Foreword

This user manual is briefly describing the operational aspects of the POLO TURBO machine. In this
document, the step-wise instructions for handling various aspects of the machine with visual screens are
provided for easy and better understanding. It also describes the error messages encountered while
working with the machine with appropriate remedial actions required to be taken by the user.

This manual serves as the reference tool, which guides their customers how to use or operate the POLO
TURBO machine without anyone else assistance. The information provided in this document ensures its
uniqueness and language quality. For safe and proper use of the product, please read this manual carefully
and follow all the instructions.

Disclaimer

The information and instructions provided in this user manual have been checked for accuracy,
uniqueness, and reliability. ColorJet group reserves all the rights to modify and revise this manual as per
the company requirements without any prior notice.

“No part of this document shall be reproduced or used by externals without prior permission of the
ColorJet group”.

The reference table is shown in the below table:

Doc Type Doc Code Version Machine Name Date of Issue

User Manual GXX11XXX01 1.1 POLO TURBO June 2019

POLO TURBO
 Table of Contents
1. About Document ......................................................................................................................................... 3
Purpose ........................................................................................................................................................ 3
Intended Audience ....................................................................................................................................... 3
2. Printer Accessories ...................................................................................................................................... 3
3. Printer Overview .......................................................................................................................................... 4
Back View of the Printer .............................................................................................................................. 5
Control Panel Details.................................................................................................................................... 6
4. Getting Familiar with Printer Manager Interface ........................................................................................ 7
5. Main Menu Options ..................................................................................................................................... 8
Setting Menu................................................................................................................................................ 8
Tools Menu ................................................................................................................................................ 11
Help Menu ................................................................................................................................................. 12
6. Getting Ready for Printing ......................................................................................................................... 13
Switch ON Procedure ................................................................................................................................. 13
Loading Media............................................................................................................................................ 13
Ink Filling .................................................................................................................................................... 17
7. Printing ....................................................................................................................................................... 18
Nozzle Testing ............................................................................................................................................ 18
Print Head Calibration ................................................................................................................................ 19
Calibration Wizard ................................................................................................................................. 19
Horizontal Calibration ............................................................................................................................ 21
Step Calibration...................................................................................................................................... 23
Setting Print Origin..................................................................................................................................... 24
Setting Print Parameters ............................................................................................................................ 25
Adding Jobs ................................................................................................................................................ 25
Editing Job .................................................................................................................................................. 27
Ripping and Printing ................................................................................................................................... 28
Pausing and Canceling Printing .................................................................................................................. 29
8. Head Cleaning ............................................................................................................................................ 30
Head Blotting ............................................................................................................................................. 30

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 Head Purging .............................................................................................................................................. 31
Head Spraying ............................................................................................................................................ 32
9. Shutdown & Capping the Print Head ......................................................................................................... 33
10. Maintenance ............................................................................................................................................ 34
Print Head Maintenance ............................................................................................................................ 34
Daily maintenance ..................................................................................................................................... 34
11. Troubleshooting ....................................................................................................................................... 35
12. Error Code Specifications ......................................................................................................................... 37

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 1. About Document
Purpose
The purpose of this document is to guide and educate the targeted audience about the Printer and its
Printer Manager software so that they can easily and effectively handle as well as use it as per their
requirements. Additionally, this document also provides step-wise instructions for handling various
aspects of the printer and its related software with the help of graphical screens for easy and better
understanding. Moreover, the document also describes commonly encountered problems while working
with the printer and Printer Manager software with appropriate remedial actions.

Intended Audience
This document is meant for all the users who want to use the Printer for their printing business.
Sometimes, the targeted audience has little knowledge about the printer but in most of the cases,
targeted audience is much familiar with the terminologies of printer and printing business. Thus, this
document is designed to facilitate both types of users.

2. Printer Accessories

Please make sure that all the items listed below are available with the printer. If anything is missing, kindly
report the same to the dealer. The following items are included with the printer as given below:

1. USB Cable 2. Door Key

3. Zinc coated Screws LN 4x16 for fixing head 4. Computer Power cable (6A)
5. Zinc coated Screws LN 4x20 for fixing display 6. Media Clips
7. Air locking pipes with leurs and its cap 8. HIB Cable 55 cm
9. Tissue papers 10. Software & driver CD
11. Syringe 50ml 12. Rip software-ONYX
13. Keyboard 14. HIB connector
15. Mouse 16. INKS (CYMK)
17. Display with Power Cable 18. 1-FUSE 6A
19. Gloves 20. 2-FUSE 10A

* The list can be varied as per the company norms and standard.

