JPI JP-33 User manual

JP-33 SERVICE MANUAL
Revision5.03
Issue:2004/04/01
Service Manual
JP-33 Automatic Film Processor
Maintenance and Technical Support
Corporate:
JUNGWON PRECISION IND. CO., LTD
www.jpi.co.kr
Woolim e-Biz center #608,170-5, Kuro-3-dong,
Kuro-gu, Seoul, Korea, 152-847
TEL : [phone] FAX : [phone]
U.S. Office:
JPI AMERICA, INC
www.jpiamerica.com
22-36 Harman Street, Ridgewood, NY 11385
TEL: [phone] Fax: [phone]
- -
1

JP-33 SERVICE MANUAL
Maintenance Program
This chapter provides instructions for cleaning and preventive maintenance of the JP33, and
explains how users may keep the processor in optimal condition.
Only experienced technicians should install the JP-33. The technicians who install the unit
should review the JP-33 Instruction Manual before installation and should strictly follow all
guidelines of the manual. The technician should instruct and train all users to perform daily
and weekly maintenance and provide users with blank copies of maintenance records. We
highly recommend that an experienced technician perform the monthly and annual
maintenance. A proper maintenance program will guarantee trouble free use with optimal
performance.
Use of Maintenance Record
Use the maintenance record as a guideline and to log daily, weekly, monthly and annual
maintenance performed. The user must keep records for technician evaluation. The JP-33
warranty will be void if maintenance is not performed properly.
Do not use the original maintenance record; copies should be made for use.
- -
2

JP-33 SERVICE MANUAL
- -
3
Maintenance Record
X-Ray Film Processor JP-33 Term Code: D – Daily, W – Weekly M – Monthly, Y - Yearly
Date of (Jan, Feb, March,April, May, June, July,Aug, Oct, Sep, Nov, Dec,) Year 20____
Check Item
Term
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Clean feed tray D
Clean film receiver D
Clean Roller by cleaning
film D
Check Chemical Level D
Check Hose Plumbing D
Clean DEV Rack W
Clean FIX Rack W
Clean Wash Rack W
Clean Wash Tank W
Clean Drain Filter W
Check Roller Damage or
Scratch W
Check Roller Spring
Tension W
Clean DEV, FIX, Wash
Rack M
Clean DEV, FIX, Wash
Tank & O/F M
Check Hose Clamp,
Plumbing M
Check Lubricant M
Clean Valve of
Pumps Y
Check Worm & Drive
Gear Y
XPlease cross out each box when task is complete.
Do not use the original maintenance record; extra copies should be made for use.

JP-33 SERVICE MANUAL
- -
4
MaintenanceProgram - Cleaning
Cleaning
Cleaning is one of the most important factors in the maintenance program. It is very important for proper
operation. Stains or contamination on the unit from water or chemicals may cause damage and corrosion. It
may also seriously affect the unit’s performance, which may deteriorate image quality.
Caution: The temperature of water used for cleaning the tanks should not be more than 129°F (54°C).
The technician cleaning the unit should follow the instructions provided in the service manual. Do not use
any abrasive detergent or material to clean the unit. Only use neutral detergent and soft lint-free material.
Warning: For safety purposes, unit should be turned off while performing maintenance and /or service
on mechanical and electrical parts (gear, shaft, PCB, pumps, etc.)
Daily Cleaning
The daily cleaning should be performed in accordance with the maintenance schedule.
1. Clean the feed tray
A. Use a damp lint-free cloth to clean the film inlet and inside the feed tray. All chemical residues
should be cleaned
B. Make sure the surface is dry after cleaning, use a dry lint-free cloth if needed.
Note: Be careful not to touch the film sensor lever when cleaning the feed tray.
2. Cleaning the film receiver
Apply a damp, lint-free cloth to clean the film receiver on the top cover. Make sure the surface is
dry after cleaning; use a dry lint-free cloth if needed.
3. Clean roller with Cleaning-Film
We recommend using 3~5 pieces of cleaning film.
Continuously feed the cleaning film to get rid of any impurities (artifacts) on the rollers and film
guides. This step is not mandatory if the weekly inspection is performed regularly or scratches are
found on image. In the event there are scratches on the image, please refer to trouble shooting
section 1.3.

