6 Servicing Instructions

AUTOLITH TP
Servicing Instructions 6
November 2000 Page 1
1 About servicing instructions ................................................................................. 3
2 General maintenance instructions........................................................................ 4

2.1 Introduction ...................................................................................................... 4
2.2 Electrostatic discharge .................................................................................... 5
3 Frame and external parts ....................................................................................... 6
3.1 What is in this chapter ..................................................................................... 6

3.2 Feed and delivery tables ................................................................................. 7
3.3 Left and right upper covers.............................................................................. 9
3.4 Control panel assembly ................................................................................. 11
3.5 Control panel components............................................................................. 13
3.6 Emergency stop buttons................................................................................ 15
3.7 Lid closed switch............................................................................................ 17
3.8 Main isolator .................................................................................................. 19
3.9 Main doors ..................................................................................................... 20
3.10 Re-entry sensor ............................................................................................ 21
4 Drive system ......................................................................................................... 23
4.1 What is in this chapter ................................................................................... 23

4.2 Main drive motor/gearbox.............................................................................. 24
4.3 Scrub motor ................................................................................................... 26
5 Feed-in section ..................................................................................................... 28

5.2 Feed-in sensors ............................................................................................. 29
6 Developing section............................................................................................... 31
6.2 Developer circulation pump ........................................................................... 32
6.3 Developer auto-fill pump................................................................................ 34
6.4 Developer replenishment pump..................................................................... 36
6.5 Filters ............................................................................................................. 38
6.6 Replenishment and waste/auto-fill probe assemblies ................................... 40
6.7 Conductivity probe ......................................................................................... 42
6.8 Developer float switch ................................................................................... 44
6.9 Developer temperature sensor ...................................................................... 46
6.10 Developer heater assembly.......................................................................... 48
6.11 Developer level sensing device .................................................................... 50
6.12 Developer cooling tube assembly................................................................. 52
7 Wash section ........................................................................................................ 54

7.2 Water level sensing device............................................................................ 55
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AUTOLITH TP
6 Servicing Instructions
Page 2 November 2000
7.3 Water recirculation pump............................................................................... 57

7.4 Solenoid valve ............................................................................................... 59
8 Finisher section .................................................................................................... 61

8.2 Finisher pump ................................................................................................ 62
8.3 Finisher probe assembly ............................................................................... 64
9 Drier section 66

9.2 Drier fan assembly......................................................................................... 67
10 Exit section ........................................................................................................... 68
10.1 What is in this chapter .................................................................................. 68

10.2 Exit sensors .................................................................................................. 69
11 Prebox section...................................................................................................... 70
11.1 What is in this chapter .................................................................................. 70

11.2 Power main filter ........................................................................................... 71
11.3 Transformer .................................................................................................. 72
11.4 Capacitor....................................................................................................... 73
11.5 Bridge rectifier............................................................................................... 74
11.6 Ventilating fan ............................................................................................... 75
11.7 Prebox PCB assembly.................................................................................. 76
11.8 Imager interface............................................................................................ 77
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AUTOLITH TP
1 About servicing instructions

Introduction This section contains the servicing instructions for the
AUTOLITH TP. For each section of the Processor, you will find:
• a detailed operational description
• how to remove and install parts of that section.
For whom is this manual These Servicing Instructions are intended for:
intended
• Agfa service technicians
Notation conventions The following indicators are used in the illustrations:
Indicator Used for Example

waste flow, finisher flow,
letters: A, B, C flows
…
symbols: M12, MG1, electrical motors, switches,
… parts sensors, automatic
valves, …
numbers: 1, 2, 3, … all other rollers, trays, manual
parts valves, …
Overviews and references At the beginning of each chapter, you will find:
• an overview of the information in that chapter
• references to other parts of the Servicing Instructions.
If you need more information If you are not able to solve a problem yourself, or if you need
more information, please feel free to contact your local Agfa
service centre.
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AUTOLITH TP
2 General maintenance instructions
2.1 Introduction
This section contains the general information about servicing the

AUTOLITH TP.
READ THIS SECTION CAREFULLY BEFORE CARRYING OUT
ANY MAINTENANCE TASKS ON THE PROCESSOR
THE ELECTRICAL POWER SUPPLY MUST BE

DISCONNECTED AT SOURCE BEFORE ANY MAINTENANCE
IS CARRIED OUT ON THE PROCESSOR.
AFTER ANY MAINTENANCE TASK, CHECK OUT A
FUNCTION CHECK OF THE SYSTEM ASSOCIATED WITH
THAT COMPONENT.
Always use the approved tools, and size of tools for the
maintenance task to be carried out.
For some maintenance operations, remove the relevant main

doors of the Processor to provide improved access to
components.
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2.2 Electrostatic discharge
The PCBs within the control panel and the prebox can be
damaged by improper handling. This section describes the
correct methods and techniques that should be utilised when
handling these components.
To effectively reduce damage from electrostatic discharge, the
following precautions must be taken:
• reduce the generation of static electricity
• dissipate all built-up charges
• handle equipment correctly
• use protective devices
Reduce generation of static Do not wear clothing that readily generates static electricity;
electricity clothing made of synthetic materials generates large amount of
static electricity.
Keep all plastic items away from any area where electronic
devices are handled. This includes foam cups, synthetic carpet,
etc.
Avoid actions that generate static, such as wiping feet, when in
the vicinity of static-sensitive devices.
Maintain a high humidity.
Dissipate all built-up Always discharge any static charge before touching and PCB.
charges To do this, touch and hold a grounded metal object for a
minimum of two seconds.
When connecting a cable to a PCB, discharge the cable
connector before connecting.
Handle equipment correctly Do not touch any components or connectors on the PCB. Hold
PCBs by the edge.
Protective devices Always leave covers on any receptacle that has no cable
connected to it. Always install covers on receptacles when the
PCB is in storage.
When a PCB has been removed, inset it into an anti-static
protective bag.
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3 Frame and external parts
3.1 What is in this chapter
Introduction This chapter tells you all about the frame of the Processor and
its external parts.
Overview This chapter covers the following topics:
Topic See
What is in this chapter Page 6
Feed and delivery tables Page 7
Left and right upper covers Page 9
Control panel assembly Page 11
Control panel components Page 13
Emergency stop buttons Page 15
Lid closed switch Page 17
Main isolator Page 19
Main doors Page 20
Re-entry sensor Page 21
For more information, refer also to the Section 4 - Spare Parts.
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3.2 Feed and delivery tables
3.2.1 Description
Feed and delivery tables The feed table provides a platform from which the incoming plate
can be fed into the Processor. The delivery table provides a
platform onto which the plate is delivered after processing. The
feed and delivery tables are optional.
3.2.2 Removal
How to remove the feed Proceed as follows:

table
Figure 3.2(a) Feed table

Step Action
Switch off the Processor at the main isolator and
1
disconnect from power supply at source.
Support the weight of the feed table and remove six
2
screws and washers.
3 Remove feed table.
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How to remove the delivery Proceed as follows:

table
Figure 3.2(b) Delivery table

Step Action
1
Support the weight of the delivery table and remove
2
four screws and washers.
Loosen four grub screws on the support beam
3
receptacles.
4 Remove delivery table.
5 Remove two supports.
3.2.3 Installation
How to install the feed and The installation procedure is the reverse of the removal
delivery tables procedure.
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3.3 Left and right upper covers
3.3.1 Description
Left and right upper covers The upper covers protect the internal mechanical parts, pumps,
and electrical equipment.
Figure 3.3 Left and right upper covers
3.3.2 Removal
How to remove the left and

Proceed as follows:
right upper covers
Use the correct size Allen key.
Take care not to damage the emergency stop button on the left
side when removing and installing the left upper cover.
Step Action
1 Switch off the Processor at the main isolator and
2 Open both lids.
3 Loosen two screws that secure the upper cover.
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Step Action
4 Carefully remove the upper cover.
5 When removed, place the upper cover on a clean,
dry surface
3.3.3 Installation
How to install the left and The installation procedure is the reverse of the removal
right upper covers procedure.
Ensure the covers are fitted correctly on the two locator pins
before securing the two screws.
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3.4 Control panel assembly
3.4.1 Description
Control panel assembly The control panel assembly (U3) is used to operate and set-up the
Processor.
The control panel assembly can be fitted on the left or right side of the
Processor.
Figure 3.4.1 Control panel assembly
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3.4.2 Removal
How to remove the control Proceed as follows:

panel assembly
Step Action
2 Open both lids.
3 Remove upper cover.
4 Disconnect connectors P1 and P6.
5 If the control panel is installed on the left side of the
Processor, remove the emergency stop bracket.
6 Remove two screws attaching the P-clips to the
blanking plate. Be careful not to lose the screws.
7 Remove the screws attaching the control panel
assembly to the frame and remove the control
panel assembly and blanking plate.
8 Remove the remaining two screws attaching the
blanking plate to the control panel assembly and
remove the blanking plate.
9 For further disassembly refer to Section 3.5.
3.4.3 Installation
How to install the control The installation procedure is the reverse of the removal
panel assembly procedure.
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3.5 Control panel components
3.5.1 Description
Control panel components The control panel assembly can be further broken down into the
following components:
• control panel PCB
• two-line display unit
• touch panel
Figure 3.5 Control panel components
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3.5.2 Removal
Ensure the all ESD precautions are taken when handling the
control panel components. See Section 2.2.
How to remove the control Proceed as follows:

panel PCB
Step Action
1 Remove control panel assembly. See Section 3.4.
2 Remove three plastic nuts.
3 Remove the two screws attaching P1 to the frame
and the two screws attaching P6 to the frame.
4 Carefully lift the PCB from the frame to allow
access to the connectors on the PCB.
5 Disconnect the ribbon cable from P5 by carefully
lifting the top If the connector away from the PCB.
This will release the ribbon cable.
6 Disconnect connector P3 and remove the PCB.
How to remove the two-line Proceed as follows:
display unit
Step Action
1 Remove control panel PCB. See above.
2 Remove four plastic nuts.
3 Remove the two-line display unit.
How to remove the touch Proceed as follows:

panel
Step Action
1 Remove the two-line display. See above.
Remove the four screws and washers and remove
2
the bezel.
3 Peel off the touch panel from the frame.
3.5.3 Installation
How to install the control The installation procedure is the reverse of the removal
panel components procedure.
Fix the touch panel central between the bezel screw holes.
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3.6 Emergency stop buttons
3.6.1 Description
Emergency stop buttons The emergency stop buttons are to stop the Processor in the
event of an emergency.
Figure 3.6 Emergency stop buttons
3.6.2 Removal
How to remove the right Proceed as follows:

emergency stop button
Step Action
2 Remove both upper covers.
3 Remove four screws from rear upper cover.
4 Carefully pull rear upper cover away from the
Processor until access is gained to the rear of the
emergency stop button.
5 Raise locking device slightly and push to one side,
disconnecting the connection block from the button.
6 If necessary, remove the locking ring from the
button and remove the button.
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Step Action
7 If necessary, remove the two screws connecting the
cables to the connection block and remove the
connection block.
How to remove the left Proceed as follows:

emergency stop button
Step Action
2 Remove left upper cover.
3 Raise locking device slightly and push to one side.
This disconnects the connection block from the
button.
4 If necessary, remove the locking ring from the
button and remove the button.
5 If necessary, remove the two screws connecting the
cables to the connection block and remove the
connection block.
3.6.3 Installation
How to install the The installation procedure is the reverse of the removal
emergency stop buttons procedure.
BE SURE TO CARRY OUT A FUNCTIONAL CHECK OF THE

EMERGENCY STOP SYSTEM.
Be sure that the rear upper cover is flush with the side covers
after installation has been completed. If not, remove upper side
covers and adjust position of rear upper cover by releasing the
four attaching screws and adjusting the height of the rear upper
cover as necessary.
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3.7 Lid closed switch
3.7.1 Description
Lid closed switch If the lids are opened, or not closed correctly, the Processor will
not operate. Therefore, the Processor is provided with one
switch, which detects whether the lids are closed (correctly) or
not.
If not, the switch stops the operation of the Processor, similar to
an emergency stop. A message will be displayed; SAFETY
CIRCUIT OPENED.
Figure 3.7 Lid closed switch
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3.7.2 Removal
How to remove the lid