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 3. Printer Overview

Front View of the Printer

1 2
The Front View of the printer is shown as below:

14
4
13
5

8
12 Fig 1: Displaying the Front View 10
11 00 9
0
Table 1: Different Parts of the Printer

1. Front Glass Door 2. LCD Monitor

3. Emergency Button 4. Power ON/OFF Button
5. Switch Panel 6. Keyboard Tray
7. CPU Panel 8. PID Controller
9. Take-up Regulator 10. IR Heater
11. Dryer Fans 12. Take-up Bracket
13. Front Door 14. Emergency Button

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 Back View of the Printer
The Back View of the printer is shown as below:

22 15

20
21 Fig 2: Displaying the Back View 17
16
19 18

Table 2: Different Parts of the Printer

15. Waste Bottle Tank 16. Main Ink Tank

17. Pre Heater 18. Pinching Roller / Vinyl Supply Roller
19. Supply Roller 20. Media Roller
21. Machine and Heater Power Cords 22. Machine Power MCB

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 Control Panel Details
The Control Panel Screen is shown as below:

Emergency Switch

Power ON/OFF Buttons

LCD Monitor

Post Heater
Pre Heater IR Heater Auto/Manual
Lever
IR Heater Supply Auto/Manual
Keyboard Supply Rev/Fwd
Bed Vacuum Take-up Rev/Fwd
Take-up Regulator

Take-up ON/OFF

Computer System Slot

Fig 3: Displaying the Control Panel

The description of different parts of the machine is given as below:

• Emergency Switch: Enable to Switch OFF the printer in any emergency situation.
• Switch ON/OFF: Switch ON/OFF the printer.
• IR Heater Auto/Manual: Enable to set the IR heater controlling modes viz. Auto or Manual.
• Supply Auto/Manual: Enable to set the Supply controlling modes viz. Auto or Manual.
• Supply Rev/Fwd: Control the power and direction of the Supply motor.
• Take Up Rev/Fwd: Control the power and direction of the Take-up motor.
• Pre Heater: Display and control the pre heater temperature.
• Post Heater: Display and control the post heater temperature.
• IR Heater: Control the IR heater (Print Dryer).
• Bed Vacuum: Control the bed vacuum blower speed to hold media firmly over the printing bed.
• Take-Up Regulator: Control the take-up system.
• Take-Up ON/OFF: Enable to ON/OFF the Take-up.

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 4. Getting Familiar with Printer Manager Interface
The User Interface of the Printer Manager software is shown as below:
Window Controls
Quick Access Toolbar

System Status
Print Parameters

Job Preview

Job Information

Job List

Error Information

Fig 4: Displaying the User Manual of Printer Manager

Main Menu

The description of the Printer Manager window is given as below:

• Window Control: Use to minimize, resize or close the Printer Manager window.
• Main Menu: Consist of several sub menu options viz. Settings, Tools, and also provide variety of
functions in well organize manner.
• Quick Access Toolbar: Display frequently performed actions like Add Job, Delete Job, Print Job,
Pause or resume, Abort job, Check nozzle, Auto clean, Move left, Move right, Set print origin,
Move forward, Move backward, Move carriage to origin, and Edit job are available as buttons on
the Quick access toolbar.
• Job Information: Display the properties of the selected job like file name and path, Status, Print
Size, Print Area, DPI, Pass, and more.
• Job Preview: Show the job preview as well as print progress in this area.
• Job List: Displays the thumbnail preview of added jobs.
• Error message: Displays the system generated error messages.

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 5. Main Menu Options
The Main Menu options are shown in the image below:

Fig 5: The Main Menu Options

Setting Menu
The Setting menu options are shown in the image below:

Fig 6: The Setting Menu Options

• Save: Using this option, you can save the default settings of the machine. When you save the
settings, an xml file will be created for further references.
• Load: Using this option, you can load the previous saved machine’s settings.
• Save To Printer: When you click on this option, all the current settings get saved in the Main
Board of the machine.
• Load From Printer: When you click on this option, the printer settings get saved from Main Board
to Printer Manager software.
• Edit: Using this option, you can edit the previously made settings of Printer. On clicking the Edit
option, the Setting window with Printer, Move, Preference, and Calibration tabs appears on the
screen.

