Test page output procedure; Poor plot quality; Print Head Cleaning.

TechJET Color 5324/5336, 5324/5336 GT, 5336i, or 5336iMX:
Print Head Cleaning/Priming Updated: 11 April 1997
Technical Support Call Center 1-800-CALCOMP (1-800-225-2667) 53CLEAN3.DOC

Symptom or Problem:
Inking problem/Poor plot quality:[Missing colors, streaks, fuzzy lines];
Print head misfiring; Print Head Cleaning.

A. Verify the firmware revision level:

1. If this is a 5336i:

a. Verify that the plotter firmware is 1.62 or later. The
firmware in the plotter may be upgraded by downloading
the latest firmware upgrade file from the CalComp Web site at: , executing the self-
extracting file, and sending the firmware file to the
plotter. (For more detailed information on upgrading the
firmware, the readme file, contained in the self-
extracting firmware file, provides a step-by-step
procedure to follow).

2. For 53xx, 53xx GT, 53xx GT/PS models:

a. Ensure that plotter firmware is 1.10 or later (released
in mid-February 1995). This firmware uses a sonic method
to clean the print head assembly. The firmware in the
plotter may be upgraded by downloading the latest
firmware upgrade file from the CalComp Website
(http://www.calcomp.com). Executing the self-extracting file,
and sending the firmware file to the plotter. (For more
detailed information on upgrading the firmware, the
readme file, contained in the self-extracting firmware
file, provides a step-by-step procedure to follow).

B. Verify that ink is present at the print head assembly:

1. If this is a 5336i:

a. Verify that the black InkPak has a gold star on the back.
Earlier black InkPaks used an ink that would cause a
fuzzy output.

b. If the plotter contained one of the older InkPaks, then:

i. Install a newer black InkPak with a gold star on
the back.

ii. Use the menu selection on the plotter to select the
CLEAN NOZZLES option on the plotter for the black
color. This process should be performed six (6)
times to purge the old black ink from the line.

iii. Visually verify that all four ink tubes are free of
air bubbles. If air bubbles appear, then repeatedly
select the CLEAN NOZZLES selection on the plotter
for the affected color tube(s) until the air
bubbles have been purged.

iv. Use the menu selection on the plotter to output the
stitch plot. Make sure that the Plot Mode is set to
NORMAL first. To do this, perform the following:

iv.1. Load the media into the plotter. A-size
media is sufficient. Lower both the pinch
rollers.
iv.2. Press ON LINE.
iv.3. After the plotter has sized the media,
the plotter will display either: ONLINE 0:00
or MANUAL 0:00.

Press the MENU key until the plotter displays:
MENU - USE ARROW KEYS TO CHANGE

iv.4. Press the DOWN ARROW key until the
plotter displays: PLOT MODE:

iv.5. Press the right (+) key until the
plotter displays: PLOT MODE: NORMAL

iv.6. Press the DOWN ARROW key until the
plotter displays: INTERNAL TEST: OFF

iv.7. Press the right (+) key until the
plotter displays: INTERNAL TEST: STITCH PLOT

iv.8. Press the ON LINE key. Wait for the plotter
to complete the test.

iv.9. Examine the eight by eight grids (nozzle
check) on the stitch plot. Each segment
represents an individual nozzle. They are
output in groups of eight. Each group of
eight will be offset from the previous group.
Each nozzle within each group should be the
same distance apart.

c. If the problem is still present, then continue with the
remaining steps.

2. If the MaxInk System is being used on this plotter, check the
following:

a. Verify that ink is being supplied to the reservoir
cartridge(s). Perform the following:

i. Press the + or - key on the plotter to bring the
carriage/print head from the print station area.

ii. Close the pinch clamp(s) on the ink feeder hose(s)
at the MaxInk box and disconnect the corresponding
ink supply tubing which connects to the top of the
reservoir cartridge(s). Place the open tubing over
a container or an absorbant towel to accept waste
ink.

iii. Verify that ink flows by momentarily releasing the
corresponding pinch clamp(s). If there is no ink
flow, then the MaxInk System requires
cleaning/priming.

b. The print head is shipped with an ink supply gasket
installed around the four screens. Verify that it has
been removed. If it has not, remove it now.

c. If the MaxInk System will be idle for two or more weeks,
the ink feeder hoses must be flushed with distilled
water, leaving them free of ink. Failure to do this will
cause dried ink to form, causing clogging. If the clog
cannot be cleared, the entire chain assembly must be
replaced at the user's expense.

d. To determine if there is a problem with the MaxInk
System, a standard 9, 14, or 25ml cartridge may be
substituted. Perform the following:

i. Close the pinch clamps on the ink feeder hose(s)
that are having problems.

ii. Remove the corresponding reservoir cartridge(s) and
replace with the appropriate individual 9, 14, or
25ml ink color cartridge.

iii. Try outputting to the plotter with this
configuration.

iii.1. If problems still exist, then continue
with the remaining procedure.

iii.2. If problems have been resolved, then the
MaxInk components require cleaning, priming,
and/or repair.

