comments" section of the Lotem 800 Q / II Family Planned Maintenance Checklist. For the customer's information, make a note of:

All FCOs that were installed
All firmware updates 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 Checklist must be signed off by the customer and returned to Creo.