JP-33 SERVICE MANUAL
- -
5
MaintenanceProgram - Cleaning
Weekly Cleaning
Caution!
When cleaning tanks and roller, do not use any abrasive material that can damage the surface.
Caution!
When removing the rack assembly from the unit, make sure the unit is turned off. Do not spill
chemicals or water into other tanks or onto other parts of the unit, such as the control panel. In the
event water or chemistry spills onto any electrical parts immediately dry the part using a dry lint-free
cloth and a blow dryer.
1. Cleaning the DEV, FIX, WASH rack
Caution: When removing and cleaning racks, note that the worm wheel (gear) maybe lubricated with
grease. Avoid allowing grease to come in contact with clothing, rollers, gears or any other part of the
rack.
A. Carefully remove rack covers.
B. Be careful not to spill chemicals while removing the DEV, FIX and WASH racks.
C. Use a lint-free cloth to clean the rack and rack cover. If required, apply alcohol or
a neutral detergent onto a soft sponge to remove foreign substances on the surface. The surface
of each roller should be thoroughly cleaned out.
Note: Soft materials like a sponge should be used to clean the roller. Do not use abrasive
materials (scrubbing brush, etc.). Abrasive material may damage the surface of rollers. Do not
apply too much pressure; it may damage the roller tension spring.
D. Check the rollers and the operational condition of each rack. Check the condition of film guides
and make sure they are mounted properly.
2. Cleaning the wash tank
A. The wash tank should be cleaned once a week.
B. Open the wash drain valve to empty the wash tank.
C. Use a soft sponge and/or soft scrubbing brush with lukewarm water to clean the base and walls
inside the tank.

JP-33 SERVICE MANUAL
MaintenanceProgram - Cleaning
3. Cleaning the drain filter of the DEV, FIX, WASH tanks
A. In the event there is trouble with the drain filters in the tanks (clogging or obstructions by leftovers),
problems with the circulation and replenishment of the chemicals may occur. This may accelerate
contamination of chemicals and can rapidly increase or decrease the temperature of the chemistry.
B. Remove all the drain filters from tanks.
C. Wash residue and all foreign objects off by running the filter under lukewarm water.
D. Make sure the filter mesh is not damaged.
E. Install the cleaned drain filter back in its original location.
4. Place all parts and rack assemblies back securely in their original location.
- -
6

JP-33 SERVICE MANUAL
- -
7
MaintenanceProgram - Cleaning
Monthly Cleaning
All rack assemblies and tanks must be cleaned thoroughly every month. This procedure may take up to
two hours.
Caution!
Make sure unit is turned off before performing monthly cleaning.
1. Clean the DEV, FIX, WASH racks
A. Open the drain valve to remove the developer, fixer and water from tanks.
B. Remove the racks from the unit and clean the racks. (Follow weekly cleaning procedure on page 5)
C. Remove all drain filters and rinse them with lukewarm water.
D. Check the condition of each rack and rack side plates. Rotate rollers, by turning worm wheel (Gear)
in one direction, to make sure rotation is smooth.
Note: Fixer rack has a higher potential for damage than the developer rack. This originates from the
chemical reaction of the fixer. Therefore, the conditions of the fixer rack (rollers, gears, guides,
side plates and bushings) must be checked thoroughly and frequently.
2. Clean the DEV, FIX, WASH tanks and OVER FLOW line
A. With racks out of the tanks, close drain valves and pour lukewarm water into the tanks. With a soft
brush clean the base and walls of each tank. Once finished, open drain valves to remove water.
B. Pour lukewarm water into the overflow hole to remove foreign substances.
C. Once you have cleaned all the tanks, make sure to close the drain valves, fill each tank with
lukewarm water then mount all the racks and turn the unit on. You should run the processor for
approximately 15 minutes while you are checking the circulation of the water and the operation of
each rack.
D. Once this is complete drain the water and follows procedures for filling chemistry. (Page 10)