3. For 53xx, 53xx GT, 53xx GT/PS models: Visually verify that the
filter on each ink tank cartridge is saturated with ink. If it
is dry, then the print head will not draw the ink by capillary
action. If it appears dry and there is still sufficient ink in
the ink tank cartridge, then:

a. Examine the small hole on the ink tank cartridge.

i. On the 9ml and 14ml ink tank cartridges, it is
above the filter opening.

ii. On the 25ml ink tank cartridge, the opening is at
the top, near the square-end.

b. If necessary, enlarge the small hole with a pin, or try
another ink tank cartridge.

c. After all four ink tank cartridges have been installed
into the carriage assembly, select the CLEAN NOZZLES
selection on the plotter for the affected ink tank
cartridge(s). Then use the menu selection on the plotter
to output the stitch plot. Make sure that the Plot Mode
is set to NORMAL first. To do this, perform the
following:

i. Load the media into the plotter. A-size media
is sufficient. Lower both the pinch rollers.

ii. Press ON LINE.

iii. After the plotter has sized the media, the
plotter will display either:
ONLINE 0:00 or MANUAL 0:00.

Press the MENU key until the plotter displays:
MENU - USE ARROW KEYS TO CHANGE

iv. Press the DOWN ARROW key until the plotter displays:
PLOT MODE:

v. Press the right (+) key until the plotter displays:
PLOT MODE: NORMAL

vi. Press the DOWN ARROW key until the plotter
displays:
INTERNAL TEST: OFF

vii. Press the right (+) key until the plotter displays:
INTERNAL TEST: STITCH PLOT

viii. Press the ON LINE key. Wait for the plotter
to complete the test.

ix. Examine the eight by eight grids (nozzle check) on
the stitch plot. Each segment represents an
individual nozzle. They are output in groups of
eight. Each group of eight will be offset from the
previous group. Each nozzle within each group
should be the same distance apart.

d. If the problem is still present, then continue with the
remaining steps.

C. Ensure that print head assembly is properly cleaned. (Note: If this
is a new, out-of-the-box print head assembly, start with next step.
If plotter plotted before, but now is having a problem, then perform
this step).

1. Press the + or - key on the plotter to bring the carriage/print
head from the print station area.

2. Remove the four ink tanks (or ink supply for 5336i) from the
print head carriage assembly. Lift up the print head carriage
cover.

3. Remove the print head assembly being careful to not let the
four print heads touch anything. Set the print head assembly on
a table with the four print heads facing up.

a. If a KeyKleen wiper cleaning kit is available (CalComp
part number 22380-0012), then lightly wipe each of the
four print heads with the KeyKleen swab. Note: This is
the only swab that is recommended for actual contact with
the print heads. Other swabs may cause permanent damage
to the print heads.

b. If the wiper cleaning kit is not available, then apply a
small drop of isopropyl alcohol onto each of the four
print heads. Do not touch the print heads. Also do not
pour isopropyl alcohol onto the print heads; do not soak
the print heads in alcohol; simply drop a small drop onto
each print head and perform the next step.

4. Set the print head assembly on its side (with the four that
accommodate the four ink tanks facing up). Apply a drop of
isopropyl alcohol onto each of the four screens. Again, do not
soak the print heads and/or input screens with alcohol; simply
drop a small drop onto each screen and perform the next step.

D. Ensure that the print head assembly is loaded correctly into the
carriage assembly.

1. Load the print head assembly into the carriage assembly. For
model 5336i, the ink supply must be connected to the print head
assembly first.

2. Clean the contact plate on both the print head assembly and the
underside of the print head carriage cover. Wipe these two
areas with a cloth. A cloth with isopropyl alcohol would be
best. A dry cloth will suffice.

3. Push the print head assembly back towards the hinged portion
of the print head carriage cover while closing the print head
carriage cover. Make sure it snaps securely.

4. Install the ink tank cartridges (non-5336i models) to the
print head assembly.

5. To verify that the print head connection has been made, perform
the sensor test diagnostic. Perform the following steps:

a. Enter the Test Menu on the plotter by pressing and
holding both the UP and DOWN arrow keys while turning on
the plotter power. Keep both keys depressed until
initialization has completed.

b. The Test Menu will remain active until the plotter is
turned off or is initialized. When in this mode, the
plotter menu will add additional diagnostics and test
menu selections.

c. Press the + or - key on the plotter to bring the
carriage/print head from to the print station area.

d. Use the menu selection on the plotter to select
DIAGNOSTICS.
Use the + or - keys to select SENSOR TEST and press ON
LINE.

e. The plotter will display the sensor information. Press
the + or - key to display the temperature sensor test.
The letters:
K C M Y will appear on the top line.

f. The values displayed underneath each letter indicate the
print head temperature in Celsius for each individual
print head. Normal values displayed are the current room
temperature in Celsius. For example, if 20 is displayed,
it is equivalent to 68 degrees Fahrenheit. If the print
head has been in use, the value may be higher than room
temperature. However, if any of the values shown are
negative values, then the print head must be replaced. If
the print head is not installed correctly, the value
below that print head will display a question mark.

g. If a question mark appears, then the print head needs to
be reseated. Adjust as necessary until the question mark
has been replaced by a numeric value.

h. If the values displayed are out of range, then the print
head may be defective.

i. To exit the test, press the MENU key once.

E. Inspect the plot station area (on the right side under the control
panel where the plotter normally parks the carriage/print head).

1. The plot station should rock up and down freely. If it does not
check for any foreign material such as packing material that
might be causing this problem.

2. The plot station area should show four rectangular black caps
which the plotter caps the print heads, preventing the print
heads from drying out. Also, in front of the four caps, is a
fifth black cap which performs all of the cleaning/priming for
all four print heads. In front of that is a clear plastic
wiper.

a. Ensure that all five black caps are in place. The black
caps fit on top of a white sleeve.

b. Clean the five black caps and wiper with isopropyl
alcohol on a q-tip.

c. The E-shaped pad which surrounds the rectangular caps
will discolor over time. This is normal. However, try and
remove some of the dried ink with a q-tip and isopropyl
alcohol.

F. Ensure that the print head assembly is properly primed.

1. Press the + or - key on the plotter to return the
carriage/print head back to the print station area.

2. Use the menu selection on the plotter to clean the appropriate
nozzles (i.e., clean all nozzles if nothing was coming out,
clean cyan if only cyan was not printing).

G. Use the menu selection on the plotter to output the stitch plot.
Make sure that the Plot Mode is set to NORMAL first. To do this,
perform the following:

1. Load the media into the plotter. A-size media is sufficient.
Lower both the pinch rollers.

2. Press ON LINE.

3. After the plotter has sized the media, the plotter will display
either: ONLINE 0:00 or MANUAL 0:00.
Press the MENU key until the plotter displays:
MENU - USE ARROW KEYS TO CHANGE

4. Press the DOWN ARROW key until the plotter displays: PLOT MODE:

5. Press the right (+) key until the plotter displays:
PLOT MODE: NORMAL

6. Press the DOWN ARROW key until the plotter displays:
INTERNAL TEST: OFF

7. Press the right (+) key until the plotter displays:
INTERNAL TEST: STITCH PLOT

8. Press the ON LINE key. Wait for the plotter to complete the test.

9. Examine the eight by eight grids (nozzle check) on the stitch
plot. Each segment represents an individual nozzle. They are
output in groups of eight. Each group of eight will be offset
from the previous group. Each nozzle within each group should
be the same distance apart.

H. If no ink is coming out, repeat the clean nozzles selection. This
time, while the print head assembly is being primed, assist in the
priming. There is a black piece of plastic on the print station which
extends in front of the carriage assembly. By pressing down on this
and varying the amount of pressure while the priming process is being
performed, the amount of suction will vary.
NOTE: The plotter is moving while this process is being performed.
Be careful. For safety, use a pencil to perform this step.

I. If the nozzle checks show blobs of ink, white spaces where a nozzle
should be firing, then either the print head/print station needs more
cleaning/priming, or the print head assembly needs to be replaced. A
print head can wear out prematurely by allowing the ink tank to run
dry. This will cause the print head to warp. CalComp only warrants
the print head assembly for 30 days.

J. If no ink is coming out from any of the four print heads after
selecting clean nozzles on the plotter menu three times, then the
plotter needs service. Either not enough vacuum; the print head is
misaligned; or there is a problem with the rasterizer board, ribbon
cable to carriage, or some other component. Not user serviceable.