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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


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


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


Paper magazines Remove dust / deposits inside (vaccum cleaner)

1.7.3 Paper magazine compartment left and right


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


AGFA d-lab.1 2004-07-30 / PN 03063_01 7

1.7.5 Computer System (CS)


Power supply units Clean the power supply units (vacuum cleaner)

Fans Clean the two fans (IPU and MPU)

1.7.6 Scanner (SC)


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


8 2004-07-30 / PN 03063_01 AGFA d-lab.1

1.7.8 Paper Processor (PP)


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


AGFA d-lab.1 2004-07-30 / PN 03063_01 9

1.7.9 End of the Maintenance Work (Machine ON)


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


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


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


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


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


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


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


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


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


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.


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


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)

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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!


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)

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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)

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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


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


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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


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


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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


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


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


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


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


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


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)


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


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


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


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

Print

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 —


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


44 2004-07-30 / PN 03063_01 AGFA d-lab.1

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

Index Maintenance Kits

46 2004-07-30 / PN 03063_01 AGFA d-lab.1

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