Proceed as follows:
closed switch
Step Action
1
2 Remove the right upper cover.
Remove the two screws attaching the lid closed
3
switch to the frame.
Open the back of the lid closed switch by releasing
4
the latch with a flat-head screwdriver.
Note the position of the cables and disconnect by
5
releasing the two screws.
Loosen the nut at the rear of the switch and
6
carefully pull the cables out of the switch.
Refer to wiring diagram in Section 8 – Diagrams for cable
connection details.
3.7.3 Installation
How to install the lid closed The installation procedure is the reverse of the removal
switch procedure.
BE SURE TO CARRY OUT A FUNCTIONAL CHECK OF THE

SAFETY SYSTEM.
Check for the correct mechanical functioning of the lid closed

switch. The switch position can be adjusted slightly by loosening
the two attachment screws and adjusting the position.
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3.8 Main isolator
3.8.1 Description
Main isolator The main isolator controls the supply of mains electrical power to
the Processor and the chiller unit.
3.8.2 Removal
THE ELECTRICAL POWER SUPPLY MUST BE

DISCONNECTED AT SOURCE BEFORE ANY MAINTENANCE
IS CARRIED OUT ON THE PROCESSOR.
How to remove the main
Proceed as follows:
isolator
Step Action
1
Remove the six screws attaching the isolator panel
assembly to the frame and remove the isolator
2 panel assembly. This will provide access to the
isolator block, located in the left rear area of the
Processor.
Remove the plastic cover from the top of the
3
isolator block.
Note the position of the cables and disconnect all
4
cables from the isolator by releasing the screws.
5 Remove the two attaching screws.
6 Remove the main isolator.

connection details.
3.8.3 Installation
How to install the main The installation procedure is the reverse of the removal
isolator procedure.
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April 2001
3.9 Main doors
3.9.1 Description
Main doors The main doors cover the internal parts of the Processor below
the operating area.
Figure 3.9 Location of main doors
3.9.2 Removal
How to remove the main Proceed as follows:

doors
Step Action
Remove the doors by lifting from the hinge
1
brackets.
3.9.3 Installation
How to install the main The installation procedure is the reverse of the removal
doors procedure.
If the doors do not close correctly or smoothly the hinge brackets
can be adjusted by releasing the two attachment screws and
adjusting the position of the brackets.
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3.10 Re-entry sensor
3.10.1 Description
Re-entry sensor The re-entry sensor detects when a plate is fed back directly into
the wash section.
The re-entry sensor is designated SQ3 and is located on the
rear lid.
Figure 3.10 Position of re-entry sensor
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3.10.2 Removal
How to remove the re-entry Proceed as follows:

sensor
Step Action
3 Disconnect connector X18.
4 Feed the cable through the grommet in the side of
the Processor.
5 Open the rear lid.
6 Unclip the cable from the lid.
7 Make a note of the position of the sensor end with
respect to the black locking ring.
8 Remove the black locking ring and remove the
sensor.
connection details.
3.10.3 Installation
How to install the re-entry The installation procedure is the reverse of the removal
sensor procedure.
Ensure that the end of the sensor is in exactly the same position
as it was before any maintenance was carried out. The end of
the sensor should be located just below the surface of the black
locking ring.
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4 Drive system
Introduction This chapter contains information about the;

• drive system that transports the plate through the Processor
• drive system that powers scrub brushes.
Topic See
Main drive motor Page 24
Scrub motor Page 26
For more information, refer also to the Section 4 - Spare Parts

List.
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4.2 Main drive motor/gearbox
4.2.1 Description
Main drive motor The main drive motor/gearbox provides power for all the rollers
in the Processor. See item 1 in Figure 4.2.
Figure 4.2 Main drive motor assembly
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4.2.2 Removal
How to remove the main

Proceed as follows:
drive motor
Step Action
2 Remove left upper cover and remove the left front
access door.
3 Remove two screws and remove the chain guard.
This will give access to motor/gearbox.
4 Locate the connecting link in the main drive chain.
Remove connecting link and remove the main drive
chain.
5 Disconnect connectors X23 and X40 from the
motor. Note that X40 is sleeved. To access X40, cut
the two cable ties and slide the sleeve along the
cable.
6 Remove the six screws that attach the motor
mounting plate assembly (4) to the main frame.
7 Remove the motor mounting plate assembly
(including the main drive motor).
8 Place the assembly on a work bench.
9 Locate the connecting link in the chain (11)
connecting reduction sprocket (12) and motor
sprocket (7). Remove connecting link and chain.
10 Remove the three screws that attach the bearing
assembly to the motor mounting plate. Remove the
motor mounting plate.
11 Remove circlip (9) and sprocket (7).
12 Remove three bolts (6) and washers (5).
13 Remove main drive motor from the bearing
assembly.
4.2.3 Installation
How to install the main drive The installation procedure is the reverse of the removal
motor procedure.
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4.3 Scrub motor
4.3.1 Description
Scrub motor The scrub motor provides power to the scrub rollers in the
developer section and the scrub roller in the wash section.
Figure 4.3 Scrub motor assembly
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4.3.2 Removal
How to remove the scrub

Proceed as follows:
motor
Step Action
2 Remove left upper cover and remove the left front
access door.
3 Remove two screws and remove the chain guard.
This will give access to scrub motor.
4 Locate the connecting link in the scrub chain.
Remove connecting link and remove the scrub
chain from the drive sprocket.
5 Remove cable ties and disconnect connector X1
(six-pin Molex connector).
6 Remove the washer and nut from the capacitor and
support. Support the scrub motor. Remove the four
screws that attach the scrub motor to the main
frame.
7 Remove the scrub motor (including sprocket).
8 Place the scrub motor on a work bench.
9 Note the position of the sprocket on the output shaft
of the motor. Remove the grub screw and remove
the sprocket.
4.3.3 Installation
How to install the scrub The installation procedure is the reverse of the removal
motor procedure.
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5 Feed-in section
Introduction This chapter contains information about the feed-in section of

the Processor.
Topic See
Feed-in sensors Page 29
For more information, refer also to the Section 4 -Spare Parts

