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Transcript of Bedienung Deckblatt deutsch - saal-group. · PDF file1.7.4 Film Processor (FP) ... 1.11...
Maintenance Kits
Digital Minilab
d-lab.1Type 8070/050 / Type 8070/100Type 8070/200 / Type 8070/300
Maintenance
Order number DD+18070010D0Edition 2004-07-30Version English, 03063_01
Modification History
Version Edition Modifications
03063_00 2004-04-14 Start Version
03063_01 2004-07-30 Modified: Kit for yearly maintenanceNew: Kit for maintenance every second year
Published in compliance with EN 55022 (valid in EU):
Warning!The equipment complies with the limits for a Class A device. Operation of the equipmentin residential areas may cause radio interference in which case the user at his ownexpense will be requested to take whatever measures may be required to correct theinterference.
© 2004 Agfa-Gevaert AG. All rights reserved.
No part of these instructions may be reproduced, copied, or transmitted in any form or byany means without prior written permission by Agfa-Gevaert AG.
Maintenance Kits Contents
AGFA d-lab.1 2004-07-30 / PN 03063_01 i
Contents
1 Maintenance.........................................................................................................................11.1 Purpose .................................................................................................................................................................................11.2 Safety Prescriptions..........................................................................................................................................................11.3 To all Service Engineers..................................................................................................................................................21.4 Maintenance Kits (wearing Parts) ...............................................................................................................................3
1.4.1 Kit for Maintenance – Yearly....................................................................................................................31.4.2 Kit for Maintenance – Every Second Year ...........................................................................................4
1.5 Lubricants and Cleaning Agents..................................................................................................................................51.6 Special Tool .........................................................................................................................................................................51.7 Overview: Maintenance Jobs to be performed by the Service Engineer......................................................6
1.7.1 General machine............................................................................................................................................61.7.2 All Paper magazines.....................................................................................................................................61.7.3 Paper magazine compartment left and right .....................................................................................61.7.4 Film Processor (FP)........................................................................................................................................61.7.5 Computer System (CS).................................................................................................................................71.7.6 Scanner (SC) ....................................................................................................................................................71.7.7 Paper Advance (PA).......................................................................................................................................71.7.8 Paper Processor (PP).....................................................................................................................................81.7.9 End of the Maintenance Work (Machine ON).....................................................................................9
1.8 Overview: Maintenance Jobs to be performed by the Customer................................................................. 101.9 General machine ............................................................................................................................................................ 11
1.9.1 Cleaning the inside compartments ..................................................................................................... 111.10 Cleaning the Paper Magazines inside.................................................................................................................... 111.11 Checking the Paper Magazine Compartments ................................................................................................... 111.12 Film Processor (FP) (d-lab.1 allrounder)................................................................................................................. 12
1.12.1 FP: Cleaning and checking the film loading units and the film magazines........................ 121.12.2 FP: Lubricating the main drive chain and the motor gear, cleaning and
lubricating the dryer.................................................................................................................................. 121.12.3 FP: Squeegee unit, replace worn parts if required......................................................................... 131.12.4 FP: Cleaning the racks and replacing worn parts if required..................................................... 141.12.5 FP: Cleaning the processing tanks....................................................................................................... 151.12.6 FP: Servicing hoses, valves, circulation pumps............................................................................... 161.12.7 FP: Servicing the replenisher pumps .................................................................................................. 161.12.8 FP: Servicing the Docking System....................................................................................................... 17
1.12.8.1 Nozzle sets and Opener.................................................................................................171.12.8.2 Locking mechanism of the docking door................................................................ 21
1.12.9 FP: Cleaning and lubricating the Leader cutter .............................................................................. 221.13 Computer System........................................................................................................................................................... 231.14 Scanner (SC) ..................................................................................................................................................................... 24
1.14.1 SC: Negative mask support, replacing worn parts if required ................................................... 241.14.2 SC: Cleaning the Cartridge Feeder....................................................................................................... 241.14.3 SC: Lubricating all negative masks (if required) ............................................................................. 25
1.15 Paper Transport (PA)...................................................................................................................................................... 261.15.1 PA: Cleaning the Print Engine ............................................................................................................... 261.15.2 PA: Cleaning the cutter units................................................................................................................. 261.15.3 PA: Servicing the Lane Distributor ....................................................................................................... 271.15.4 PA: Cleaning the back printer head..................................................................................................... 27
Contents Maintenance Kits
ii 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.16 Paper Processor (PP) ..................................................................................................................................................... 281.16.1 Paper Processor – Important note....................................................................................................... 281.16.2 PP: Cleaning the gears and bearings.................................................................................................. 281.16.3 PP: Checking / replacing the gear for frequency adjustment (every second year) .......... 291.16.4 PP: Crossovers, replace worn parts if required................................................................................ 291.16.5 Cleaning / servicing the squeegee unit............................................................................................ 301.16.6 PP: Racks, replace worn parts if required.......................................................................................... 311.16.7 PP: Cleaning the processing tanks...................................................................................................... 321.16.8 PP: Servicing hoses, valves, pumps..................................................................................................... 321.16.9 PP: Cleaning the water tank .................................................................................................................. 331.16.10 PP: Servicing the replenisher pumps.................................................................................................. 33
1.16.10.1 PP: Replacing the poppet valves of the replenisher and water pumpsif required............................................................................................................................ 34
1.16.11 PP: Cleaning the Docking System....................................................................................................... 351.16.11.1 Locking mechanism of the docking door ............................................................... 39
1.16.12 PP: Cleaning the dryer rack.................................................................................................................... 401.16.13 PP: Dryer rack, replace worn parts if required, lubricate the chain ........................................ 401.16.14 PP: Cleaning and checking the densitometer................................................................................. 411.16.15 PP: Cleaning the Sorter............................................................................................................................ 41
1.17 Switching on the machine ......................................................................................................................................... 421.17.1 FP/PP: Checking the circulation pumps (running noise)............................................................ 421.17.2 FP/PP: Calibrating the water pumps .................................................................................................. 421.17.3 Functional check of the machine ........................................................................................................ 421.17.4 Eliminate ghost effects (if required).................................................................................................... 42
2 Index.................................................................................................................................. 45
Maintenance Kits Purpose
AGFA d-lab.1 2004-07-30 / PN 03063_01 1
1 Maintenance
1.1 Purpose
Maintenance to keeps the machine in good working condition. Some of the maintenancejobs have to be performed by the customer himself, others are done once a year by aservice engineer.