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 The Setting window with the Printer tab is shown in the below image:

Fig 7: Displaying the Setting Window

Describing the different sections of the Setting window, as given below:

• Print setting
o Auto skip white: Enable to auto skip the white space in the image during printing.
o Step Time: Set time interval of the feed motor during printing.
o Job Space: Set space between multiple jobs.
o Feather: Select the type of feather effect and intensity percentage of the feather.
o Multiple Ink: Enable to select the color depth of an image according to the passes. The
available options are Default, Double, and More.
• Color Bar
o Space: Specify the distance of the color bar from the image.
o Width: Set width of the color bar.
o Placement: Enable or disable the color bar and its placement viz. left, right, or both.
o Height same with image: If enabled, the height of the color bar is same as the image
height.

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 • Spray setting
• Auto Spray: Set the duration (number of passes) for auto spraying.
• Spray Period: Define the duration for spraying (set as 180). If the duration increased,
spray frequency gets decreased.
• Print Pre-spray Time: This is the duration of spray before start of print.
• Idle Spray: Spray during carriage at home position. This option must be enabled.
• Spray Before Print: This option enables spray before start of print.

This option works when the Spray Before Print option is enabled.
The Move tab is shown in the image below:

Fig 8: Displaying the Move Tab

The Preference Tab is shown in the image below:

Fig 9: Displaying the Preference Tab

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 The Calibration tab is shown in the image below:

Fig 10: Displaying the Calibration Wizard

Tools Menu
The Tools menu options are shown in the image below:

Fig 11: The Tools Menu Option

• Update: This option enables to apply latest changes and updates in the machine. This option
supports .dat file format.
• Password: This option enables to feed the time and language passwords of the printer.
• DemoPage: This option displays the bi-direction check output to improve the bi-direction printing
capability.
• Calibration Wizard: Using this option, you can perform different types of calibration viz. Angle
Check, Vertical Check, Nozzle Check, and more. For more details, please read the “Calibration
Wizard” section carefully.
• HW Setting: This option enables to select the encoder type of the printer as per the compatibility
either linear or servo.

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 • Real Setting: This option enables to check and reset the temperature as well as voltage of each
Print Head.
• Wave Form Setting: This option helps in controlling and setting the wave form of the printer with
respect to ink, Print Head type, and speed.
• Auto stop pump ink when time out: Enable or disable the pump automatically when time out
occurs.

Help Menu
The Help menu option is shown in the image below:

Fig 12: The Help Menu Option

• About: Enable to view the details about Printer Manager software viz. software version and
copyrights.

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 6. Getting Ready for Printing
Switch ON Procedure
Follow these steps to switch ON the printer:

Step 1: Check the Waste Bottle.

Step 2: Check Ink Level.

Step 3: Maintain the room temperature.

Step 4: Move the carriage manually away from the home position.

Step 5: Switch ON the printer from the main power or board.

Step 6: Load the media.

Step 7: Perform purging and then, nozzle test.

Now, the printer is ready for printing.

Loading Media
Follow these steps to load the media:

Step 1: Lift up the Media Lever, as shown below:

Fig 13: Displaying the Media Lever

Step 2: Unwind the media roll to reach near the platen and hold it.

Step 3: Insert the taken-out media between the platform and the pinch roller.

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 Step 4: Pull the media out in front of the machine.

Step 5: Holding the media firmly and push down the Media Lever.

Step 6: Turn on the Supply Auto/Supply switch in auto mode and carefully observe the direction of media
either reverse or forward.

Step 7: Install the media clamps from both ends, as shown below:

Fig 14: Installing the Media Clamp

Step 8: Pull the enough media so that it reaches to the Take Up roller (or let the media down by issuing
the Print command).

Step 9: Paste the front edge of the media on the Core.

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 Step 10: Turn on the Take Up System and observe the media direction (either reverse or forward), as
shown below:

Fig 15: Enabling the Take-Up System

Step 11: Move the media forward so that it rolls easily over the Core.

Now, the media gets loaded.

Note: Before issuing the Print command, verify the following things:

• Check the Waste Bottle and empty it, if required.

• Check the ink level in main tanks and refill it, if required.

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 The media loading path of the machine is shown with help of line diagram:

Fig 16: Displaying the Media Loading Path

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 Ink Filling
Please use the recommended ink in the printer for high printing quality and long life of print and Print
Head.