List.
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5.2 Feed-in sensors
5.2.1 Description
Feed-in sensors The feed-in sensors detect the presence and the length of a
plate.
The feed-in sensors are designated SQ2 (right) and SQ5 (left).
There are three possible positions that the two sensors can be
fitted. Either SQ2 or SQ5 can be fitted in the centre position.
Figure 5.2 Feed-in sensors
5.2.2 Removal
How to remove the feed-in

Proceed as follows:
sensors
Step Action
2 Remove front divert assembly and feed-in nip
rollers (set number 1). See Instruction Manual for
removal procedure.
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AUTOLITH TP
Step Action
3 Remove three screws and washers and the sensor
mounting plate assembly.
4 Open left main door of the Processor to gain access
to connectors X21 and X22, located at the front of
the Processor. Disconnect X21 (SQ2) and X22
(SQ5).
5 Note the position of the sensor relative to the
sensor bracket. Remove locknut and remove the
sensor.
5.2.3 Installation
How to install the feed-in The installation procedure is the reverse of the removal
sensors procedure.
Make sure the sensor is fitted in exactly the same position,
relative to the sensor bracket, as the previous sensor.
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AUTOLITH TP
6 Developing section
Introduction This chapter contains information about the developing section

of the Processor.
BEFORE ANY OF THE MAINTENANCE TASKS LISTED

BELOW ARE CARRIED OUT, THE MAIN DEVELOPER TANK,
THE ISOLATED REAR SECTION, AND FILTER BOWLS MUST
BE DRAINED OF DEVELOPER.
Topic See
Developer circulation pump Page 32
Developer auto-fill pump Page 34
Developer replenishment pump Page 36
Filters Page 38
Replenishment and waste/auto-fill Page 40
probe assemblies
Conductivity probe Page 42
Developer float switch Page 44
Developer temperature sensor Page 46
Developer heater assembly Page 48
Developer level sensing device Page 50
Developer cooling tube assembly Page 52
For more information, refer also to the Section 4 - Spare Parts

List.
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AUTOLITH TP
6.2 Developer circulation pump
6.2.1 Description
Developer circulation pump The developer circulation pump is used to pump developer
through the two filters and back into the developer tank and the
developer spray bar.
The developer circulation pump is designated M4, and is located
under the flat surface of the base frame, on the front right side.
Figure 6.2 Developer circulation pump
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AUTOLITH TP
6.2.2 Removal
How to remove the

Proceed as follows:
developer circulation pump
ALWAYS WEAR PROTECTIVE GLOVES AND GOGGLES
WHEN CARRYING OUT MAINTENANCE ON A PART OF THE
PROCESSOR WHERE CHEMICALS ARE PRESENT.
Step Action
2 Drain developer tank.
4 Remove the right forward door.
5 Remove all cable ties from the pump cable.
7 Remove four screws and stiff-nuts that attach the
pump to the Processor frame.
8 Release the quick-release connectors from the inlet
and outlet of the pump.
9 Carefully lower the pump away from the Processor,
taking special care to avoid spillage of developer.
6.2.3 Installation
How to install the developer The installation procedure is the reverse of the removal
circulation pump procedure.
After installation, carry out a complete auto-fill procedure, see
Instruction Manual. Check for leaks and for quiet operation of the
pump.
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6.3 Developer auto-fill pump
6.3.1 Description
Developer auto-fill pump The developer auto-fill pump is used to fill the developer tank
when the tank has been emptied.
The developer auto-fill pump is designated M6, and is located
under the right upper cover.
Figure 6.3 Developer auto-fill pump
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6.3.2 Removal
How to remove the Proceed as follows:

developer auto-fill pump
Step Action
5 Remove hose clips from the inlet and outlet of the
pump.
6 Remove four screws that attach the pump to the
Processor frame.
7 Take note of the orientation of the inlet and outlet
elbows.
8 Remove the pump.
6.3.3 Installation
auto-fill pump procedure.
The inlet and outlet hoses require new PTFE tape to ensure
leak-free operation.

Section 2 - Instruction Manual. Check for leaks and for quiet
operation of the pump.
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6.4 Developer replenishment pump
6.4.1 Description
Developer replenishment The developer replenishment pump is used to add developer to

pump the tank dependent on the area of plate being processed.
The developer replenishment pump is designated S2, and is
located under the left upper cover.
Figure 6.4 Developer replenishment pump
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6.4.2 Removal

developer replenishment
pump
Step Action
2 Remove the left upper cover.
5 Disconnect the two wires from the microswitch.
6 Remove hose UNEX clips from the inlet and outlet
of the pump.
7 Remove four screws and stiff-nuts that attach the
pump to the Processor frame.
8 Remove the pump.
6.4.3 Installation
replenishment pump procedure.
Section 2 - Instruction Manual. Check for leaks and for quiet
operation of the pump.
The stroke of the pump is factory set. However, it is
recommended that a calibration is carried out after fitting a new
pump, or carrying out maintenance on an existing pump. This
sequence can be found in Section 9 – AndroDiags.
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Page 38 April 2000

November 2001
6.5 Filters
6.5.1 Description
Filter The filters remove residue from the developer.