JP-33 SERVICE MANUAL
MaintenanceProgram - Inspection
Preventative maintenance
Daily Inspection
1. Check the tank levels
Make sure that the chemistry inside the tanks is at the appropriate level. Also make sure to check the
level of the replenishment tanks.
2. Check the hoses and plumbing
Check all hose and connections for leaks. If there are any leaks contact your service center
immediately. Check each hose for kinks and make the appropriate adjustments to eliminate the kinks.
Weekly Inspection
1. Check the roller and film guide
Check the surface of roller for any damage, scratch or pollutants.
Check the film guide for any damage. Make sure all film guides are mounted firmly in their location.
2. Check the roller spring tension
A. The spring tension supporting the roller is a very important part of the rack.
B. The spring tension should firmly support the roller and it should not be loose.
-If the spring tension supporting the dryer exit rollers is loose, the film may not be guided out
properly and may be lost inside the unit or Jam the unit.
-If the spring tension supporting the squeegee rollers (rubber rollers) is loose, they will not
squeeze (dry) the chemistry or water, which will affect the image quality.
-The spring tension should not be too hard. This will make it difficult for the racks to rotate
smoothly. In this case, the rack will jump and/or film will jam.
-The spring tension should be the same on both ends of the roller. If not, due to uneven tension the
film may be guided off alignment and jam.
- -
8

JP-33 SERVICE MANUAL
- -
9
MaintenanceProgram - Checking and Inspect
Monthly Inspection
1. Check the hoses, clamps and plumbing
-Do not tighten the hose clamps too much. Clamps that are too tight may cut hose and cause leakage,
which may result in damage to pumps and electrical components.
-Check hose for kinks or cracks.
2. Check lubricated parts
Remove old lubrication and apply new lubrication for appropriate parts in accordance with the oiling
schedule.
A. Remove old lubricant
Old lubricant should be removed before applying new fresh lubricant. The absorption of dust or
other foreign substances on the old lubricant may cause unwanted friction.
B. Cleaning
Before applying new lubricant, use a brush to remove any foreign material or pollutant from the
gears.
C. Lubricating pointer
Main drive shaft and Bracket Oil/Teflon oil
Worm Gear, Drive Gear Oil/Teflon oil
Main Motor Sprocket and Chain Grease
Annual Inspection
1. Check the RPL. Pump Valve
A. Unscrew the valve-fixing cap off the replenishment pump.
B. Remove the valve from the pump to prevent damage.
C. Soak the separated valve in warm water. Physically check the valve for pollutant.
D. Carefully place the clean and checked valve back into the pump. Make sure the valve is positioned
properly.
E. Screw the valve-fixing cap back onto pump.
F. Handling of the valve of RPL pump should be in strict accordance with the above
instructions and other instructions in this manual.
2. Check the worm drive and worm wheel (gear)
A. The worm drive and worm wheel (gear) are critical parts of the transport system. These two parts
are exposed to great pressure. Therefore, it is important to carefully examine the parts for wear
and tear.
B. Carefully check the worm drive and worm wheel (gear) for wear and tear, and replace the part when
needed.

JP-33 SERVICE MANUAL
- -
10
MaintenanceProgram - Change Chemical
When & How to Replace Chemicals
Important: The chemistry’s condition is important for proper film processing. Exhausted and/or
contaminated chemistry will lead to poor images. Since the processor is used in the final stage of
generating an image, it is normally blamed for poor image quality, overlooking the chemistry.
Before assuming the poor image quality is due to a processor problem we highly recommend that
the chemistry be checked.
1. Generals
When is to replace the Chemistry.
: Refer to trouble shooting guide section 4, reasons for poor image quality.
When there are no problems, chemistry should be replaced in accordance to the chemical
manufacturer’s guidelines.
2. Procedure for replacing the chemistry
1) Removing old chemistry.
-Before opening drain valves, make sure the drain hoses are inserted inside the tank or drain.
-Remove all the racks (DEV, FIX, WASH). Be careful worm wheel (gear) is lubricated.
DO NOT GET LUBRICANT ON CLOTHING OR OTHER PARTS OF THE RACK.
Open top cover Æremove rack cover Æopen rack locks Æremove DEV, FIX, WASH
racks Æbe careful not to spill chemicals on the floor, on any electrical components and
keep the chemicals away from the operator’s body and clothes.
-Open drain valve to drain the old chemicals.
2) Waste disposal
Disposal of waste should be performed in accordance to local rules and regulations.

JP-33 SERVICE MANUAL
- -
11
MaintenanceProgram - Change Chemical
3) Clean processor before adding new chemistry
-Cleaning tanks (Close drain valves)
zWith lukewarm water rinse each tank.
zDrain the used water by opening the drain valves.
zDry all tanks with a lint-free cloth
zClose the drain valve after cleaning all the tanks.
-Cleaning of rack
Important: Do not submerge worm gear in water. Grease from worm gear may loosen
and stick to other parts of rack, also when handling worm gear make sure to not get
grease on other parts of rack.
Soak the three racks in water separately, or clean each rack with running water while
rotating the worm wheel (gear). Be careful not to damage the roller surface during
cleaning.
-Cleaning of replenishment tanks
Wash out the tanks with lukewarm water. Make sure there are no foreign materials
inside the tanks.
4) Prepare new chemicals
-Please follow chemical manufacturer’s mixing process and guidelines.
5) Filling processor tanks
Important: To prevent cross contamination; make sure to add fixer before developer.
Then with a damp lint-free cloth wipe clean developer tank. Make sure to clean any
fixer residue.
A. Add fixer into the fixer tank by using the pitcher provided with the processor.
- Wash out the measuring cup with running water.
- Fill the fixer tank.
- Pour about 2~2 1/2 pitchers into the tank. Make sure to fill the tank up to overflow
level.
B. Filling developer tank: make sure the tank is clean and the pitcher is thoroughly clean.
To fill developer tank, follow the same method used to fill the fixer tank.
Be careful not to mix the developer and fixer when handling the chemicals.
C. Fill washer tank with water up to overflow level.

JP-33 SERVICE MANUAL
- -
12
MaintenanceProgram - Change
6) Install replenishment tanks
-Place replenishment tanks in their proper location under the processor.
-Connect hoses or insert hoses into tanks. Refer to color codes and picture to prevent error.
-Color codes of hoses used with the processor
zRed: Developer
zBlue: Fixer
zClear: Washer (Or Black six-foot hose with ¾ inch fittings).
7) Inspection
Check all hoses and connections for leaks.
Clean any spilled chemicals inside and outside the processor
8) Installation of racks and final testing.
-Install the cleaned rack in the marked location
Make sure main worm gears are positioned properly on the worm drive.
Lock racks into place
-Cover all racks.
-Turn the power on.
Check the operation of the racks and make sure there are no unusual noise, leaks or odors.
-Place top cover into position.
9) Check for proper operation by running one test film.

JP-33 SERVICE MANUAL
- -
13
TechnicalSupport
This chapter provides technical supports for technical service personnel.
Part I. Trouble Shooting. -------------------------------------- page 14
Part II. Developer-Temperature calibration. ---------------- page 30
Part III. AC-Power voltage setting (220/240V). ----------- page 31
Part IV. How to replace key parts. --------------------------- page 35
Part V. Location of Components ----------------------------- page 43
1. Location of Electrical Components
2. Location of Developer Rack Components
3. Location of Fixer Rack Components
4. Location of Washer/Dryer Rack Components
5. Location of the Main Drive Shaft Components
Part VI. Electrical schematics ------------------------------- page 49
1. Block-Diagram of Electrical
2. Schematic Circuit Diagram
3. Microprocessor Sequence Table
Part VII. Part List --------------------------------------------- page 53

JP-33 SERVICE MANUAL
- -
14
TechnicalSupport - Trouble Shooting
PART I -Trouble Shooting
Please refer to this trouble-shooting guide before contacting technical support. This guide
provides possible causes for the problems you are experiencing. Some simple checks or
minor adjustments on your part may eliminate the problems and restore proper operation.
To resolve a problem you will need to check the trouble-shooting table of contents to find the
problem or related problems. Once you have identified the problem you may need to use
one or more of the provided solutions to eliminate the problem. In the event you have tried
the remedies indicated but the problem is not solved; contact technical support as soon as
possible.
Table of Contents
1. General problems
1-1. Cannot insert film, or unit does not activate when film is inserted.
1-2. Unit continues to operate as if film is being processed (non-stop).
1-3. Scratch or marking on film.
a. White or black streaks parallel to film feed direction.
b. Scratches or markings on the film that are perpendicular to film feed direction and are
similar in size, distance and location.
c. Scratches or markings on the film that are not similar in size, distance or location.
1-4. Film Jam or lost film in processor.
1-5. Chemistry is not replenishing.
1-6. Replenishing rate is too high or too low.
1-7. Unit continuously replenishes.
1-8. Film is not dry.
1-9. During processing you hear squeaking.
2. Electrical problems
2-1. Unit does not turn on.
2-2. Circuit breaker continuously trips.
2-3. Unstable operation, the unit repeatedly runs and stops.
2-4. Display panel does not work.
2-5. Buzzer is not working
2-6. Main motor is not working.
2-7. Developer displayed temperature not the same as actual temperature.
2-8. Over or under supply of water.
2-9. Dryer heater does not work.
2-10. DEV heater overheats.

JP-33 SERVICE MANUAL
- -
15
TechnicalSupport - Trouble Shooting
3. Mechanical problems
3-1. The unit squeaks during operation.
3-2. Rack jumps and rattles.
3-3. Wrinkled film.
3-4. Film exits unit at an angle.
4. Poor image quality.
4-1. High contrast.
4-2. Low contrast.
4-3. Film is milky.
4-4. Film surface is spotty.
4-5. Wet film.
4-6. Dirty film.
4-7. Film is sticking in dryer.
4-8. Film emulsion is coming off in developer.
4-9. Increased base fog.
4-10. Scratches or markings on film.
4-11. Sandy film
4-12. Developer turn dark
4-13. Strong Ammonia smell from processor.
4-14. Fixer color is milky.

JP-33 SERVICE MANUAL
TechnicalSupport - Trouble Shooting
Troubleshooting general problems
1-1. Problem
Cannot insert film, or unit does not activate when film is inserted.
Check Film Sensor manually.
Film Sensor is located inside the Feed Tray.
: It can easily be seen and accessed when feed tray cover is opened.
Check the operation of the sensor by a dummy film inserting.
: If the magnetic sensor is not working properly because of obstructions, sensor bar can
not sensing (: up) or recovering position (: down).
You can repair a obstruction by sensor adjusting.
You check wiring by bellow diagram.
- -
16

JP-33 SERVICE MANUAL
TechnicalSupport - Trouble Shooting
- -
17
1.2 Problem
Unit continues to operate as if film is being processed (non-stop).
zControl Panel displays “Feed-In” and the Feed Time continues to increases.
zMain motor is on and unit continues to replenish chemistry.
zNext film feed in indicator does not prompt.
Check to see if main motor is operating.
Remove the top-cover and check if the motor is operating.
: If motor is not functioning properly, contact tech support.
Check if DEV Rack is placed in tank properly.
: Make sure worm wheel (gear) is resting properly and securely on worm drive.
Index: instruction manual page 19 “4.6.3. Check installing the Rack.”
Check if the tension spring supporting DEV Rack Roller is loose and rollers are running idle.
: Adjust the spring tension manually for proper operation.
If rollers are running idle because of the
Tension Spring is loose, bend the Tension Spring so that it will increase tension on the
roller.
Check Film Sensor manually.
Film Sensor is located under the Feed Tray.
: It can be easily accessed when feed tray is retracted.
If the Sensor Lever is not returning to its original position and is stuck, a manual adjustment
will have to be made.
-If the lever gets stuck on any part of the unit and does not return to its original
position, manual adjustments will have to be maid to avoid obstacles.
-Check if there is any chemical residue that is preventing the sensor from working
p
roperly. To correct this problem, clean the lever and the area around the sensor
with an alcohol or water dipped lint-free cloth, make sure not to bend lever out of
shape.
Note:Incaseversion2.0,Film Sensor is located inside the Feed-Tray
Youcanseeonthismanualpage16
th.

JP-33 SERVICE MANUAL
TechnicalSupport - Trouble Shooting
1.3 Problem
Scratches or Markings on developed Film.
A. There are white or black lines parallel to film feed direction.
Check if the Film-Guide is contaminated, damaged or dislocated.
Clean the Film Guide or replace the damaged Film Guide.
Check if the Film Guide is bent. Make manual adjustments if necessary.
Check if the film is being feed on an angle or is exiting on an angle.
Check if the user inserts the film on an angle?
Make sure tension springs on the rollers are not too tight. If so, make manual adjustment
Make sure unit is level.
B. There are scratches or markings on the film that are perpendicular to film feed direction and are
similar in size, distance and location.
Check if there is any damage or contamination on the surface of the Roller.
Clean and/or replace the Roller.
C. There are irregular scratches or markings.
Check if there is any damage of contamination on the part of Feed Tray.
Clean the Feed Tray.
Check if there was damage or contamination on the film before developing.
Inspect Film Cassette for contamination or damage.
Check if the damage arises during use of ID Printer.
1.4 Problem
Film jammed or lost in processor.
Check if the Rack is dislocated.
Make sure unit Base and Unit are level.
Make sure racks are positioned properly in place.
Make sure worm wheel (gear) is resting properly and securely on worm drive.
Check Roller Tension Springs.
If the Tension Springs are too loose or tight:
zToo loose: The film will not be guided properly.
zToo tight: The film may not be able to go in between rollers
Film Guide is dislocated or transformed.
Correct the location of the Film Guide by making manual adjustments
- -
18

JP-33 SERVICE MANUAL
TechnicalSupport - Trouble Shooting
1.5 Problem
Achemical is not replenishing.
.
Air is in the pipe or hose.
Remove air bubbles by opening the Drain Valve to release air.
Reduce the size of RPL Hose if it is to long.
RPL rate is to low
Set RPL Time over 30 seconds.
: In this case 100ml of chemical is supplied for 30 seconds to develop a sheet of film.
Set RPL Time as over “00” in Setting Mode.
: Replenishment is supplied automatically according to the size of film.
REVIEW REPLENISHMENT RATE CHART IN SECTION 1.6 OF TROUBLE SHOOTING
GUIDE
Check and make sure there are no particles inside hoses and pipes
Check the pipes connecting to replenishment tanks
Check if there is any alien substance or dried chemicals in the pipe and hoses.
1.6 Problem
Replenishment rate is too high or too low.
Adjust the replenishment rate.
Set “RPL Time” high/low in System Setting Mode.
The RPL is factory set at “00”: RPL “00” is for standard processing conditions.
JP-33 Film Processor is set-up to replenish Developer and Fixer according to the following chart.
Please program the RPL time accordingly to required specifications for your applications.
Replenishment rate of DEV, FIX chemical (bases on 14” x17” film = 50sec loading time)
Set RPL Time in sec.
RPL pump capacity (ml/sec.) 00 10 20 30 40 60
Fixer 100% 4.16 ml/sec 200ml 42ml 83ml 125ml 166ml 250ml
Developer 80% 3.33 ml/sec 160ml 33ml 67ml 100ml 133ml 200ml
Note: The IWAKI-bellows type pumps used on the JP-33 has a mechanical cam adjustment
screw. If your processing needs requires increasing the RPL, you can adjust the cam up
to 100% of the pumps capacity.
- -
19

JP-33 SERVICE MANUAL
TechnicalSupport - Trouble Shooting
1.7 Problem
Chemicals are being supplied without stopping.
Check the operation of the Film Detection Sensor.
Check feed sensor, refer to trouble shooting section 1.2.
1.8 Problem
Film is not drying
Check if the Dryer air is warm or cold.
If the dryer air is cold, then the dryer heater is malfunctioning. Contact Technical
support ASAP.
If the dryer air is warm, then the fixer may be exhausted or the washer is contaminated.
Replace the fixer and/or cleaning water.
Check if dryer vents in the Dry Rack are aligned properly.
1.9 Problem
During processing you hear squeaking
Check for air bubbles in re-circulation pump or if the pump is empty.
Check if there is sufficient chemical in the tank.
Drain the air bubbles.
: How to drain air bubbles is described in trouble shooting section 1.5.
- -
20