Follow these steps to fill ink in the printer

Step 1: Open the left door of the printer to find out main tanks.

Step 2: Fill recommended ink in main ink tank (as per the color sticker) as per the requirement, as shown
below:

Fig 17: Displaying the Ink Tank

Ink gets filled in the Sub tanks shown below:

Fig 18: Displaying the Ink Sub Tank

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 7. Printing
Nozzle Testing
Before starting with calibration tests, the Print Heads should be checked for blockage. Each Print Head has
multiple tiny nozzles through which ink drops emerge and get deposited onto the print medium. Any
nozzle blockage can compromise the print quality by forming discolored horizontal streaks or bands.

The good and bad nozzle test results are shown in the image below:

Fig 19: Good and Bad Nozzle Test Result

To check the nozzle, click on the Check Nozzle icon available on the Quick Access Toolbar, as shown
below:

Fig 20: Clicking the Check Nozzle Icon

In case of blockages, refer to the Head Cleaning section to perform head cleaning before proceeding to
other calibration steps.

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 Print Head Calibration
The Print Head calibration is categorized into the following types:

• Mechanical Check: Includes Vertical Check and Angle Check

• Software Calibration: Includes Horizontal Calibration and Step Calibration

Note: Mechanical checks are only performed by the Service Engineer.

Calibration Wizard
Print Heads should be calibrated to ensure good printing quality. To open the Calibration Wizard, click on
the Main Menu→Tools→Calibration Wizard path, as shown below:

Fig 21: Selecting the Calibration Wizard Option

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 This should bring up the calibration wizard which is shown below:

Fig 22: Displaying the Calibration Wizard

When you press the Next button, we redirect to the software calibration screen, as shown in the below
images:

Fig 23: Displaying the Printer Calibration Options

Note: Base Step value should be 25000.

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 Horizontal Calibration
Horizontal Calibration checks the bi-directional, left, and right alignment and corrects it by adding or
subtracting the correction value from the default set value. It has to be performed for each print mode,
whichever is required. Let’s discuss each type of horizontal test one by one.

Bi-direction Calibration

Bi-directional calibration is performed to achieve dot placement accuracy between the “Left to Right” and
“Right to Left” print sweeps. If the bi-direction offset value is correct, the Left to Right test print would
align accurately with the Right to Left test print at“0” position. In case of error in the Bi-Direction offset,
the Left to Right and Right to Left print would align at some other point on the scale.

The Bi-direction Calibration result is shown in the image below:

Fig 24: The Bi-Direction Calibration Output

Based on the above figure, you can notice that the Bi-direction calibration is good at “0” position. The
correction value is “0” which means you need not to correct the bi-direction value. Sometimes, the
correction value can either positive or negative. If the correction value is positive, then you need to add it
in the current bi-direction adjust value or subtract the same if negative.

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 Left to Right and Right to Left Calibrations

Left to Right Calibration is performed to achieve dot placement accuracy of all colors (Black, Cyan, and
Yellow) with respect to Magenta during the carriage’s left to right print sweep. Similarly, Right to Left
calibration is used to achieve dot placement accuracy during the carriage’s right to left sweep.

When the position of the test head is correct, then it would align perfectly with the reference color at “0”
position, indicating that the error position is “0”. If the test Print Head’s position saved in the system is
inaccurate then it would not align at “0” position, but at some other point on the calibration scale. The
position at which the test head aligns perfectly with the reference head, indicates the error in position.

The Left and Right Calibration Results is shown in the image below:

Fig 25: The Horizontal Left and Right Checks

Left Check Right Check

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 Step Calibration
The printer step calibration is performed to verify and correct media feeding. The printer prints a
complete image pass by pass. A pass is the horizontal carriage sweep perpendicular to the media
movement. After each pass the printer moves the media forward for the next pass. This movement of
media is called a step. The distance by which the media is moved is called the step size and it has to be
accurate. Step size errors cause horizontal white or dark bands to appear in the print output.

Step size needs to be adjusted for multiple factors like thickness and roughness of the print media etc.
Step calibration should be used to fine adjust the step size and has to be done for each desired pass. Step
value can be adjusted using the Steps field, as shown below:

To view the Step Calibration result, click on the Next button (Refer to Fig 23) until the Step Calibration
screen appears and then click on the Print button. The Step Calibration result image is shown as below:

Fig 26: Displaying the Output of the Step Calibration

From the above figure, you get the accurate step adjust correction value. The correction value is either
positive or negative. If the value is positive, then add it in the current step adjust value for the Print Head
calibration. On the other hand, if the value is negative, then subtract the value from the current step
adjust value. From the above, you can conclude that the pattern is corrected at “0” position.