The filters bowls are located on a sliding assembly under the flat
surface of the base frame at the right, rear side.
Figure 6.5 Filter assemblies (Typical)
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April 20012000
November Page 39
6.5.2 Replacement of a filter
How to replace a filter Proceed as follows:

The filters should be changed when the developer is changed.
Step Action
2 Open the right doors.
3 Pull out the sliding filter assemblies
4 Use the filter bowl key to unscrew the filter cartridge
bowls.
5 Remove the 75 micron filter cartridges. Discard
safely.
6 Clean filter bowls.
7 Check that the o-rings located in the filter bowls are
positioned correctly.
8 Fit new filter cartridges and make sure that they
are located at the bottom of the filter bowls.
9 Carefully screw the filter bowls on to the filter
heads. Secure the filter bulbs hand-tight only (do
not use filter bowl key).
10 Check that the filter head valves are in the correct
(open) position. This is indicated by the white dots
on the top of the filter heads and also by the yellow
label on the front of the filter assemblies.
Make sure orange drain taps on the filter bowls are
11
closed.
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Page 40 April 2001

November 2000
6.6 Replenishment and waste/auto-fill probe assemblies
6.6.1 Description
Probe assemblies The probe assemblies are used to draw developer from the
bottles, located under the Processor. Fluid level sensors are
integral to the probe assemblies. A strainer is fitted to a suction
tube to protect the replenishment/autofill pump from ingress of
dirt particles.
The replenishment autofill probe assembly is designated X35,
and the waste/auto-fill probe assembly is designated X37.
6.6.2 Removal
How to remove the probe

Proceed as follows:
assemblies
Step Action
2 Open right main doors.
3 Remove probe assembly from the bottle.
4 Disconnect outlet and, if fitted, inlet hose.
5 Remove all cable ties between probe assembly and
the sensor connector.
6 Disconnect connector. The connector is located
below the flat surface of the Processor, behind the
developer circulation pump (M4).
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April 20012000
November Page 41
6.6.3 Cleaning the Strainer
How to clean the strainer Proceed as follows:

assembly
Step Action
4 Release the quick release connector that secures
the strainer assembly to the suction tube, and
remove the strainer assembly
5 Inspect, and if necessary wash the strainer in water
to remove any dirt particles.
How to install the strainer The installation procedure is the reverse of the removal
assembly procedure
After installation check operation of the probe assemblies, by

installing full bottles of chemistry and running the pumps. Check
for leaks.
6.6.4 Installation
How to install the strainer The installation procedure is the reverse of the removal
assemblies procedure.
installing full bottles of chemistry, and running the pumps.
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Page 42 April 2001

November 2000
6.7 Conductivity probe
6.7.1 Description
Conductivity probe The conductivity probe is used to measure the quality of the
developer being used.
The conductivity probe is designated CD1, and is located on the
right of the developer tank.
Figure 6.7 Conductivity probe
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April 20012000
November Page 43
6.7.2 Removal
How to remove the

Proceed as follows:
conductivity probe
Step Action
3 Remove right upper cover.
5 Remove conductivity probe locking bezel.
6 Remove lock-nut and washer.
7 Take note of the orientation of the conductivity
probe. Remove the conductivity probe and the
washer.
6.7.3 Installation
conductivity probe procedure.
Make sure the mating surfaces of the probe, lock-nuts and
washers are free from contamination.
After installation and filling with developer, check for leaks.
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Page 44 April 2001

November 2000
6.8 Developer float switch
6.8.1 Description
Developer float switch The developer float switch is a safety device used to detect if
there is insufficient developer in the main developer tank. If
activated, power is disconnected from the developer pump and
the heater assembly.
The developer float switch is designated SL1, and is located on
the right of the developer tank.
Figure 6.8 Developer float switch
abc
AUTOLITH TP
April 2001 2000

November Page 45
6.8.2 Removal

developer float switch
ALWAYS WEAR PROTECTIVE GLOVES AND GOGGLES WHEN
CARRYING OUT MAINTENANCE ON A PART OF THE PROCESSOR
WHERE CHEMICALS ARE PRESENT.
Step Action
1 Switch off the Processor at the main isolator and disconnect
from power supply at source.
5 Remove lock-nut, protection guard and washer.
6 Remove developer float switch.
6.8.3 Installation
How to install developer

The installation procedure is the reverse of the removal procedure.
float switch
Make sure the mating surfaces of the float switch, lock-nuts and washers
are free from contamination.
Make sure that the movement of the float switch is vertical after the
locknut is tightened.
After installation and the Processor is filled with developer, check for
leaks and for correct operation.
abc
AUTOLITH TP
Page 46 April 2001

November 2000
6.9 Developer temperature sensor
6.9.1 Description
Developer temperature The developer temperature sensor is used to measure the temperature of
sensor the developer.
The developer temperature sensor is designated TP2, and is located on
the right of the developer tank.
Figure 6.9 Temperature sensor
abc
AUTOLITH TP
April 20012000
November Page 47
6.9.2 Removal
How to remove the

developer temperature Proceed as follows:
sensor
Step Action
5 Release black cable lock-nut.
6 Remove temperature sensor. Take care, as the probe is
close to the cooling tube.
6.9.3 Installation
How to install the developer

temperature sensor
Make sure the mating surfaces of the temperature sensor, lock-nuts and
washers are free from contamination. The gland nut should clamp the
washers on the bulb and not on the cable.
leaks. Check for correct operation using AndroDiags, see Section 9 -
AndroDiags.
abc
AUTOLITH TP
Page 48 April 2001

November 2000
6.10 Developer heater assembly
6.10.1 Description
Developer heater assembly The developer heater assembly is used to heat the developer, as
required.
The developer heater assembly is designated EH2, and is located on the
right of the developer tank.
Figure 6.10 Developer heater assembly
abc
AUTOLITH TP
April 20012000
November Page 49
6.10.2 Removal

developer heater assembly
Step Action
3 Remove scrub rollers and plate guide. See Section 2 –
Instruction Manual.
5 Disconnect connector X10, located under the flat surface of
the Processor.
6 Move the Autofill tube to one side, and remove the heater
assembly lock-nut.
7 Remove heater assembly and washer.
6.10.3 Installation
How to install developer

heater assembly
Make sure the mating surfaces of the heater assembly, lock-nuts and
washers are free from contamination.
leaks. Check for correct operation using AndroDiags, see Section 9 -
AndroDiags.
abc
AUTOLITH TP
Page 50 April 2001

November 2000
6.11 Developer level sensing device
6.11.1 Description
Developer level sensing The developer level sensing device is used to monitor the level of the
device developer.
The developer level sensing device is designated RL3/4, and is located
on the left side of the developer tank.
Figure 6.11 Level sensing device (Typical)
abc
AUTOLITH TP
April 20012000
November Page 51
6.11.2 Removal
How to remove the

developer level sensing Proceed as follows:
device
Step Action
5 Remove two screws and remove the level sensing
device.
6.11.3 Installation
How to install level sensing The installation procedure is the reverse of the removal
device procedure.
Make sure the level sensing device probes are clear of the tank
side after installation. Check the cables are secured clear of any
chains.
After installation and the Processor is filled with developer,
check for leaks. Check for correct operation using AndroDiags,
see Section 9 - AndroDiags.
abc
AUTOLITH TP
Page 52 April 2001

