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Falcon head alignments (Excel)

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					             Alignment Procedure for RJ-6000, 43/46 or 62 inch models
      Falcon, Falcon Plus and Falcon Outdoor
      Six color head alignment procedure for
      These alignments are performed in Diagnostic mode.

      To access Diagnostics Mode:           Hold the 'Shift', 'Menu' and 'Cleaning' buttons while powering on the printer.
      Release after the 'beeps'.

      The following diagram represents the colors in the heads when looking at the heads.
      Also use this pattern to help diagnose why some colors may prime and others may not.
      Use this pattern in this procedure, when adjusting the alignment of the heads. If this is not printed out already, it is
      strongly suggested that you print it out in color.


          Left Head ink colors                                         Right Head ink colors

         K                C                 LM or                    M                 Y                LC or
                                            Green                                                       Orange




      From Diagnostics mode, Press MENU and find the Diag: Adjustments screen, press ENTER.
      Generally, Pressing MENU will advance to the next test and Pressing a Value key will make a
      change to a value.

1 "Check nozzles" pattern prints first:
      If many nozzles are missing but there are some nozzles of every color then perform a 'Normal cleaning' from the
      "Clean" menu, However, if many nozzles of one or more color are missing then perform a 'Powerful Cleaning' from
      the "Clean" menu.

      If an entire color is missing then perform another 'ink fill' (HeadRank Enter, Enter etc Ink Fill). Print 'Check nozzles'
      again to confirm.

      If only a couple of nozzles are missing then they should come back during the alignment procedure. Just make sure
      that it is not a 'top' or 'bottom' nozzle in the pattern.
      Compare the relative alignment of the two heads:


1.1

        LC Y M LM C                                         K          LC Y M LM C                                        K
1.2 If you notice the tops of any outside adjacent colors (Lm to M or K to Lc) being off (up and down) by more than two
      lines then go back and examine the physical layout of the two heads as they sit in the head carriage.

      The tops of the back edges of the two heads should be perfectly parallel to one another, not too far back or too far
      forward. If this pattern is close then there will be minimal alignment adjustments required later.

1.3 With the basic visual alignment taken care of you are ready to start the mechanical and electrionic 'alignment'
      procedures.




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            Alignment Procedure for RJ-6000, 43/46 or 62 inch models
      The First two alignments (Left Tilt and Right Tilt) are 'physical' mechanical
2 alignments and common to models mentioned above.


      Two things to keep in mind: 1) A 'loop' is helpful in determining the 'error' to be corrected.



2.1
      "Left Tilt" pattern is the First physical 'alignment' and it is for the LEFT head
      ONLY. The goal is to make the LEFT head parallel with the printing direction:

               If K and Lm are up or down to one another then the
               head is 'tilted'. Rotate to adjust.
2.2
                LM     K      LM       K         C       K        C        K       LM     K      LM     K

      Each 'Lm to K' example in this pattern is the same so one adjustment will affect all. Since C is the
2.3
      center of this head it should never be off from K or Lm.

      If the tops of these colored boxes are all straight across then the "Left Head" is aligned properly.
2.4
      However, if they are high or low to one another then the head is slightly rotated (tilted).

      Look for anywhere that K and Lm touch. If they are high or low then this head must be rotated
      (push the left or right side away or pull toward you).
      The small levers on the front of the head carriage may be used - But first loosen the adjustment
      screw slightly and then either push or pull the edge of the head - toward or away from you. Gently
      tighten the screw and print the test again.
      Examine the affect of your adjustment - too little or too much, adjust as required. If the little lever
      on the front does not seem to make a difference then either you have a very fine adjustment to
      make or the adjustment screw is still too tight.
      If it is a fine adjustment that is required then either pushing or pulling gently on the right or left edge
      of the head and gently tightening the screw, will align it.
2.5   Note:   The adjustment levers will not work unless the adjustment screw is loosened. Loosening
      too much however may cause other alignments to change.
2.6 Always keep the colors of the heads in perspective as you complete the alignments. This
    decreases the alignment time.




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            Alignment Procedure for RJ-6000, 43/46 or 62 inch models

3 "Right Tilt" pattern is the Second physical 'alignment':                             Again a 'loop' is
      helpful in determining the 'error' to be corrected.
      This pattern (grossly out of alignment in this example) is used to make TWO adjustments to the
      RIGHT head. If it were off this bad then you would go back to section 1.1 above.

3.1


                               L          L
                             LM KLLM YCYLM KLLM
                                    K          K
3.2 The FIRST adjustment for the RIGHT head is to make it parallel (considering only the MYLc colors
    and shown by the BLUE arrow) to the printing direction just as you did in the previous adjustment
    for 'Left tilt' (using KCLm) in section 2.1 above.
      M and Lc are the two outside colors of the right head
      so rotate the head until these are square to each
      other.
3.3 The SECOND adjustment is to then bring the Right head (MYLc) directly parallel to the Left head
    (KCLm) which is already parallel from the earlier adjustment.
3.4 Make this adjustment while considering the two outside most colors of the two heads K and Lc (as
    shown by the RED arrow in 3.1 above), since this is where the greatest 'error' will be located. Also
    consider the inner colors of M and Lm during this align
3.5 The 'Tilt' or First adjustment uses either the front lever or a physical 'rotating' movement and the
    Second adjustment uses a small lever on the right side of the carriage.
    This lever sweeps from front to back and will then bring each of the individually parallel heads in
    direct parallel with each other. It will break if the screw is not loosened.
3.6   In the example 3.1, the BLUE arrow shows that both heads are parallel to the printing direction
      however, the two heads are not directly parallel to each other.
3.7 Use the side lever (loosen the adjust screw) to move the head forward or back. If the colors are
    too high, as they are in this example, then push the lever up a couple of notches and then try it
    again.
3.8 CAUTION: Always loosen the adjust screw before moving the plastic levers. Failure to loosen
      the screw will damage the plastic levers and possibly require additional parts to be sent out.
      Repeat these patterns as often as required.
      In this adjusted pattern you can see that all of the MYLc (M & Lc) are now straight across as well
      as the outside colors from each head (K and Lc) are now square to one another.




3.9
           L    M   L    K    L    L   M    K    Y   C    Y    L    M    L    K    L    LC   M        K
           M        C         M    C                           M         C         M


      When the colors form a straight line from left to right then the heads are physically aligned
      properly. Gently tighten the adjustment screws and print the pattern again.



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             Alignment Procedure for RJ-6000, 43/46 or 62 inch models
4 The Third set of adjustment patterns:                      is a series of thin dashed lines and is used
      to adjust the 'electronic' timing measurements that the printer sets for Bi-Directional printing in
      both Normal dot and Microdot as well as an up and down head height
      position for each of these in the Plus model.
      These first 'electronic timing' patterns will ask you for the correction of both heads. for instance, KCG -235um will be
      displayed and then MYO -240um .

      Press the 'value + or value -' buttons to either increase or decrease this negative number according to the 'tip' shown
      below.

                                 Right head                                 Left head

4.1              LC               Y              M                LM              C               K



4.2                                              LYM CK
                                                    L                       Third print pass: These lines print from
                                                                            right to left <---

      Use the Value Up button
      to move to the left
                                               LYM CK
                                                  L                         Second print pass: These lines print from
                                                                            left to right --->


      TIP:
                                               LYM CK
                                                  L                         "First" print pass: These lines print from
                                                                            right to left <---
      To simplify this procedure, ignore the "First" printed set of lines: Look at the Second and Third printed sets of lines,
      whichever direction the Third set of lines need to move (right or left) Press the 'Value Up (button left of center) or Value
      Down' (
      right of center) buttons.
4.3 In this case you want the top pattern to move to the left so press the 'Value Up' button some number of times.
      Possibly three presses to move 1 line width. Print the pattern again to verify your adjustment. Repeat as necessary.




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4.3
             Alignment Procedure for RJ-6000, 43/46 or 62 inch models
      The Fourth set of patterns:             is a series of stacked boxes and is used to adjust the
      'electronic' timing measurements that the printer sets for Uni-Directional printing in both Normal
      dot and Microdot as well as an up and down head height position for each
      of these in the Plus model.
5
        L L L C C C K KKL L L C C C K KK                                                                 Value Down button
                                                                                                         to move to the right

        L YML YML YM YML YML YM
                        L
        L L L C C C K KKL L L C C C K KK
5.1
      TIP:
      To simplify this procedure, ignore the "First" printed set of lines: Look at the Second and Third printed sets of lines,
      whichever direction the Third set of lines need to move (right or left) Press the 'Value Up (button left of center) or Value
      Down'
5.2   In this case you want the top pattern to move to the left so press the 'Value Up' button some number of times.
      Possibly three presses to move 1 line width. Print the pattern again to verify your adjustment. Repeat as necessary.


      The Final set of adjustments and their explanations:                                               Also in Service manual
      BAC 2110.
      Flushpoint (spittoon boxes) are just to the right and left of the printing area along the
      platen. The 43/46" model has one and 62" model has two.
      The pattern will show one head as a series of lines and the other head as dots. Position these patterns so that they fall
6     INTO the spittoon and not down the sides, outside the spittoon.

      TIP: Tear a piece of paper with a sharp corner about 2" x 4". Hold the sharp edge at the edge of
      the spittoon and activate the pattern. Move the paper and confirm the position of the pattern to be
      inside the spittoon.
6.1    "X" length (sets the line step measurement by printing a 300mm line. Measure the printed line
      and enter the actual length using the 'value' buttons. "X" Length2 is the same pattern only 900mm
      long. Make sure to set the resolution in User Mode to less


7      Margins adjustments: is used to measure top, bottom and R&L margin values:
      This routine will cut off the leading edge, print a wide black band and then cut off that 'image', producing an 'image' with
      the four exact margin measurements.
       If the top margin in the first print is 'off' by 5 or more please double check the set screws in the "X" drive, grid roller
      shaft series of couplings. Do the 'margins' adjustment again to confirm the 'error' to be corrected.

8 Rear sensor measurement requires a pre-cut piece of media larger than 8 1/2 x 11.              Set in
      rollers and the printer will locate and measure the position of the rear sensor. Press ENTER to
      exit.




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