The maintenance performed by the service engineer encompasses the following jobs:
– Cleaning the machine and the major functional parts
– Replacing wearing parts
– Greasing and lubricating functional partsOnly the lubricants listed in the appendix are allowed to be used,see 1.4.2 Lubricants and Cleaning Agents.
– Checking the maintenance jobs to be performed by the customer resp. performingthem in case of need, see 1.8 Overview: Maintenance jobs to be performed by thecustomer
1.2 Safety Prescriptions
CAUTION!
The maintenance jobs described in this chapter must only be performed by anAgfa service technician or a person authorised by Agfa.
The safety prescriptions on all machine stickers and in chapter 1 of this foldermust be observed by all means.
Be sure to observe the safety precautions relating to the individual maintenancejobs.
CAUTION!
Risk of injury!Cleaning must be avoided or done with particular care while the drive is switchedon.
Risk of cutting yourself!Mind sharp corners or edges while working in the Printer area.
Note:The maintenance jobs must be carried out while the machine is switched off. Do notforget to switch it off again if it has to be switched on for some time. e.g. to clean theprocessing tanks.
Maintenance Kits To all Service Engineers
2 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.3 To all Service Engineers
Your opinion about the parts in the PMV Kits is important for us to know in order toensure optimum maintenance prerequisites.
Please tick off the parts in the column Not used in the parts lists which were notneeded for the maintenance.
Please enter in the following table Additional parts the wearing parts which in youropinion should be included in the PMV Kits, giving a brief justification.
Please send this page and the following two (parts lists) completed with the date,your name and your signature to:
Address: Fax:
Agfa Gevaert AG 0049-89-62 07 72 77Attn. Ingo WawartaTegernseer Landstr. 161D-81539 München
Sender:
Name: ....................................................................................................
Country: ................................................................................................
Departm. / Phone: ...........................................................................
Date / Signature: ..............................................................................
Additional parts
Part number Assembly group * / Part name Quantity Reasons
* FP Film ProcessorFD Film DrivePA Paper AdvancePP Paper Processor
Maintenance Kits Maintenance Kits (wearing Parts)
AGFA d-lab.1 2004-07-30 / PN 03063_01 3
1.4 Maintenance Kits (wearing Parts)
1.4.1 Kit for Maintenance – Yearly
Order no.: 10+9.9999.1162.1
Part number ABC Code Bezeichnung Description Quantity not used
Filmprozessor Film processor
CL+P4-87162 89ECE Kegelrad Bevel gear 8
CL+P3-87166 9BUZA Antriebswelle Bevel gear shaft 2
CL+P4-87163 83GHH Bundbuchse Bush, metal 8
CL+P4-61823 YVW3G Zahnrad Gear 1
CL+P4-87183 9BVHD Zwischenzahnrad Idle gear 2
CL+P4-87190 9BVKH Einlaufrolle Inlet roller 1
CL+P4-87186 9BVJF Rolle Roller 1
CL+P4A-87303 9B3ST Walze Roller 1
CL+P4A-87313 9B44M Walze Roller 5
CL+P4-49901 YOL9S Sicherungsring Stop ring 4
CL+P4-49902 YOW3R Sicherungsring 0,7 mm Stop ring 0.7 mm 10
CL+P4-55751 W6YZY Sicherungsring, groß Stop ring, large 5
CL+P4-61791 YVW6N Sicherungsring, klein Stop ring, small 15
Filmlauf Film drive
L9.8506.5024.1 QZWYB Antriebsrolle Drive roller 2
L9.8506.5015.1 QZWX8 Andruckrolle TR5 kompl. Pressure roller TR5 assy 2
Papierprozessor Paper processor
CL+P3-86701 9HDEL Kegelrad Bevel gear 2
CL+P3-86740 82NOC Kegelrad Bevel gear 2
CL+P4-86738 82NQG Kegelrad Bevel gear 1
CL+P4-86702 9B5XD Kegelrad Achse oben Bevel gear (top of shaft) 2
CL+P4-86748 9HDHR Zahnrad Gear 2
CL+P4-86656 9ELTK Zahnrad Gear 4
CL+P4-86731 9B5YF Zahnrad Gear 1
CL+P4-95549 1J2HW Führungsstift Inner pin 5
CL+P4-86665 9HDGP Stift Pin 4
CL+P4-86778 9JL1X Stift Achsantrieb Pin (shaft drive) 5
CL+P4-6110(2/1) TOU8E Rückschlagventil, Teflon Poppet Valve, Teflon 6
CL+P3-97017 UL2GF Rolle B Roller B 2
CL+P3-97018 UL2FD Rolle C Roller C 4
CL+P3-97019 V5RRW Rolle M Roller M 2
CL+P4-39286 YDVL6 Wellenlagerung Shaft holder 5
CL+P4-F4668 WRKKY Silikonschlauch Silicon tube 4
CL+P3-86685 96G75 Silikonschlauch Silicon tube 1
CL+P4-86757 92753 Lagerbuchse (Kö.Welle) Sleeve 2
CL+P4-E5404 TFJTA Lagerbuchse Antriebswelle Sleeve 2
CL+P4-E5403 Q6VSA Lagerbuchse Sleeve 22
CM+7M200RA01C TON26 Feder Spring 10
Maintenance Kits Maintenance Kits (wearing Parts)
4 2004-07-30 / PN 03063_01 AGFA d-lab.1
Part number ABC Code Bezeichnung Description Quantity not used
Papierprozessor (Fortsetz.) Paper processor (cont.)
CL+P4-86705 82NFU Feder Spring 2
CL+P4-E5354 TCM8R Schenkelfeder mit Spirale Spring (coil) 4
CL+P3-E5394 TFNWX Abquetschrolle Squeeze roller 4
CL+P3-E6344 TJNCJ Abquetschrolle Squeeze roller 4
CL+P3-96865 TGAWQ Abquetschrolle Squeeze roller 2
CL+P3-F4078 V7J57 Abquetschrolle Trocknerrack Squeeze roller, dryer rack 1
CL+P3-F4079 V7J6A Abquetschrolle Trocknerrack Squeeze roller, dryer rack 1
CL+P4-86753 9XYDL Sicherungsring Stop ring 20
CL+P4A-E9698 UAM7P Steckachse Support 2
1.4.2 Kit for Maintenance – Every Second Year
Order no.: 10+9.9999.1172.0
Part number ABC Code Bezeichnung Description Quantity not used
Filmprozessor Film processor
CL+P3-87159 83GNS Kettenzahnrad Sprocket gear 8
Papierprozessor Paper processor
CL+P4-E5403 Q6VSA Lagerbuchse Sleeve 10
CL+P3-86595 9B9TM Zahnrad 50/60 Hz Anpassung Gear for 50/60Hz (motor) 1
CL+P3-86685 96G75 Silikonschlauch Silicon tube 3
CL+P3-86703 82NGW Kettenzahnrad Sprocket gear 6
CL+P3-97018 UL2FD Rolle C Roller C 20
CL+P3-97019 V5RRW Rolle M Roller M 8
CL+P3-E5394 TFNWX Abquetschrolle Squeeze roller 4
CL+P3-E6344 TJNCJ Abquetschrolle Squeeze roller 4
Maintenance Kits Lubricants and Cleaning Agents
AGFA d-lab.1 2004-07-30 / PN 03063_01 5
1.5 Lubricants and Cleaning Agents
Designation Order no. ABC Code Quantity
Compressed air spray CM+9.9999.9274.0 8CANZ —
Constant OY 220 CM+9.9999.9271.0 774KR 100 ml
Lixtop plastic cleaner CM+9.9999.9231.0 WL9MK 1000 ml
Klueberalfa HX83-302 CM+9.9999.9287.0 UW126 20 g
Klueberplex BE 31-502 (for heavy-duty requirements) CM+9.9999.9280.0 Q3WQK 100g
Bio PVC Cleaner CM+9.9999.9221.0 V7W91 5 liter
Note:The structure of the maintenance schedule and the subsequent description allowsystematic working:
The order of the maintenance jobs corresponds to the functional blocks of the machine.
All lubrications are done on the spot at the same time.
CAUTION!The Film Processor dryer is made of a plastic compound that is particularlysensitive to lubricants. The chains in the FP dryer should therefore only belubricated with Klueberalfa.Never use any other grease that is recommended for other chains as otherwise theplastic will break!
1.6 Special Tool
Note:A meter is needed to check and adjust the toothed belt tension.
Maintenance Kits Overview: Maintenance Jobs to be performed by the Service Engineer
6 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.7 Overview: Maintenance Jobs to be performed by the Service Engineer
1.7.1 General machine
Components Maintenance jobs
General machine Clean inside compartments
1.7.2 All Paper magazines
Components Maintenance jobs
Paper magazines Remove dust / deposits inside (vaccum cleaner)
1.7.3 Paper magazine compartment left and right
Components Maintenance jobs
Coupling: check and replace if necessaryPaper magazinecompartment Check magazine locking
1.7.4 Film Processor (FP)
Components Maintenance jobs Lubricants
Blow out film loading unitFilm loading unitsand film magazines Check the gears and on the film magazine the counter-gears and
the locking lever and replace them if necessary
Main drive chainand motor gear
Lubricate the main drive chain andthe motor gear
KlueberalfaKlueberplex
Blow out / clean dryer
Clean dryer inlet rubber rollers, replace them if necessary
Dryer
Lubricate continuous chain and drive chain Klueberalfa
Clean squeegee unitCheck wearing parts and replace them if necessary
Clean racks and check their smooth movementCheck wearing parts and replace them if necessary
Clean processing tanks, if necessary
Wet section
Check hoses, valves, circulation pumps; replace valves if required
Replenisher pumps Check pumps and replace valves or bellows if required
Clean drip tray
Clean nozzle set (incl. bellows and opener)
Docking system
Check the locking mechanism of the docking door
Blow out Leader cutter and the light sensors
Clean rubber rollers
Leader cutter
Remove glue residue from the cutter blade
Maintenance Kits Overview: Maintenance Jobs to be performed by the Service Engineer
AGFA d-lab.1 2004-07-30 / PN 03063_01 7
1.7.5 Computer System (CS)
Components Maintenance jobs Lubricants
Power supply units Clean the power supply units (vacuum cleaner)
Fans Clean the two fans (IPU and MPU)
1.7.6 Scanner (SC)
Components Maintenance jobs Lubricants
Negative masksupport
Check rollers and replace them if necessary
Cartridge Feeder Blow out mechanical parts and light sensors
Negative masks Lubricate the clamp actuator and the holes in the bearing plate (ifrequired)
Klueberalfa
1.7.7 Paper Advance (PA)
Components Maintenance jobs Lubricants / cleaningagents
Remove paper dust
Clean transport belts and check their tension
Lubricate the bearing points of the rocker, replace if necessary Klueberplex
Print engine
Clean light sensors
Clean cutter units with a vacuum cleanerCutter units
Clean rollers, guide plates and cutters
Remove paper dust
Clean guide plates
Clean rubber rollers (use Isopropanol sparingly if they are very dirty)
Clean plastic rollers Lixtop plastic cleaner
Check roller pressure springs and plastic bearings, replace them ifnecessary
Lubricate bearing points Constant OY 220