November 2000
6.12 Developer cooling tube assembly
6.12.1 Description
Developer cooling tube The developer cooling tube assembly is used to circulate chilled
assembly water around the developer tank to help maintain the
temperature of the developer.
Figure 6.12 Cooling tube assembly
abc
AUTOLITH TP
April 20012000
November Page 53
6.12.2 Removal
How to remove the

developer cooling tube Proceed as follows:
assembly
Step Action
3 Remove scrub rollers and plate guide. See Section
2 – Instruction Manual.
5 Disconnect quick-release connectors and remove
the supply pipes.
6 Disconnect the clip between the heater assembly
and the cooling tube.
7 Release gland nuts and withdraw the cooling tube.
6.12.3 Installation
How to install developer The installation procedure is the reverse of the removal
cooling tube assembly procedure.
After installation and the Processor is filled with developer,
check for leaks. Check for correct operation using AndroDiags,
see Section 9 - AndroDiags. Simulate a over-temperature
condition. Once correct operation is confirmed, return
temperature to its normal setting.
abc
AUTOLITH TP
Page 54 April 2001

November 2000
7 Wash section
Introduction This chapter contains information about the wash section of the
Processor.
Topic See
Water level sensing device Page 55
Water recirculation pump Page 57
Solenoid valve Page 59
For more information, refer also to the Spare Parts List.
abc
AUTOLITH TP
April 20012000
November Page 55
7.2 Water level sensing device
7.2.1 Description
Water level sensing device The water level sensing device is used to monitor the level of the
water.
The water level sensing device is designated RL6/7, and is
located on the left side of the water section.
Figure 7.2 Water level sensing device (Typical)
abc
AUTOLITH TP
Page 56 April 2000

November 2001
7.2.2 Removal
How to remove the water

Proceed as follows:
level sensing device
Step Action
2 Drain water tank.
5 Remove one screw and remove the level sensing
device.
7.2.3 Installation
How to install the water level The installation procedure is the reverse of the removal
sensing device procedure.
Make sure the level sensing device probe is clear of the tank
side after installation. Check the cables are secured clear of any
chains.
After installation, check for correct operation by draining and
refilling the water tank.
abc
AUTOLITH TP
April 20012000
November Page 57
7.3 Water recirculation pump
7.3.1 Description
Water recirculation pump The water recirculation pump is used to supply water to the three
water spray bars.
The water recirculation pump is designated M9, and is located
under the right upper cover.
Figure 7.3 Water recirculation pump
abc
AUTOLITH TP
Page 58 April 2001

November 2000
7.3.2 Removal
How to remove the water

Proceed as follows:
recirculation pump
Step Action
2 Drain water tank.
4 Remove cable tie from the water inlet valve. Place a
container under the valve as residual water could
be present.
5 Remove four screws that attach the pump to the
Processor frame.
6 Release the two quick-release couplings from the
inlet and outlet of the pump.
7 Carefully pull the pump away from the Processor
frame.
8 Take note of the orientation of the inlet and outlet
elbows and remove the valve and outlet connector.
7.3.3 Installation
How to install the water The installation procedure is the reverse of the removal
recirculation pump procedure.
After installation, check for leaks and for quiet operation of the
pump.
abc
AUTOLITH TP
April 20012000
November Page 59
7.4 Solenoid valve
7.4.1 Description
Solenoid valve The solenoid valve is used to control the supply of water to the
Processor.
The solenoid valve is designated YV1, and is located on the rear
frame of the Processor.
Figure 7.4 Solenoid valve
abc
AUTOLITH TP
Page 60 April 2001

November 2000
7.4.2 Removal
How to remove the solenoid Proceed as follows:

valve
There will be a certain amount of water in the incoming supply
pipe which will spill out when the incoming quick release
coupling is disconnected. Make sure there is an appropriate
container available to catch this water.
Step Action
2 Turn off incoming water supply
2 Disconnect connector from solenoid valve.
3 Remove two screws and remove the solenoid valve
cover.
solenoid valve.
5 Remove the two screws that attach the solenoid
valve to the Processor frame.
6 Remove the solenoid valve.
7.4.3 Installation
How to install the solenoid The installation procedure is the reverse of the removal
valve procedure.
After installation, reconnect to the main water supply and check
for leaks.
abc
AUTOLITH TP
April 20012000
November Page 61
8 Finisher section
Introduction This chapter contains information about the finisher section of

the Processor.
Topic See
Finisher pump Page 62
Finisher probe assembly Page 64
For more information, refer also to Section 4 - Spare Parts List.
abc
AUTOLITH TP
Page 62 April 2001

November 2000
8.2 Finisher pump
8.2.1 Description
Finisher pump The finisher pump is used to supply finisher to the finisher
rollers.
The finisher pump is designated M2, and is located under the
right upper cover.
Figure 8.2 Finisher pump
abc
AUTOLITH TP
April 2001 2000

November Page 63
8.2.2 Removal
How to remove the finisher

Proceed as follows:
pump
Step Action
inlet and outlet of the pump.
4 Remove four screws, washers and rubber
mountings that attach the pump to the Processor
frame.
5 Carefully pull the pump away from the Processor
frame.
8.2.3 Installation
How to install the finisher The installation procedure is the reverse of the removal
pump procedure.
After installation, check for leaks and for quiet operation of the
pump. This can be done by running the pump using AndroDiags,
see Section 9 – AndroDiags.
abc
AUTOLITH TP

April 2001
8.3 Finisher probe assembly
8.3.1 Description
Probe assembly The gum probe assembly is used to draw gum from the bottle, located
under the Processor. Fluid level sensors are integral to the probe
assembly. A strainer is fitted to the suction tube to protect the finisher
pump from ingress of dirt particles.
The gum probe assembly is designated X36.
8.3.2 Removal
How to remove the probe