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 The Step Calibration and its parameters are shown in the image below:

Fig 27: The Step Calibration Parameters

Follow these steps to perform step calibration:

Step 1: Select the desired pass from the list and click on the Print button (Refer to Fig 27).

Step 2: Feed the correction value in the Revise field (the correction value up to two decimal places) (Refer
to Fig 27).

Step 3: Click on the => icon (Refer to Fig 27) on the Step Calibration window. The correction value result
will be reflected in the Step field (Refer to Fig 27). The same step value will also be displayed in the Steps
field on the Quick Access Toolbar.

Setting Print Origin

Print origin sets the print starting point with right most print head position as the reference point. It can
be set by two ways; moving and positioning the carriage and typing the offset value directly in the given
field.

Follow these steps to change the print origin:

Step 1: Move the carriage at the position from where you want to start the printing by clicking on the left
and right buttons on the Quick Access Toolbar, as shown below:

Fig 28: Adjusting the Carriage Position

Step 2: After positioning the carriage, click on the Set print origin icon on the Quick Access Toolbar, as
shown below:

Fig 29: Selecting the Set Print Origin Option

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 On clicking the Set print origin icon, the current position of the carriage gets updated in the Origin X text
box, as shown below:

Fig 30: Displaying the Origin Value

Now, the printing origin gets set. Additionally, you can also enter the print origin value manually in the
Origin X field under the Print Parameter section.

Setting Print Parameters

Using the Printer Manager, you can manually change print preferences as per the printing requirements
such as print origin, printing speed, no of steps, and more as shown below:

Fig 31: Setting Printing Parameters

The description of printing parameters is given as follows:

• Origin X: Directly enter the print origin value.

• Steps: Remove step size errors in the current print job by specifying number of steps.
• Pass: Choose the number of passes with which the print job should be printed. Increasing the
number of passes improves the print quality but at the cost of printing time.
• Speed: Choose the printing speed like High Speed, Medium, and Low.
• Medium Speed: Set the Y printing speed viz. Standard Speed and Low.

Adding Jobs
There are two ways to add jobs in the Job List area viz. the Add Job button and right click on the Job List
area. Let’s discuss both the ways one by one.

Follow these steps to add jobs in the Job List area:

Step 1: Click on the Add Job button on the Quick Access Toolbar, as shown below:

Fig 32: Clicking on the Add Job Button

The Open window appears on the screen.

Step 2: Navigate to the location where the image file with extension “.prt” and “.prn” is stored (Refer to
Fig 33).

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 Step 3: Click on the Open button to add the file into the Job List area, as shown below:

Fig 33: Adding the Job

Now, the selected image appears in the Job List area, as shown below:

Fig 34: Displaying the Added Job and Their Details

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 Once a file has been added its information such as file path, size, resolution, and number of passes can be
viewed in the Job Information area. User can also add a job simply by right clicking on the Job List area and
selecting the Add Job option from the context menu, as shown below:

Fig 35: Displaying the Context Menu

On selecting the Add Job option, the Open window appears and follow the above-mentioned steps to add
more jobs.

Note: To delete the selected job, click on the Delete job icon on the Quick Access Toolbar.

Editing Job
Follow these steps to edit the selected job:

Step 1: Select the job for which details you want to edit from the Job List area.

Step 2: Right-click on the selected job. The context menu appears on the screen.

Step 3: Select on the Edit option from the context menu, as shown below:

Fig 36: Selecting the Edit Job Option

The Edit Job Form appears with the list of options viz. Clip, Reverse Print, and Tile.

Step 4: Select the desired checkbox in front of the Clip, Reverse Print, and Tile options. Clicking to any
option will enable its related parameters on the right pane and you can edit them as per the
requirements. In our case, we have selected the Clip checkbox.

Clip: By enabling this, a portion of the image can be selected by dragging the image preview. And its
height and width can be adjusted. Also the crop margins can be adjusted in x and y direction.

Tile: By enabling this, desired number of counts in x and y directions can be printed. Also the distance
between each count can be adjusted.

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 Copies: Feeding any number of copies will repeat the prints in Y direction. Careful, the Print will stop and
restart after each copy.

Foot note: You can add footnote printing with each printed image. Parameters required can be selected.

Step 5: After making the desired changes, click on the OK button to apply the settings, as shown below:

Fig 37: Displaying the Edit Job Form Window

Similarly, you can click on any other option and its related options get enabled in the right pane of the Edit
Job form.

Ripping and Printing

Ripping is an independent process which converts a raw image file into the machine-readable format and
get the file ready for printing. The Rip software supports the tiff, jpeg, eps, psd, bmp file formats. After
ripping the image file, the output file will be in “.prt” or “.prn” file format. Thus, you should first rip the
image file before printing and then issue the Print command. While ripping, the color profiles are used to
automatically perform the color corrections in the image. Now, you can print an image on the selected
media simply by clicking on the Print Job button available on the Quick Access Toolbar, as shown below:

Fig 38: Issuing the Print Job Command

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 After issuing the Print command, the printing gets started and its progress details displays in the Job
Information area, as shown below:

Fig 39: Displaying the Printing Details

Pausing and Canceling Printing

If you find any defect during the printing process, you can immediately pause or cancel the current
printing job using the Pause or resume and Abort Job buttons available on the Quick Access Toolbar as
shown below:

Fig 40: Issuing the Pause or resume Command

Similarly, you can abort the process by right clicking on the selected Job in the Job List area and select the
Abort Job option from the context menu.

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 8. Head Cleaning
Print Head is a delicate part which needs to be cleaned as per the recommended methods to have long life
and to ensure consistent print quality. Below sections give recommended steps to clean the Print Heads.

Head Blotting
Head blotting refers to the process in which the head surface area is cleaned with the help of tissue paper
or cloth. Blotting removes ink drops adhering to the Print Head nozzle surface. Gently touch or wipe with a
clean recommended head cleaning tissue on the head’s nozzle plate. One should make sure that the tissue
is clean, soft, and also does not have any chemicals on it.

The Head Blotting process is shown in the image below:

Fig 41: Blotting the Print Head with a Piece of Cloth

Perform these steps to wipe the Print Head to clean:

Step 1: Multifold the tissue paper 3-4 times.

Step 2: Hold it from one end such that other end remains flexible and extra pressure is not getting applied
on the heads.

Step 3: Wet the other end of the tissue paper with solvent.

Step 4: Wipe it softly once, to soak all residue inks on the nozzle plate.

Now, the Print Head gets wiped.

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 Note: Please strictly follow the below mentioned instructions:

• Avoid using the same tissue paper to wipe the Print Head.
• Blotting with dry and inferior quality tissue paper will damage the nozzle film by making scars (see
image in next page).
• Strictly use recommended tissue paper (Contact your dealer for tissue paper).
• Always use wet tissue paper to absorb the residue ink.
• Don’t wipe hard, just absorb the residue inks on nozzle plate.
• Softly touch with a lint free bloating tissue paper (duly wet by cleaning solvent) by changing the
tissue paper position with respect to nozzle plate.
• Do not apply force while absorbing residue inks with tissue paper after purging.
• Leaving head plate uncapped while printer off, will block nozzles permanently due to ink
solidification.
• Color bar should always be enabled while printing and idle spray should always be enabled for
long life of the Print Head.

Note: Scratches created on nozzle surface will damage the head. Sometimes the damage is not visible to
naked eye and nozzle check is clear, but nozzles gets blocked after printing for some time. Scratches
changes the firing angle of drops and causes inks to pile up near nozzles during printing and it blocks the
head firing after sometime.

Head Purging
Head purging refers to the method in which heads are cleaned by forcing pressurized ink through the
nozzles. In the POLO TURBO printer, head purging buttons for each color are available on the carriage, as
shown in the below figure:

Head Purging

Fig 42: Head Purging Buttons

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 Note: If nozzles are found blocked even after normal purging, then try the powerful purging (“P” switch in
purging board has to be kept pressed for few seconds and then required color switch has to be pressed).

Head Spraying
Head spraying clears the mixing of colors during blotting, may also clear few dry nozzles. When heads are
sprayed, all the nozzles are actuated at a high rate which helps in opening up few dry nozzles of the
printer. To perform head spraying, click on the Spray button available under the Quick Access Toolbar, as
shown below:

Fig 43: Displaying the Spray Button

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 9. Shutdown & Capping the Print Head
Capping refers to the process of protecting the Print Head to become dry.

Perform the following steps to cap the Print Head:

Step 1: Clean the capping area.

Step 2: Fill the capping pads with solvent, as shown below:

Capping Slots

Fig 44: Displaying the Capping Station

Step 3: Switch off the printer.

Step 4: Move the Carriage manually toward the Capping Station.

Step 5: Place the Carriage completely over the Capping Station so that Print Heads get engaged over the
capping pads.

Step 6: Slide up the Capping Plate with the Carriage to lock its position.

Now, Print Heads are capped properly and protected from being dried.

POLO TURBO Page | 33

 10. Maintenance
Print Head Maintenance
Print Head is an important and delicate part of the printer. Thus, it must be handled with care to ensure
the long life of the Print Heads. For Print Head maintenance, the following instructions should be taken
care:

• Perform the nozzle test daily 2-3 times before printing to monitor the blockage in the head nozzles
• Avoid head damage due to media and Print Head confliction
• Capping station should be cleaned
• Capping station should be wet to avoid Print Head dryness with solvent
• Media clamps should be used during printing
• Colorbar should be ON
• Avoid ink spilling on the Print Head and head cables
• Don’t use expiry ink and store the ink at favorable environment

Daily maintenance
• Perform the nozzle test daily before printing
• Check the room temperature while start using the printer
• Keep the capping plate surface clean, particularly before capping
• Capping station should be wet to avoid head dryness
• Check the waste ink tank daily and empty it, if required
• Check ink level in the main and sub ink tanks and fill it, if required
• Use the recommended ink
• Use single phase power with a dedicated ground connection
• Clean heads using head cleaning techniques viz. head blotting, purging, and spraying

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 11. Troubleshooting
PRINTER NOT INITIALIZING

• Encoder scale is having ink stains (print shows vertical color bands)
• Encoder sensor is not cleaned
• Emergency button is pressed

PRINTER MANAGER NOT SHOWING “READY”

• USB cable is not connected to the computer or loose

• USB cable is faulty

PRINT STOPS IN BETWEEN PRINTING

• USB cable is loose or faulty

• Open heavy file that can slow down the data transfer
• Ground wire is disconnected
• Encoder scale is having ink stains
• Pulley or belt is slipping
• Ripped file is having error

PRINT MARGIN IS SHIFTING, OR JUNK PRINTING

• Encoder scale is having ink stains

• Encoder sensor is not clean
• Pulley or belt is slipping
• Data cable is faulty

PRINT IS BLUR (NOT SHARP)

• Improper printer calibration – bi-directional and step

• Improper head mounting and calibration
• Selection of incorrect resolution (dpi)

LINES IN PRINT

• Head nozzles are blocked

• Incorrect step calibration

HEATERS NOT WORKING

• Check if inlet power cord is connected

• Check the set temperature in the controller

HEAD NOZZLES NOT FIRING

• Clean heads using head cleaning techniques and verify by performing nozzle testing
• Check if any air lock or no ink in the ink pipes

POLO TURBO Page | 35

 • Check the ink and air pipe for any cuts or loose connection

TAKE – UP NOT WORKING

• Take-up switch is not ON

• Take-up regulator is in OFF position

MEDIA SUPPLY NOT WORKING

• Supply switch is not ON

• Media is not in sensor range

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 12. Error Code Specifications

Table 3: The Error Code and their Description

Error Code Error Description Remedial Action

04020008 Wrong input or forbidden character in the Re-input the Correct Time Limit
Time Limit Password field. Password Field
04020009 Illegal Time Limit Password. Re-input the Correct Time Limit
Password Field
0402000A Time Limit Password and Manufacturer ID Re-input the Correct Time Limit
doesn’t match. Password Field
0402000B Time Limit Password and Board ID doesn’t Re-input the Correct Time Limit
match. Password Field
0402000C First Warning: 100 hours left in the Please request a new password
completion of the current Time Limit from the dealer
Password.
0402000D Second Warning: 50 hours left in the Please request a new password
completion of the current Time Limit from the dealer
Password.
0402000E Last Warning: 1 hours left in the completion Please request a new password
of the current Time Limit Password. After 1 from the dealer
hour, the printing process gets stopped.

POLO TURBO Page | 37

 For Any Query
Please Contact Us
www.colorjetgroup.com
Call us on +91-120-4548195
Email on [email protected]
For Ink Enquiry:- [email protected]
For Support:- [email protected]