Check the tension of the toothed belt drive gears, adjust ifnecessary
Clean coupling and counter-pressure plate
Lane distributor
Clean the paper rotation unit andcheck the tension of the toothed belt
Back printer Clean the back printer head Isopropanol
Maintenance Kits Overview: Maintenance Jobs to be performed by the Service Engineer
8 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.7.8 Paper Processor (PP)
Components Maintenance jobs Lubricants
PP, in general Clean all gears and bearings Lixtop plastic cleaner
Main drive chain Lubricate the main drive chain Klueberalfa
Gear 50/60 Hz Check the gear and replace it if necessary (every second year)
Check crossovers and replace the silicon tubes if required
Check squeegee unit and replace the wearing parts if necessary Klueberplex
Wet section
Clean racks and check their smooth movementCheck wearing parts and replace them if necessary
Clean processing tanks
Rinse hoses
Replace valves (if required)
Processing tanks
Check circulation pumps
Clean water tank BiocleanerWater tank
Check float sensors for smooth movement
Replenisher pumps Check pumps and replace valves or bellows if necessary
Poppet valve Check poppet valves (replenisher and water pumps), replace them ifnecessary
Clean drip tray
Clean nozzle sets (incl. bellows and opener), replace if necessary
Docking system
Check the locking mechanism of the docking door
Clean gears, rollers, bearings and paper guide elements
Check rollers, replace if necessary
Dryer rack
Lubricate the chain Klueberalfa
Clean calibration plate
Check mechanism of solenoids for smooth movement
Densitometer
Check the position of the magnetic read head with respect to thecalibration plate (parallelism)
Clean the paper guide elements and the rollers
Clean transport belt and print deposit
Sorter
Check toothed belt tension, adjust if necessary
Maintenance Kits Overview: Maintenance Jobs to be performed by the Service Engineer
AGFA d-lab.1 2004-07-30 / PN 03063_01 9
1.7.9 End of the Maintenance Work (Machine ON)
Components Maintenance jobs Lubricants
Check the circulations pumps (noice) and replace them, if required:– Film Processor (only d-lab.1 allrounder)– Paper Processor
Calibrate the water pumps:– Film Processor (only d-lab.1 allrounder)– Paper Processor
Check general machine function:– Process a film– Print– Eliminate ghost effects if necessary (script)
End of themaintenance work
Check correct condition of the safety appliances
Maintenance Kits Overview: Maintenance Jobs to be performed by the Customer
10 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.8 Overview: Maintenance Jobs to be performed by the Customer
Assembly group Check parts on the basis of the list and clean or replace them in case of need
Clean processing racks
Clean squeegee unit
Replace chemical filters
Check the quality of the chemistry: check film process
Film Processor
Replace air filter in dryer
Clean magnetic read head of APS negative mask
Clean drive rollers in negative mask area
Clean pressure rollers in negative mask area
Clean film brushes (2 pcs.)
Clean film brush for IX240 films
Negative mask: remove dust
Lens: remove dust
Clean film takeup
Scanner
Clean film chuter
Replace air filter in fan box
Clean paper deck
Paper transport
Lane distributor: remove paper dust / deposits
Clean processing racks
Clean paper guide, tank crossovers and squeegee unit in Paper Processor
Replace chemical filters
Check the quality of the chemistry: check paper process
Replace air filters
Clean dryer rack
Clean densitometer calibration plate and guide plate in paper exit unit
Paper exit: clean guide plate and transport belts
Paper Processor
Sorter: clean transport belts and print deposit
Maintenance Kits General machine
AGFA d-lab.1 2004-07-30 / PN 03063_01 11
1.9 General machine
1.9.1 Cleaning the inside compartments
Remove the covers
Blow out the inside compartments includingthe air hoses
Clean the air intake area of the cooling fans(grids, fan paddles)
1.10 Cleaning the Paper Magazines inside
3002_111
Clean the paper magazines inside:
Remove the paper roll in the dark room
Use a vacuum cleaner to remove dustand deposits
Put the paper rolls back into theirmagazines
1.11 Checking the Paper Magazine Compartments
3002_013
Check the drive couplings (1) for the papermagazines (visual check) and replace ifnecessary
Check the magazine locking (2):The actuating roller must not be askew
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
12 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.12 Film Processor (FP) (d-lab.1 allrounder)
1.12.1 FP: Cleaning and checking the film loading units and the film magazines
Blow out the film loading units
Check the gears and on the film magazinethe counter-gears and the locking lever andreplace them if necessary
1.12.2 FP: Lubricating the main drive chain and the motor gear, cleaning and lubricating the dryer
3002_015
CAUTION!The Film Processor dryer is made of aplastic compound that is particularlysensitive to lubricants. The chains (1), (2)and (3) should therefore only belubricated with Klueberalfa.Never use any other grease as otherwisethe plastic will break!
Lubricate the continuous chain (1) and thedrive chain (2) with Klueberalfa
Lubricate the main drive chain (3) withKlueberalfa:
Use the crank handle to move the chain
After lubricating the chain removeexcess lubricant with a cloth
Lubricate the motor gear to the 50/60 Hzgear with Klueberplex
Blow out / clean the whole dryer and thesensor
Clean the dryer inlet rubber rollers, replacethem if necessary
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
AGFA d-lab.1 2004-07-30 / PN 03063_01 13
1.12.3 FP: Squeegee unit, replace worn parts if required
3002_003
Check the wearing parts and replace them ifnecessary:
Roller (1 x)Part no. CL+P4A-87303ABC Code 9B3ST
Stop ring, large (5 x)Part no. CL+P4-55751ABC Code W6YZY
Roller (5 x)Part no. CL+P4A-87313ABC Code 9B44M
Stop ring, small (15 x)Part no. CL+P4-61791ABC Code YVW6N
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
14 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.12.4 FP: Cleaning the racks and replacing worn parts if required
Clean the racks and check them for smoothmovement
Check the gears, roller shafts, slide bearingsand springs on all racks for damage / wearand replace them if necessary
3002_001
Check the wearing parts and replace them ifnecessary:
Sprocket gear (2 x)Part no. CL+P3-87159ABC Code 83GNS
Stop rings (4 x)Part no. CL+P4-49901ABC Code YOL9S
Bevel gear (8 x)Part no. CL+P4-87162ABC Code 89ECE
Bush, metal (8 x)Part no. CL+P4-87163ABC Code 83GHH
Stop rings (10 x)Part no. CL+P4-49902ABC Code YOW3R
3002_002
Check the roller of the SB3 rack and replaceit if necessary:
Roller (1 x)Part no. CL+P4-87186ABC Code 9BVJF
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
AGFA d-lab.1 2004-07-30 / PN 03063_01 15
3002_130
Check the inlet roller of the SB1 rack andreplace it if necessary:
Inlet roller (1 x)Part no. CL+P4-87190ABC Code 93VKH
1.12.5 FP: Cleaning the processing tanks
This task is necessary under the following conditions:Process is not OK and there are stains or deposits on developped films
CAUTION!Ask the customer's permission!
Drain the processing solutions
Rinse the main tank and the temperaturecontrol tanks several times with water
With a full main tank, switch on the machinefor a short while to rinse the circulationpumps and the hoses
Drain the water
Check that the drain valves are closed
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
16 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.12.6 FP: Servicing hoses, valves, circulation pumps
Check the hose connections between tanksand circulation pumps, circulation pumpsand drain cocks for traces of leakage
Check the hoses for kinks and siphonformation
Check the circulation pumps for tightnessand tight seating
If the circulation pump makes a noise whilerunning, replace it: pump type MD6
1.12.7 FP: Servicing the replenisher pumps
3002_033
Check the replenisher pumps (1) for leaksand replace the replenisher pump valves orthe pump bellows if required
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
AGFA d-lab.1 2004-07-30 / PN 03063_01 17
1.12.8 FP: Servicing the Docking System
1.12.8.1 Nozzle sets and Opener
The part called nozzle set is bonded to form a unit. It includes a bellows and an opener.
Take out the easy film boxes.
Check the nozzle sets:Push the nozzle sets up. If one does notmove smoothly, it must be cleanedthoroughly.
3002_085
Remove the cover plate (1)
Remove the clamps (2) and disconnect thehoses:
For the water inlet
To the replenisher tanks
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
18 2004-07-30 / PN 03063_01 AGFA d-lab.1
3002_148
Remove the docking station:
Unscrew:2 screws on the machine frame2 screws inside the docking station (1)
Lift the docking station out of themachine and put it down
3002_144
Remove the T-joints with the pipes (waterrinsing system):
Remove the clamp (1)
Take out the T-joint with the pipe (2)
Note:An O-ring (3) is attached to the pipe (2).
3002_139
Clean or replace the parts:
Pipe (1) for CD A/B/C (3 x)(delivered with O-ring)Color redPart no. CL+P4A-F2053ABC Code WANX8
Pipe (2) for FX, SB (3 x)(delivered without O-ring)Color blackPart no. CL+P3-F2054ABC Code WANYB
O-ring for pipe FX, SBPart no. CL+ZQY-7ABC Code URURN
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
AGFA d-lab.1 2004-07-30 / PN 03063_01 19
3002_143
Remove the nozzle set:
Unscrew the springs (1) from the rear ofthe docking stations and remove them
3002_146
Pull down the stoppers (1) which holdthe nozzle sets (2) in the correctposition
3002_131
Push the bracket (2) to the back
Remove the two drip trays (1) and cleanthem
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
20 2004-07-30 / PN 03063_01 AGFA d-lab.1
3002_133
CAUTION!Sharp blade. Risk of injuries whenworking on the nozzle set.Do not push down the bellows around theopener.
Hold the bellows, turn it 90° anti-CWand lift the nozzle set out
3002_134
Service the nozzle sets and sleeves orreplace them, if necessary (see below):
Check the nozzle sets for leaks andcrystal deposits and clean them
Grease the nozzle sleeve lightly withKlueberalfa HX83-302 (see arrows)
Replace the nozzle sets and sleeves:
Nozzle set (6 x)Part no. CL+PA3-F4205ABC Code WANV4
Sleeve with felt (6 x)Part no. CL+P4-6275ABC Code WANW6
Clean the docking station:Wash off crystal deposits and dried chemicalresidues in the docking station
Reinstall the two drip trays:
CAUTION!Make sure that the drip trays audibly clickinto place, otherwise the nozzle setscannot return to their home position afterthe docking sequence.When inserting a new easy box, thechemicals would run into the machine.
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
AGFA d-lab.1 2004-07-30 / PN 03063_01 21
3002_142
Reinstall the nozzle set:
Insert the nozzle set
While pushing the nozzle holder (1)approx. 2 mm upwards, turn the nozzleset (2) 90° CW, until it audibly clicksinto place
Fix the nozzle set with the stopper (3)
1.12.8.2 Locking mechanism of the docking door
3002_042
Check the locking mechanism of thedocking door:
The locking device (1) and the lockingbolts (2) must move smoothly
It should not be possible to open thedoor when it is locked
Maintenance Kits Film Processor (FP) (d-lab.1 allrounder)
22 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.12.9 FP: Cleaning and lubricating the Leader cutter
3002_138
CAUTION!Do not dismantle the Leader cutter.Otherwise it is no longer adjusted.
Blow out the Leader cutter and the lightsensors
Clean the rubber rollers (1)
Remove glue residues from the cutter bladewith Isopropanol
Reinstall the Leader cutter:Push it in to the limit (elongated holes) andsecure it with the screws
Maintenance Kits Computer System
AGFA d-lab.1 2004-07-30 / PN 03063_01 23
1.13 Computer System
3002_128
Remove the cover (1)
Check the fans for dust:If the fan of the MPU is very dirty, disconnectthe wiring and pull out the T-rack
Clean the two fans (IPU and MPU) of theheat sinks on the main processors:
First use a vacuum cleaner
Then carefully remove any deposits.
3002_141
Clean the power supply units (1) of thecomputer system (vacuum cleaner)
Switch the machine on to check the correctfunction of the fans:If the sound indicates that a fan runs untrueit has to be replaced.
Maintenance Kits Scanner (SC)
24 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.14 Scanner (SC)
1.14.1 SC: Negative mask support, replacing worn parts if required
3002_005
CAUTION!Make sure that neither screws norwashers fall into the machine: Use asupport.
Observe the correct position of thewasher!
Check the wearing parts and replace them ifnecessary:
Pressure roller, top (2 x)Part no. CM+9.8506.5015.1ABC Code QZWX8
Pressure roller, bottom (2 x)Part no. CM+9.8506.5024.1ABC Code QZWYB
1.14.2 SC: Cleaning the Cartridge Feeder
Remove the front cover of the computersystem (CS)
Remove the covers of the Cartridge Feeder
CAUTION!Do not blow dust and fluffs into thenegative mask area.
Blow out the mechanical parts and the lightsensors with a compressed air spray
Maintenance Kits Scanner (SC)
AGFA d-lab.1 2004-07-30 / PN 03063_01 25
1.14.3 SC: Lubricating all negative masks (if required)
3002_041
Lubricate the clamp actuator and the holesin the bearing plate sparingly withKlueberalfa
Maintenance Kits Paper Transport (PA)
26 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.15 Paper Transport (PA)
1.15.1 PA: Cleaning the Print Engine
3003_031
Unscrew the bottom cover (containing theelectronic) and fold it down
Pull out the print engine
Remove the paper dust with a brush or avacuum cleaner
Lubricate the bearing points of the rocker(Klueberplex)
Transport belts of the exposure table:
Clean with a damp cloth
Inspect that the belt runs smoothly
Clean the light sensors
1.15.2 PA: Cleaning the cutter units
Clean the cutter units with a vacuum cleaner
Remove the top guide plate
Take the cutter units completely out of themachine
Blow out the cutter units
Clean the rollers, the bottom guide plate andthe cutter with a damp cloth
Maintenance Kits Paper Transport (PA)
AGFA d-lab.1 2004-07-30 / PN 03063_01 27
1.15.3 PA: Servicing the Lane Distributor
3002_026
Pull out the lane distributor on thetelescopic rails, lift it out and put it down
Remove the paper dust with a vacuumcleaner:
Lane distributor
Lane distributor compartment in themachine
Remove the guide plates and clean themwith a damp cloth or Agfa Cleaner
Clean all transport rollers:
Clean all rubber rollers with a damplintfree cloth, use Isopropanol if theyare very dirty
Clean the plastic rollers with Lixtopplastic cleaner
Check the roller pressure springs and replacethem if necessary
Check the plastic bearings for wear andreplace them if necessary
Lubricate the bearing points a little withConstant OY 220
Check the condition of the toothed belts andthe tension of the toothed belt drive gearsand adjust it if necessary
Clean the coupling and the counter-pressureplate
Service the paper rotation unit:
Blow off the paper dust from the lightsensors
Clean the paper rotation unit and thecounter-pressure plate for the backprinter with a damp cloth
1.15.4 PA: Cleaning the back printer head
Clean the back printer print head withIsopropanol
Maintenance Kits Paper Processor (PP)
28 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.16 Paper Processor (PP)
1.16.1 Paper Processor – Important note
CAUTION!Please observe the Safety precautions about the handling of chemicals inchapter 1.
Risk of injury if the wet section cover is unlocked by mistake (uncontrolled).
3009_011
Open the cover:It only locks in in vertical position and mayfall down if it is unlocked by mistake.
Close the cover:Before pushing the unlocking (PUSH HERE)support the cover with one hand and close it.
1.16.2 PP: Cleaning the gears and bearings
Clean all gears and bearings with Lixtop
Maintenance Kits Paper Processor (PP)
AGFA d-lab.1 2004-07-30 / PN 03063_01 29
1.16.3 PP: Checking / replacing the gear for frequency adjustment (every second year)
3002_009
Replace a worn part:Gear for 50/60 Hz (1 x)Part no. CL+P3-86595ABC-Code 9B9TM
1.16.4 PP: Crossovers, replace worn parts if required
3002_008
Check the wearing parts and replace them ifnecessary (observe the order of the CD rollerparts):
Silicon tube for CD (1 x)Part no. CL+P4-F4668ABC Code WRKKY
Silicon tube for BX and SB1-3 (1 x)Part no. CL+P3-86685ABC Code 96G75
Maintenance Kits Paper Processor (PP)
30 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.16.5 Cleaning / servicing the squeegee unit
3003_054
Dismount the rubber rollers, check them fordamages and replace them(observe the orderand color of the gears):Part no. CL+P3-96865ABC Code TGAWQ
Paper guide surfaces
Roller pressure equal on both sides, axialbacklash approx. 0,2 mm
If necessary (noise) grease the bearings withKlueberplex
Maintenance Kits Paper Processor (PP)
AGFA d-lab.1 2004-07-30 / PN 03063_01 31
1.16.6 PP: Racks, replace worn parts if required
3002_011
Clean the racks and check them for smoothmovement
CAUTION!The upper rack rollers should only berinsed. Cleaning them with a brush or inanother mechanical way will lead todeposits on prints. In this case run expiredpaper in order to clean up (approx.20 prints) or replace the rollers.
Check the gears, roller shafts, slide bearingsand springs on all racks for damage / wearand replace them if necessary
Check the wearing parts and replace them ifnecessary: see Table
No. Wearing part in the Kit Part no. ABC Code
1 Sprocket gear 2 pcs. CL+P3-86703 82NGW
Bevel gear 1 pcs. CL+P3-86701 9HDEL
2 Gear 2 pcs. CL+P4-86748 9HDHR
Stop ring 20 pcs. CL+P4-86753 9XYDL
Inner pin 2 pcs. CL+P4-95549 1J2HW
Gear 2 pcs. CL+P4-86656 9ELTK
3 Spring (Coil) 2 pcs. CL+P4-E5354 —
4 Pin 2 pcs. CL+P4-86665 9HDGP
5 Support 2 pcs. CL+P4A-E9698 UAM7P
Bevel gear 1 pcs. CL+P3-86740 82NOC
6 Bevel gear 1 pcs. CL+P4-86738 82NQG
7 Sleeve 2 pcs. CL+P4-86757 92753
Sleeve 16 pcs. CL+P4-E5403 Q6VSA
Squeeze roller 4 pcs. CL+P3-E6344 TJNCJ
Squeeze roller 4 pcs. CL+P3-E5394 TFNWX
8 Bevel gear 2 pcs. CL+P4-86702 9B5XD
Shaft holder 2 pcs. CL+P4-39286 YDVL6
Maintenance Kits Paper Processor (PP)
32 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.16.7 PP: Cleaning the processing tanks
This task is necessary under the following conditions:Process is not OK and there are stains or deposits on developped paper.
CAUTION!Ask the customer's permission!
Drain the processing solutions
Rinse the main tank and the temperaturecontrol tanks several times with water
With a full main tank, switch on the machinefor a short while to rinse the circulationpumps and the hoses
Drain the water
Check the drain valves for tightness
1.16.8 PP: Servicing hoses, valves, pumps
Rinse the tank effluent hoses with hot water:approx. 1 l / 60 °C
Check the hose connections between tanksand circulation pumps, circulation pumpsand drain cocks for traces of leakage
Check the hoses for kinks and siphonformation
Check the circulation pumps for tightnessand tight seating
If the circulation pump makes a noise whilerunning, replace it: pump type MD6
Maintenance Kits Paper Processor (PP)
AGFA d-lab.1 2004-07-30 / PN 03063_01 33
1.16.9 PP: Cleaning the water tank
Note:Depending on the water hardness, lime may deposit on the tank inside walls and thefloat sensors. These deposits may cause malfunctions of the float sensors, the waterreplenishment pumps and the water bellows pumps.
3002_027
If the water tank (two-part) is very dirty,clean it with diluted acetic acid (observe thethe producer's instructions) and then rinse itthoroughly several times
Check the float sensors (1) in the lid:They must move easily.
1.16.10 PP: Servicing the replenisher pumps
3002_032
Check the replenisher pumps (1) for leaksand replace the replenisher pump valves orthe pump bellows if required
Maintenance Kits Paper Processor (PP)
34 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.16.10.1 PP: Replacing the poppet valves of the replenisher and water pumps if required
3002_010
Check the wearing part and replace it ifnecessary:
Poppet valve (6 x)Part no. CL+P4-6110(2/1)ABC Code TOU8E
Maintenance Kits Paper Processor (PP)
AGFA d-lab.1 2004-07-30 / PN 03063_01 35
1.16.11 PP: Cleaning the Docking System
The part called nozzle set is bonded to form a unit. It includes a bellows and an opener.
Take out the easy paper boxes.
Check the nozzle sets:Push the nozzle sets up. If one does notmove smoothly, it must be cleanedthoroughly.
3002_034
Remove the cover plate (1)
Remove the clamps (2) and disconnect thehoses:
For the water inlet
For the replenisher tanks
3002_149
Remove the docking station:
Unscrew:2 screws on the machine frame2 screws inside the docking station (1)
Lift the docking station out of themachine and put it down
Maintenance Kits Paper Processor (PP)
36 2004-07-30 / PN 03063_01 AGFA d-lab.1
3002_145
Remove the T-joints with the pipes (waterrinsing system):
Remove the clamp (1)
Take out the T-joint with the pipe (2)
Note:An O-ring (3) is attached to the pipe (2).
3002_140
Clean or replace the parts:
Pipe (1) for BX A/B (2 x)(delivered with O-ring)Color redPart no. CL+P4A-F2053ABC Code WANX8
Pipe (2) for CD, SB (2 x)(delivered without O-ring)Color blackPart no. CL+P3-F2054ABC Code WANYB
O-ring for pipe CD, SBPart no. CL+ZQY-7ABC Code URURN
3002_147
Remove the nozzle set:
Unscrew the springs (1) from the rear ofthe docking stations and remove them
Maintenance Kits Paper Processor (PP)
AGFA d-lab.1 2004-07-30 / PN 03063_01 37
3002_132
Pull down the stoppers (1) which holdthe nozzle sets (2) in the correctposition
3002_136
Push the bracket (2) to the back
Remove the drip tray (1) and clean it
3002_137
CAUTION!Sharp blade. Risk of injuries whenworking on the nozzle set.Do not push down the bellows around theopener.
Hold the bellows, turn it 90° anti-CWand lift the nozzle set out
Maintenance Kits Paper Processor (PP)
38 2004-07-30 / PN 03063_01 AGFA d-lab.1
3002_134
Service the nozzle sets and sleeves orreplace them, if necessary (see below):
Check the nozzle sets for leaks andcrystal deposits and clean them
Grease the nozzle sleeve lightly withKlueberalfa HX83-302 (see arrows)
Replace the nozzle sets and sleeves:
Nozzle set (6 x)Part no. CL+PA3-F4205ABC Code WANV4
Sleeve with felt (6 x)Part no. CL+P4-6275ABC Code WANW6
Wash off crystal deposits and dried chemicalresidues in the docking station
Reinstall the two drip trays:
CAUTION!Make sure that the drip trays audibly clickinto place, otherwise the nozzle setscannot move back to their home positionafter the docking sequence.When inserting a new easy box, thechemicals would run into the machine.
3002_135
Reinstall the nozzle set:
Insert the nozzle set
While pushing the nozzle holder (1)approx. 2 mm upwards, turn the nozzleset (2) 90° CW, until it audibly clicksinto place
Fix the nozzle set with the stopper (3)
Maintenance Kits Paper Processor (PP)
AGFA d-lab.1 2004-07-30 / PN 03063_01 39
1.16.11.1 Locking mechanism of the docking door
3002_042
Check the locking mechanism of thedocking door:
The locking device (1) and the lockingbolts (2) must move smoothly
It should not be possible to open thedoor when it is locked
Maintenance Kits Paper Processor (PP)
40 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.16.12 PP: Cleaning the dryer rack
Lift out the dryer rack and put it down
Clean the gears, rollers and bearings as wellas the paper guide elements
1.16.13 PP: Dryer rack, replace worn parts if required, lubricate the chain
3002_012
Check the wearing parts and replace them ifnecessary:
Roller B (1) (2 x)Part no. CL+P3-97017ABC Code UL2GF
Roller C (2) (2 x)Part no. CL+P3-97018ABC Code UL2FD
Roller M (3) (2 x)Part no. CL+P3-97019ABC Code V5RRW
Roller G (4) (1 x)Part no. CL+P3-F4078ABC Code V7J57
Roller G2 (5) (1 x)Part no. CL+P3-F4079ABC Code V7J6A
Check that the paper guide elements arecorrectly positioned and locked
Lubricate the chain with Klueberalfa
Maintenance Kits Paper Processor (PP)
AGFA d-lab.1 2004-07-30 / PN 03063_01 41
1.16.14 PP: Cleaning and checking the densitometer
3002_040
Clean the calibration plate (1) with a dampcloth (alcohol)
Check:
The pressure solenoid mechanismmoves smoothly
The measuring head must be parallel tothe calibration plate
1.16.15 PP: Cleaning the Sorter
Cleaning agent:Cloth wetted in warm water
3003_041
Clean the paper guide elements and therollers
Clean the transport belt (1) and the printdeposit (2) with a damp cloth
Check the toothed belt tension of the driveand adjust it if necessary
Maintenance Kits Switching on the machine
42 2004-07-30 / PN 03063_01 AGFA d-lab.1
1.17 Switching on the machine
1.17.1 FP/PP: Checking the circulation pumps (running noise)
Replace the circulation pumps if they makea noise while running: Pump type MD6
1.17.2 FP/PP: Calibrating the water pumps
Calibrate the water pumps
Film Processor (only d-lab.1 allrounder):Path Settings > Machine Setting >FP pumps
Paper Processor:Path: Settings > Machine Setting >PP pumps
If necessary, check / replace the poppetvalves
1.17.3 Functional check of the machine
Process a film
Eliminate ghost effects, if required,see 1.17.4
Check correct condition of the safetyappliances
1.17.4 Eliminate ghost effects (if required)
Run the scripts to compensate double image effects / ghost effects in prints:Image_to_ABD.txtPrintcycle_GS.txt / Printcycle_Delay.txtWrite_GS_to_EEPROM.txt / write_Delay_to_EEPROM.txt
Note:Use 8 inch glossy paper for the test.
Fault Description Reference Script
Ghost up to 4 mm shifted double image see figure 1 Printcycle_GS.txtDelayCount up to 1 mm shifted double image see figure 2 Printcycle_Delay.txtnone no ghost effect see figure 3 —
Maintenance Kits Switching on the machine
AGFA d-lab.1 2004-07-30 / PN 03063_01 43
figure 1: ghost
figure 2: delay count
figure 3: no ghost effect
Call up the Service functions
Scripts for Service\General:
Perform script Image_to_ABD.txt
Select image GhostTest.bmp orDelayCountTest.bmp depending on thedistance of the shifted image
Select magnification 1
Scripts for Service\Exposure Controller:Depending on the drift of the shift performscript Printcycle_GS.txt (5 prints) or scriptPrintcycle_Delay.txt (8 prints)
FN Number of Exposure is a 5-digit numberon the front of the exposure unit
Select the testprints of Printcycle_GS.txt orPrintcycle_Delay.txt:Note down the GS Parameter: xx ordelay=xxx number of the back print on theprint on which the ghost effect is not visible.If the ghost effect is not visible on severalprints, take the print in the middle of thisseries.
Scripts for Service\Exposure Controller:
Perform scriptWrite_GS_to_EEPROM.txt orWrite_Delay_to_EEPROM.txt
Enter the number of theGS Parameter: xx or the number of thedelay=xxx of the print without the ghosteffect under Optimal delay value
Exit the Service functions
Maintenance Kits Index
AGFA d-lab.1 2004-07-30 / PN 03063_01 45
2 Index
!! Important note ! (Paper Processor)...........................................28
CCleaning agents................................................................................... 5Correction of ghost effects in prints...........................................42
DDouble image effects in prints .....................................................42
FFilm Processor, maintenance........................................................12
GGhost effects in prints .....................................................................42
LLubricants............................................................................................... 5
MMaintenance ......................................................................................... 1
Computer System (CS) ...............................................................23Film magazines ............................................................................12Film Processor (FP) ......................................................................12General machine..........................................................................11Machine ON...................................................................................42Paper magazine compartment ...............................................11Paper magazines..........................................................................11Paper Prozessor (PP) ...................................................................28Paper Transport (PA) ...................................................................26Scanner (SC)...................................................................................24
MMaintenance jobs
Customer, overview.....................................................................10Technician, overview .................................................................... 6
Maintenance KitEvery second year .......................................................................... 4Yearly ................................................................................................. 3
PPaper magazine
Cleaning ..........................................................................................11Compartment ................................................................................11
SSafety Prescriptions............................................................................ 1Service Engineers ................................................................................ 2Special tools.......................................................................................... 5
TTool ........................................................................................................... 5