Proceed as follows:
assembly
Step Action
4 Disconnect outlet and inlet hose.
5 Remove all spiral wrap and cable ties between probe
assembly and the sensor connector.
6 Disconnect connector. The connector is located below the flat
surface of the Processor, behind the developer circulation
pump (M4).
8.3.3 Cleaning of the strainer
Step Action
4 Release the quick release connector that secures the strainer
to the suction tube, and remove the strainer
5 Inspect and if necessary wash the strainer in water to remove
any dirt particles.
abc
AUTOLITH TP
November
April 20012000 Page 65
8.3.4 Installation of the strainer assembly
How to install the probe The installation procedure is the reverse of the removal
assembly procedure.
installing a full bottle of gum running the finisher pump. Check
for leaks.
abc
AUTOLITH TP
Page 66 November
April 2000
2001
9 Drier section
Introduction This chapter contains information about the finisher section of

the Processor.
Topic See
Drier fan Page 67
For more information, refer also to the Spare Parts List.
abc
AUTOLITH TP
April 20012000
November Page 67
9.2 Drier fan assembly
9.2.1 Description
Drier fans The drier fan is used to supply hot air to dry the plates.
The drier fan is designated M5, and is located at the rear of the
Processor.
9.2.2 Removal
How to remove drier fan

Proceed as follows:
assembly
THE DRIER FAN ASSEMBLY IS HEAVY. THE DRIER FAN
ASSEMBLY MUST BE SUPPORTED BEFORE THE
ATTACHMENT SCREWS ARE REMOVED.
Step Action
2 Remove the delivery table (if fitted)
3 Remove the four screws, which hold the rear
deflector plate and remove the lower rear cover.
4 Unplug the power connector X5 underneath the
Processor.
5 Support the fan assembly and remove the two
screws on either side of the heater element.
Carefully lower the assembly.
6 The heater assembly can be removed from the fan
by removing the four bolts that attach it to the flange
on the fan.
9.2.3 Installation
How to install the drier fan The installation procedure is the reverse of the removal
assemblys procedure.
abc
AUTOLITH TP
Page 68 April 2001

November 2000
10 Exit section
Introduction This chapter contains information about the exit section of the
Processor.
Topic See
Exit sensors Page 69
For more information, refer also to Section 4 - Spare Parts List.
abc
AUTOLITH TP
April 20012000
November Page 69
10.2 Exit sensors
10.2.1 Description
Exit sensors The exit sensors are used to detect the presence of a plate.
The exit sensors are designated SQ4 and SQ6, and are located
at the rear of the Processor.
10.2.2 Removal
How to remove exit sensors Proceed as follows:

Step Action
2 Remove the delivery table (if fitted)
3 Remove the 4 screws which hold the rear and
carefully remove the plate to expose the exit sensor
brackets (SQ4 and SQ6).
4 Remove the lower rear panel.
5 Disconnect plugs X16 or X17 and remove the two
screws securing the brackets.
6 Note the position of the sensor relative to the
sensor bracket. Remove locknut and remove the
sensor.
10.2.3 Installation
How to install the exit The installation procedure is the reverse of the removal
sensors procedure.
Make sure the sensor is fitted in exactly the same position,
relative to the sensor bracket, as the previous sensor.
abc
AUTOLITH TP
Page 70 April 2001

November 2000
11 Prebox section
Introduction This chapter contains information about the replaceable

components in the prebox.
Figure 11.1 Prebox

Topic See
Power main filter Page 71
Transformer Page 72
Capacitor Page 73
Bridge rectifier Page 74
Ventilating fan Page 75
Prebox PCB assembly Page 76
Imager interface Page 77
abc
AUTOLITH TP
April 20012000
November Page 71
11.2 Power main filter
11.2.1 Description
Power main filter The power main filter (item 1 in Figure11.1) protects the
Processor from any fluctuations and spikes in the mains power
supply.
The power main filter is designated U2, and is located in the
prebox.
11.2.2 Removal
How to remove power main

Proceed as follows:
filter
Step Action
2 Open the rear left main door.
3 Release the screw that secures the prebox into the
Processor frame, and carefully pull the prebox out
of the frame.
4 Release four camloc fasteners and remove the
prebox side cover.
5 Viewing the prebox from the cover side, the power
main filter is located top right.
6 Remove two attachment screws and washers and
carefully pull the power main filter away from the
prebox to gain access to the attached cables.
7 Label the attached cables. Disconnect all attached
cables from the power main filter.
5 Remove the power main filter.
11.2.3 Installation
How to install the power The installation procedure is the reverse of the removal
main filter procedure.
abc
AUTOLITH TP
Page 72 April 2001

November 2000
11.3 Transformer
11.3.1 Description
Transformer The transformer (item 2 in Figure11.1) converts the 230 VAC

input supply to 24 VAC.
The transformer is designated TR1, and is located in the prebox.
11.3.2 Removal
How to remove the

Proceed as follows:
transformer
Step Action
of the frame.
prebox side cover.
5 Viewing the prebox from the cover side, the
transformer is located bottom centre.
6 Remove the earthing strap.
cables from the transformer.
8 Remove four screws and washer and remove the
transformer.
11.3.3 Installation
transformer procedure.
abc
AUTOLITH TP
April 20012000
November Page 73
11.4 Capacitor
11.4.1 Description
Capacitor The capacitor (item 3 in Figure11.1) smoothes the 24 VDC

supply, delivered from the bridge rectifier.
The capacitor is designated C1, and is located in the prebox.
11.4.2 Removal
How to remove the capacitor Proceed as follows:

Step Action
of the frame.
prebox side cover.
5 Viewing the prebox from the cover side, the
capacitor is located bottom left-centre.
cables from the capacitor.
7 Remove the three screws and washers and remove
the capacitor and capacitor clamp.
8 Loosen the screws on the capacitor clamp and
remove the capacitor.
9 Remove the capacitor.
11.4.3 Installation
The installation procedure is the reverse of the removal

How to install the capacitor
procedure.
abc
AUTOLITH TP
Page 74 April 2001

November 2000
11.5 Bridge rectifier
11.5.1 Description
Bridge rectifier The bridge rectifier (item 4 in Figure11.1) converts the 24 VAC
supply to 24 VDC used in the Processor.
The bridge rectifier is designated D1, and is located in the
prebox.
11.5.2 Removal
How to remove the bridge

Proceed as follows:
rectifier
Step Action
of the frame.
prebox side cover.
5 Viewing the prebox from the cover side, the bridge
rectifier is located bottom left.
cables from the bridge rectifier.
7 Remove the one screw and washer and remove the
bridge rectifier.
11.5.3 Installation
How to install the bridge The installation procedure is the reverse of the removal
rectifier procedure.
abc
AUTOLITH TP
April 2001 2000

November Page 75
11.6 Ventilating fan
11.6.1 Description
Ventilating fan The ventilating fan (item 5 in Figure 11.1) circulates cooling air
through the prebox.
The ventilating fan is located in the prebox.
11.6.2 Removal
How to remove the

Proceed as follows:
ventilating fan
Step Action
of the frame.
prebox side cover.
5 Viewing the prebox from the cover side, ventilating
fan is located bottom left.
6 Disconnect connector P42 from the fuse panel.
7 Remove the two attachment screws and washers
that attach the ventilating fan and ventilating fan
bracket to the prebox case.
8 Remove the two attachment screws, washers and
nuts that attach the ventilating fan bracket to the
ventilating fan.
9 Remove the ventilating fan from the ventilating fan
bracket.
11.6.3 Installation
How to install the ventilating The installation procedure is the reverse of the removal
fan procedure.
abc
AUTOLITH TP

April 2001
11.7 Prebox PCB assembly
11.7.1 Description
Prebox PCB assembly The prebox PCB assembly (item 6 in Figure11.1) contains all the
controlling circuitry for the Processor.
The prebox PCB assembly comprises two circuit boards that are
attached to the connector plate located at the top of the prebox.
The prebox PCB assembly can only be replaced as a complete
assembly (not as separate PCB's).
11.7.2 Removal
How to remove the prebox

Proceed as follows:
PCB assembly
Ensure the all ESD precautions are taken when handling the
prebox PCB assembly. See Section 2.2.
Step Action
of the frame.
prebox side cover.
5 Disconnect all connectors from the connector plate
at the top of the prebox.
6 Disconnect all connectors from the side of the
prebox PCB assembly.
7 Remove earthing strap.
8 Remove the eight attachment screws and washers
located around the edge of the connector plate.
9 Carefully slide the prebox PCB assembly out of the
prebox.
10 Remove the imager interface (see Section 11.8).
abc
AUTOLITH TP
April 20012000
November Page 77
11.7.3 Installation
How to install the prebox The installation procedure is the reverse of the removal
PCB assembly procedure.
11.8 Imager interface
11.8.1 Description
Imager interface The imager interface card (item 7 in Figure11.1) provides the
interface between the Processor and the imager (if fitted).
The imager interface is a single PCB located on the prebox PCB
assembly.
11.8.2 Removal
How to remove imager

Proceed as follows:
interface
Ensure the all ESD precautions are taken when handling imager
interface. See Section 2.2.
Step Action
of the frame.
prebox side cover.
5 Viewing the prebox from the cover side, ventilating
fan is located top centre.
6 Disconnect connectors P1 and P2 from the imager
interface.
7 Remove the two attachment screws that attach the
image interface to the prebox PCB assembly and
remove the image interface.
11.8.3 Installation
How to install the imager The installation procedure is the reverse of the removal
interface procedure.
abc
AUTOLITH TP
Page 78 April 2001

November 2000
Edition The table below lists all pages in Servicing Instructions with their edition :
Page Edition Page Edition Page Edition

1 November 2000 27 November 2000 53 April 2001
12 November 2000 38 April 2001 64 April 2001
20 April 2001 46 April 2001 72 April 2001
abc

6 Servicing Instructions

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6 Servicing Instructions

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AUTOLITH TP

November 2000 Page 1

1 About servicing instructions ................................................................................. 3

2 General maintenance instructions........................................................................ 4

3 Frame and external parts ....................................................................................... 6

3.1 What is in this chapter ..................................................................................... 6

4 Drive system ......................................................................................................... 23

4.1 What is in this chapter ................................................................................... 23

5 Feed-in section ..................................................................................................... 28

5.1 What is in this chapter ................................................................................... 28

7 Wash section ........................................................................................................ 54

7.1 What is in this chapter ................................................................................... 54

Page 2 November 2000

7.3 Water recirculation pump............................................................................... 57

8 Finisher section .................................................................................................... 61

8.1 What is in this chapter ................................................................................... 61

9.1 What is in this chapter ................................................................................... 66

10 Exit section ........................................................................................................... 68

10.1 What is in this chapter .................................................................................. 68

11.1 What is in this chapter .................................................................................. 70

November 2000 Page 3

1 About servicing instructions

Notation conventions The following indicators are used in the illustrations:

Indicator Used for Example

Page 4 November 2000

2 General maintenance instructions

This section contains the general information about servicing the

THE ELECTRICAL POWER SUPPLY MUST BE

For some maintenance operations, remove the relevant main

November 2000 Page 5

2.2 Electrostatic discharge

Page 6 November 2000

3 Frame and external parts

3.1 What is in this chapter

Overview This chapter covers the following topics:

For more information, refer also to the Section 4 - Spare Parts.

November 2000 Page 7

3.2 Feed and delivery tables

How to remove the feed Proceed as follows:

Figure 3.2(a) Feed table

Page 8 November 2000

How to remove the delivery Proceed as follows:

Figure 3.2(b) Delivery table

November 2000 Page 9

3.3 Left and right upper covers

Figure 3.3 Left and right upper covers

How to remove the left and

Page 10 November 2000

November 2000 Page 11

3.4 Control panel assembly

Figure 3.4.1 Control panel assembly

Page 12 November 2000

How to remove the control Proceed as follows:

November 2000 Page 13

3.5 Control panel components

Figure 3.5 Control panel components

Page 14 November 2000

How to remove the control Proceed as follows:

How to remove the touch Proceed as follows:

November 2000 Page 15

3.6 Emergency stop buttons

Figure 3.6 Emergency stop buttons

How to remove the right Proceed as follows: