Service Manual v7 - 1500

HP Latex 1500 Printer
Service manual
Edition 7, November 30 2018 Legal notices Warranty
© 2016, 2018 HP Development Company, L.P. This document contains proprietary information The information contained in this document is
that is protected by copyright. All rights are subject to change without notice.
For HP-authorized personnel only. reserved. No part of this document may be
photocopied, reproduced, or translated to HP makes no warranty of any kind with regard
another language without the prior written to this material, including, but not limited to, the
consent of HP. implied warranties of merchantability and
fitness for a particular purpose.
HP shall not be liable for errors contained herein

or for incidental or consequential damages in
connection with the furnishing, performance, or
use of this material.
Safety Readership
The procedures described in this manual are to The primary readers of this service manual are
be performed by HP-qualified service personnel HP service engineers, although secondary
only. readership may include resellers.
The Warning symbol calls attention to a

procedure, practice, or the like, which, if not
correctly performed or adhered to, could result
in personal injury. Do not proceed beyond a
Warning symbol until the indicated conditions
are fully understood and met.
The Caution symbol calls attention to an

operating procedure, practice, or the like, which,
if not correctly performed or adhered to, could
result in damage to or destruction of part or all
of the printer. Do not proceed beyond a Caution
symbol until the indicated conditions are fully
understood and met.
Table of contents
1 Using this manual ..................................................................................................................................................................................... 1

Purpose ...................................................................................................................................................................................... 2
Chapters ..................................................................................................................................................................................... 2
Readership ................................................................................................................................................................................. 3
2 Printer systems ......................................................................................................................................................................................... 4

Electrical system: E-cabinet ................................................................................................................................................... 5
E-box ........................................................................................................................................................................................ 23
Substrate path ........................................................................................................................................................................ 28
Universal mounting beam .................................................................................................................................................... 35
Impelling system .................................................................................................................................................................... 37
Pen to Rib Space (PRS) .......................................................................................................................................................... 41
Ink system ............................................................................................................................................................................... 46
Carriage .................................................................................................................................................................................... 51
Service station ........................................................................................................................................................................ 58
Printhead cleaning system ................................................................................................................................................... 64
Drying ....................................................................................................................................................................................... 67
Curing ....................................................................................................................................................................................... 70
Vapor removal ........................................................................................................................................................................ 75
Printer status beacon ............................................................................................................................................................ 79
Subsystem block diagrams .................................................................................................................................................. 79
Accessories .............................................................................................................................................................................. 98
3 Safety requirements ............................................................................................................................................................................ 119

Printer safety features ........................................................................................................................................................ 120
Hazards ................................................................................................................................................................................. 123
Accessories installation/assembly .................................................................................................................................... 128
Safety Check ......................................................................................................................................................................... 129
4 Troubleshooting ................................................................................................................................................................................... 131

Troubleshooting with Print Care ....................................................................................................................................... 132
ENWW v
Print Care login and boot modes ....................................................................................................................................... 133
Troubleshooting system error codes ............................................................................................................................... 140
Troubleshooting without system errors .......................................................................................................................... 370
Printer calibration ................................................................................................................................................................ 450
Basic printer check for correct printing ............................................................................................................................ 467
Ink density vs number of paths ......................................................................................................................................... 469
Media path troubleshooting ............................................................................................................................................... 471
Image quality troubleshooting .......................................................................................................................................... 475
Printhead and ink cartridge troubleshooting .................................................................................................................. 494
How to extract and read the service plot ......................................................................................................................... 517
Troubleshoot non-HP ink usage ....................................................................................................................................... 529
5 Diagnostics ............................................................................................................................................................................................ 533

Overview ............................................................................................................................................................................... 534
General diagnostics ............................................................................................................................................................. 534
How to run a diagnostic test .............................................................................................................................................. 535
Boot mode permissions ..................................................................................................................................................... 537
Phone support ..................................................................................................................................................................... 538
Service tests, diagnostics, and calibrations ..................................................................................................................... 545
6 Parts and diagrams .............................................................................................................................................................................. 599

Rear left covers .................................................................................................................................................................... 601
Front left covers ................................................................................................................................................................... 602
Front center covers ............................................................................................................................................................. 604
Front right covers ................................................................................................................................................................. 605
Rear right covers .................................................................................................................................................................. 607
Window covers ..................................................................................................................................................................... 609
Structure covers ................................................................................................................................................................... 610
Vapor removal (1) ................................................................................................................................................................ 611
Vapor removal (2) ................................................................................................................................................................ 612
Vapor removal (3) ................................................................................................................................................................ 613
Drying .................................................................................................................................................................................... 614
Aerosol .................................................................................................................................................................................. 615
E-cabinet (general) .............................................................................................................................................................. 616
Left e-cabinet ....................................................................................................................................................................... 617
Inside-left e-cabinet ............................................................................................................................................................ 618
Center bottom e-cabinet .................................................................................................................................................... 619
Center-top e-cabinet ........................................................................................................................................................... 620
Right e-cabinet ..................................................................................................................................................................... 621
E-box ..................................................................................................................................................................................... 622
Printhead cleaning system (1) ........................................................................................................................................... 624
vi ENWW
Printhead cleaning system (2) ........................................................................................................................................... 626
TRS ......................................................................................................................................................................................... 627
PPS ......................................................................................................................................................................................... 628
Ink system module (1) ........................................................................................................................................................ 629
Impelling ................................................................................................................................................................................ 633
Service station (1) ................................................................................................................................................................ 635
Service station (2) ................................................................................................................................................................ 636
Substrate path (1) ................................................................................................................................................................ 638
Substrate path (2) ................................................................................................................................................................ 639
Substrate path (3) ................................................................................................................................................................ 641
Substrate path (4) ................................................................................................................................................................ 642
Substrate path (5) ................................................................................................................................................................ 643
Substrate path (6) ................................................................................................................................................................ 644
Substrate path (7) ................................................................................................................................................................ 645
Substrate path (8) ................................................................................................................................................................ 647
Curing (1) ............................................................................................................................................................................... 649
Curing (2) ............................................................................................................................................................................... 651
Old Carriage (1) .................................................................................................................................................................... 652
New Carriage (1) .................................................................................................................................................................. 653
Carriage (2) ........................................................................................................................................................................... 654
Human machine interface .................................................................................................................................................. 655
LEDs ....................................................................................................................................................................................... 656
Double sided day and night kit (accessory) ..................................................................................................................... 657
Forklift (accessory) .............................................................................................................................................................. 658
Dual roll kit (accessory) ....................................................................................................................................................... 659
R2FF (accessory) .................................................................................................................................................................. 660
Ink collector (accessory) ..................................................................................................................................................... 661
7 Removal and installation .................................................................................................................................................................... 662

Aerosol .................................................................................................................................................................................. 663
Carriage ................................................................................................................................................................................. 672
Curing ..................................................................................................................................................................................... 741
Drying .................................................................................................................................................................................... 781
E-box ..................................................................................................................................................................................... 795
E-cabinet ............................................................................................................................................................................... 820
Human-Machine interface .................................................................................................................................................. 895
Impelling ................................................................................................................................................................................ 909
Industrial design covers ...................................................................................................................................................... 944
Ink system module ............................................................................................................................................................ 1007
ENWW vii
Print to Paper Space (PPS) ............................................................................................................................................... 1059
Printhead cleaning system .............................................................................................................................................. 1085
Service station: capping and drop detector .................................................................................................................. 1145
Substrate path ................................................................................................................................................................... 1175
Tube Routing System (TRS) ............................................................................................................................................. 1274
Vapor removal ................................................................................................................................................................... 1285
Platen lights ....................................................................................................................................................................... 1326
Uptime and maintenance kits ......................................................................................................................................... 1327
Double sided day and night kit (P4P91A) – (Accessory) ............................................................................................. 1331
Forklift (K4T88-67290) – (Accessory) ........................................................................................................................... 1363
Dual roll kit (T0F91A) – (Accessory) ............................................................................................................................... 1366
R2FF (Accessory) ............................................................................................................................................................... 1375
Ink collector (Accessory) ................................................................................................................................................... 1396
8 LogMeIn rescue .................................................................................................................................................................................. 1400

Using LogMeIn rescue ....................................................................................................................................................... 1401
9 Moving the printer ............................................................................................................................................................................. 1406

Introduction ........................................................................................................................................................................ 1407
Manpower required ........................................................................................................................................................... 1407
Tools required for repacking ........................................................................................................................................... 1407
Move the printer to a new site (transport temperature below 5°C/41°F) ................................................................ 1409
10 Service maintenance ...................................................................................................................................................................... 1424

Maintenance status ........................................................................................................................................................... 1427
1500 liters or 2.5 million carriage cycles service maintenance – Service Maintenance Kit 2 .............................. 1428
Textile Maintenance at 1500 liters ................................................................................................................................. 1430
5 million cycle scan axis service maintenance ............................................................................................................. 1431
Dirtiness Check .................................................................................................................................................................. 1433
Empty the condensation collector bottle ...................................................................................................................... 1440
Clean the aerosol filters ................................................................................................................................................... 1440
Clean e-box filters ............................................................................................................................................................. 1440
Clean e-cabinet fan filters ................................................................................................................................................ 1441
Replace the printhead cleaning blade ............................................................................................................................ 1442
Replace aerosol module fans .......................................................................................................................................... 1445
Replace the intermediate tank ........................................................................................................................................ 1445
Clean the Drop detector ................................................................................................................................................... 1446
Check and clean vapor removal filter ............................................................................................................................. 1447
Check and clean dirtiness on scan axis and transmissions ........................................................................................ 1447
Clean scan axis encoder ................................................................................................................................................... 1448
viii ENWW
Clean impelling dust in sax chain .................................................................................................................................... 1449
Replace media drive motor, gears and encoder .......................................................................................................... 1449
Replace media drive PCA ................................................................................................................................................. 1449
Replace impelling .............................................................................................................................................................. 1449
Replace bearings ............................................................................................................................................................... 1450
Replace caps ...................................................................................................................................................................... 1450
Replace curing module side foams ................................................................................................................................ 1451
Swap sax rods .................................................................................................................................................................... 1451
Replace drying fan and resistor module ........................................................................................................................ 1451
Clean and lubricate the Drop detector rods .................................................................................................................. 1451
Clean ink deposits ............................................................................................................................................................. 1452
Replace curing fan/heater and internal foams ............................................................................................................. 1452
Clean aerosol filter nozzle under textile mode ............................................................................................................ 1452
Replace diverter module service .................................................................................................................................... 1453
In-line slitters blade replacement .................................................................................................................................. 1453
Replace Double-sided day and night kit front output lights ...................................................................................... 1454
Replace Double-sided day and night kit back output lights ....................................................................................... 1454
Replace Double-sided day and night kit platen substrate protector (P4P91-67004) .......................................... 1455
Replace Double-sided day and night kit substrate edge holder (P4P91-67006) .................................................. 1456
Replace and/or place spindle ruler labels ..................................................................................................................... 1457
Replace spindle gear and end-cap ................................................................................................................................. 1457
Drop-detector maintenance ............................................................................................................................................ 1457
Replace substrate drive OMAS sensor ........................................................................................................................... 1459
Replace service station cap modules ............................................................................................................................. 1459
Replace vapor removal pipes .......................................................................................................................................... 1459
Replace curing foams at curing module assembly ...................................................................................................... 1459
Replace vapor demister filter .......................................................................................................................................... 1460
Clean curing PCA fans ....................................................................................................................................................... 1460
Swap carriage slider rods ................................................................................................................................................. 1460
Replace complete tube routing system (TRS) chain with tubes and cables ............................................................ 1460
Replace carriage bushings and oiling foams and wicks .............................................................................................. 1460
Grease drop detector transmission and rods ............................................................................................................... 1461
Grease substrate drive transmission gears .................................................................................................................. 1461
Replace primer and latches ............................................................................................................................................. 1462
Replace damaged diverter wheels ................................................................................................................................. 1463
Replace pinch clamp ......................................................................................................................................................... 1463
Replace air valves .............................................................................................................................................................. 1463
Substrate-advance motor replacement ........................................................................................................................ 1464
Grease the carriage beam screws (PPS) ........................................................................................................................ 1464
Summary of maintenance operations ........................................................................................................................... 1467
ENWW ix
Appendix A Cables ................................................................................................................................................................................ 1469
K4T88-50001 – CS to P Data .......................................................................................................................................... 1476
K4T88-50003 – Pen Primer Extension ......................................................................................................................... 1477
K4T88-50004 – Cs to P Power Cable Short .................................................................................................................. 1478
K4T88-50005 – Cs to P Power Cable Short .................................................................................................................. 1479
K4T88-50008 – VEGA to SEPIAS .................................................................................................................................... 1480
K4T88-50009 – Day and Night Line Sensor Cable ...................................................................................................... 1481
K4T88-50010 – Carriage Encoder ................................................................................................................................. 1482
K4T88-50013 – Carriage Encoder ................................................................................................................................. 1483
K4T88-50014 – 42V Trailing .......................................................................................................................................... 1484
K4T88-50015 – Slinky to Color PH board ..................................................................................................................... 1485
K4T88-50016 – Slinky to PT PH Board DAT ................................................................................................................. 1486
K4T88-50017 – 24V IDS .................................................................................................................................................. 1487
K4T88-50019 – E-box Fiber Optic ................................................................................................................................. 1488
K4T88-50020 – VEGA to Slinky Power .......................................................................................................................... 1489
K4T88-50021 – Air Pump and Relief Valve Cable ....................................................................................................... 1490
K4T88-50026 – PAZ and FREYA Power Cable .............................................................................................................. 1491
K4T88-50029 – Drying Power Cable Long ................................................................................................................... 1492
K4T88-50030 – Drying Power Cable short .................................................................................................................. 1493
K4T88-50031 – Drying 24V Long Cable ....................................................................................................................... 1494
K4T88-50032 – Drying 24V Short Cable ...................................................................................................................... 1495
K4T88-50033 – Drying Data Cable ................................................................................................................................ 1496
K4T88-50035 – Drying Data Parton to Parton ............................................................................................................ 1497
K4T88-50036 – Drying Temperature Sensor Short ................................................................................................... 1498
K4T88-50037 – Drying Temperature Sensor Medium ............................................................................................... 1499
K4T88-50038 – Drying Temperature Sensor Long .................................................................................................... 1500
K4T88-50039 – Drying Heater Sensor Cable ............................................................................................................... 1501
K4T88-50040 – Drying Heater Medium Cable ............................................................................................................. 1502
K4T88-50041 – Drying Heater Long Cable .................................................................................................................. 1503
K4T88-50042 – Drying Heater Short Cable .................................................................................................................. 1504
K4T88-50043 – Drying Heater Medium Cable ............................................................................................................. 1505
K4T88-50044 – Drying Fan Long Cable ........................................................................................................................ 1506
K4T88-50054 – LY PPS Power in T Cable ..................................................................................................................... 1507
K4T88-50055 – LY-Power in T Extension Cable .......................................................................................................... 1508
K4T88-50056 – LY-Luna J4 to PPS Encoder Cab ......................................................................................................... 1509
K4T88-50061 – ISS LEDs 0 to 3 Cable .......................................................................................................................... 1510
K4T88-50068 – Aerosol Harness ................................................................................................................................... 1511
K4T88-50071 – VR Pump Control Cable ....................................................................................................................... 1512
K4T88-50073 – VR Cable Power 24V Split to PA ........................................................................................................ 1513
K4T88-50075 – VR Cable Power 230V Split to B ........................................................................................................ 1514
K4T88-50089 – Ink Cartridge Cable .............................................................................................................................. 1515
x ENWW
K4T88-50090 – Supply Engagement Cable ................................................................................................................. 1516
K4T88-50091 – Ground Braid L190mm ....................................................................................................................... 1517
K4T88-50102 – MI Motor Data Cable ............................................................................................................................ 1518
K4T88-50103 – MA PWM Data Cable ............................................................................................................................ 1519
K4T88-50104 – MA PWM Data Cable ............................................................................................................................ 1520
K4T88-50106 – AM80 Vacuum Pump Control ............................................................................................................. 1521
K4T88-50109 – MO Encoder Cable ................................................................................................................................ 1522
K4T88-50110 – MI Encoder Cable ................................................................................................................................. 1523
K4T88-50114 – E-box to WW Cable .............................................................................................................................. 1524
K4T88-50117 – Vacuum PCA to Vacuum Pump .......................................................................................................... 1525
K4T88-50118 – Vacuum Supply PCA Cable ................................................................................................................. 1526
K4T88-50121 – E-cabinet to WW Power Cable ........................................................................................................... 1527
K4T88-50123 – Curing Power ........................................................................................................................................ 1528
K4T88-50124 – 24V Curing PCA .................................................................................................................................... 1529
K4T88-50125 – VR Fans Power Cable .......................................................................................................................... 1530
K4T88-50128 – Curing Data Cable ................................................................................................................................ 1531
K4T88-50136 – Sensor Box Cable ................................................................................................................................. 1532
K4T88-50142 – Luna to DD Motor and Encoder ......................................................................................................... 1533
K4T88-50143 – DC Cable to Vega ................................................................................................................................. 1534
K4T88-50147 – ISS LEDs 0 to 3 Cable .......................................................................................................................... 1535
K4T88-50148 – Freya CAN Cable ................................................................................................................................... 1536
K4T88-50151 – DD Daisy Chain Cable .......................................................................................................................... 1537
K4T88-50153 – VR Pump Power Cable ........................................................................................................................ 1538
K4T88-50154 – Cable between Drop Mux PCA J5 ...................................................................................................... 1539
K4T88-50155 – Data Cable from Luna PCA to E ......................................................................................................... 1540
K4T88-50156 – SAX Power Cable ................................................................................................................................. 1541
K4T88-50157 – Braking Resistor Enclosure PO .......................................................................................................... 1542
K4T88-50158 – E-cab-MI Resistor Power Cable ......................................................................................................... 1543
K4T88-50159 – VR Fans Array Cable ............................................................................................................................ 1544
K4T88-50160 – E-cab-MO Resistor Power Cable ....................................................................................................... 1545
K4T88-50161 – Solenoid to SOL Cable ......................................................................................................................... 1546
K4T88-50162 – Line Sensor Cable ................................................................................................................................ 1547
K4T88-50163 – Drying Power ........................................................................................................................................ 1548
K4T88-50164 – Wire from E-stop1 to TB ..................................................................................................................... 1549
K4T88-50165 – Wire from E-stop1 to E-stop2 ........................................................................................................... 1550
K4T88-50168 – Wire from E-stop4 to TB ..................................................................................................................... 1553
K4T88-50169 – Wire from Interlock1 to TB ................................................................................................................. 1554
K4T88-50170 – Wire between Interlocks ..................................................................................................................... 1555
K4T88-50171 – Wire from Interlock2 to TB ................................................................................................................. 1556
ENWW xi
K4T88-50172 – Cable to Interlock1 .............................................................................................................................. 1557
K4T88-50173 – Cable to Interlock2 .............................................................................................................................. 1558
K4T88-50175 – E-box to E-cabinet PCA Cable ............................................................................................................ 1559
K4T88-50176 – HP Nexus Viking Cable Freya T .......................................................................................................... 1560
K4T88-50177 – HP Nexus Viking Cable Freya T .......................................................................................................... 1561
K4T88-50180 – Leakage ................................................................................................................................................. 1562
K4T88-50182 – VR Cable LAN Split to Parton ............................................................................................................. 1563
K4T88-50183 – HDE15P-HDE115S-From Freya ........................................................................................................ 1564
K4T88-50185 – SAX Data Cable .................................................................................................................................... 1565
K4T88-50186 – E-cab- MA Motor Power ...................................................................................................................... 1566
K4T88-50187 – MI Resistor-MI Motor Power CA ......................................................................................................... 1567
K4T88-50188 – MO Resistor-MO Motor Power CA ...................................................................................................... 1568
K4T88-50189 – Buzzer Extension Cable ...................................................................................................................... 1569
K4T88-50190 – E-box to Luna TUR Cable .................................................................................................................... 1570
K4T88-50191 – Pinch Switch Right Structure ............................................................................................................. 1571
K4T88-50200 – LY EC Vacuum Supply .......................................................................................................................... 1572
K4T88-50201 – LY EC VR Supply ................................................................................................................................... 1573
K4T88-50202 – LY EC PSU-1 DC Out ............................................................................................................................. 1574
K4T88-50203 – LY EC PSU-2 DC Out ............................................................................................................................. 1575
K4T88-50204 – LY EC PSU-3 DC Out ............................................................................................................................. 1576
K4T88-50205 – LY EC PSU-4 DC Out ............................................................................................................................. 1577
K4T88-50206 – LY EC PSU-5 DC Out ............................................................................................................................. 1578
K4T88-50207 – LY EC PSU-6 DC Out ............................................................................................................................. 1579
K4T88-50208 – LY EC PSU-7 DC Out ............................................................................................................................. 1580
K4T88-50210 – LY EC EN Light ....................................................................................................................................... 1581
K4T88-50211 – LY EC Safety Relay Assy ...................................................................................................................... 1582
K4T88-50212 – LY EC Fan1 Assy ................................................................................................................................... 1583
K4T88-50213 – LY EC Fan2 Assy ................................................................................................................................... 1584
K4T88-50214 – LY EC Fan Extension ............................................................................................................................. 1585
K4T88-50215 – LY EC Contactors FB ............................................................................................................................. 1586
K4T88-50216 – LY EC Curing AC .................................................................................................................................... 1587
K4T88-50217 – LY EC Drying AC .................................................................................................................................... 1588
K4T88-50224 – Drying Temperature Sensor Medium ............................................................................................... 1589
K4T88-50225 – Drying Fan Medium Cable SVS ........................................................................................................... 1590
K4T88-50226 – Drying Heater Medium Cable SV ....................................................................................................... 1591
K4T88-50227 – E-cabinet to Luna Power Cable ......................................................................................................... 1592
K4T88-50230 – LY-Power in T extension Cable .......................................................................................................... 1593
K4T88-50231 – Gabi PCA to Lifter ID1 Cable ............................................................................................................... 1594
K4T88-50232 – Gabi PCA to Lifter ID2 Cable ............................................................................................................... 1595
K4T88-50233 – Gabi PCA to Contactor Cable .............................................................................................................. 1596
K4T88-50234 – E-cabinet to Contactor Cable ............................................................................................................. 1597
xii ENWW
K4T88-50235 – Luna to Luna Cable .............................................................................................................................. 1598
K4T88-50236 – PPS Data Cable .................................................................................................................................... 1599
K4T88-50237 – Broken Bag 0-3 Cable ......................................................................................................................... 1600
K4T88-50238 – Broken Bag 4-7 Cable ......................................................................................................................... 1601
K4T88-50239 – Carriage Interconect to Primer Valves 1 .......................................................................................... 1602
K4T88-50240 – Primer Pump Cable ............................................................................................................................. 1603
K4T88-50243 – PZ LEDs (Printzone LED) .................................................................................................................... 1604
K4T88-50244 – Luna PZ LEDs Cable (Buttons) ........................................................................................................... 1605
K4T88-50246 – Interlock 3 to Interlock 1 Cable .......................................................................................................... 1606
K4T88-50247 – E-cabinet PCA to Interlock 3 Cable ................................................................................................... 1607
K4T88-50248 – Aerosol FAN Lyra to PCA ..................................................................................................................... 1608
K4T88-50250 – Safety Wiring to E-stop 1 Cable White ............................................................................................. 1609
K4T88-50251 – E-stop 1 to E-stop 2 Cable White ...................................................................................................... 1610
K4T88-50254 – Safety Wiring to E-stop 4 Cable White ............................................................................................. 1613
K4T88-50261 – E-cabinet PCA to SAX Resistor Contactor ........................................................................................ 1614
K4T88-50264 – E-cabinet PCA to SAX Resistor Contactor Feedback ...................................................................... 1615
K4T88-50268 – Brown Line Cable for Curing, Drying and Autotransformers ........................................................ 1616
K4T88-50269 – Brown Line Cable for Drying and Cooling ........................................................................................ 1617
K4T88-50270 – Black Line Cable for Drying, Curing and Autotransformers .......................................................... 1618
K4T88-50271 – Black Line Cable for Curing and Drying ............................................................................................ 1619
K4T88-50272 – Grey Line Cable for Drying, Curing and Autotransformers ............................................................ 1620
K4T88-50273 – Grey Line Cable for Curing and Drying .............................................................................................. 1621
K4T88-50274 – Blue Neutral Cable for Drying, Curing and Autotransformer ........................................................ 1622
K4T88-50275 – Blue Neutral cable for Curing and Drying ........................................................................................ 1623
K4T88-50276 – Brown Line Cable for PSU and Other ................................................................................................ 1624
K4T88-50277 – Brown Line Cable for Autotransformers .......................................................................................... 1625
K4T88-50278 – Brown Line Cable for PSU and E-box, Aux Connectors .................................................................. 1626
K4T88-50279 – Black Line Cable for PSU and Other .................................................................................................. 1627
K4T88-50280 – Black Line Cable for Autotransformers ............................................................................................ 1628
K4T88-50282 – Grey Line Cable for PSU and Other ................................................................................................... 1629
K4T88-50283 – Grey Line Cable for Autotransformers ............................................................................................. 1630
K4T88-50284 – Blue Neutral Cable for PSU and Others ............................................................................................ 1631
K4T88-50285 – Blue Neutral Cable for Autotransformers ........................................................................................ 1632
K4T88-50286 – IDS i2c Data ........................................................................................................................................... 1633
K4T88-50287 – E-box-VR Fans Cable ........................................................................................................................... 1634
K4T88-50289 – Beacon Cable Extension ..................................................................................................................... 1635
K4T88-50290 – IPS to Beacon Light Cable ................................................................................................................... 1636
K4T88-50291 – Ink Cartridge Cable Lyra ...................................................................................................................... 1637
K4T88-50292 – Supply Engagement Cable Lyra ........................................................................................................ 1638
ENWW xiii
K4T88-50313 – Black Line Cable for Curing and Drying ............................................................................................ 1639
K4T88-50318 – Grey Line Cable for Curing and Drying .............................................................................................. 1640
K4T88-50393 – Brown Line Cable ................................................................................................................................. 1644
K4T88-50394 – Blue Line Cable ..................................................................................................................................... 1645
K4T88-50413 - IPS to E-box LAN Cable ........................................................................................................................ 1646
K4T88-50415 – LY_EC_PSU-8 DC OUT ......................................................................................................................... 1647
CQ105-50010 – Hard Disk Data Cable .......................................................................................................................... 1648
CZ056-50001 – AM 80 Tokamok to Tomamok 1 ........................................................................................................ 1649
CZ056-50002 – AM 80 Tokamok to Tomamok 2 ........................................................................................................ 1650
CZ056-50003 – Engine Adaptor PCA Power Cable ..................................................................................................... 1651
CZ056-50019 – AM80 LAN Curing PCA to Curing ........................................................................................................ 1652
CZ056-50036 – MA Encoder Cable ................................................................................................................................ 1653
CZ056-50038 – Vacuum Control - OMAS Encoder ...................................................................................................... 1654
CZ056-50039 – Vacuum Control - OMAS ..................................................................................................................... 1655
CZ056-50040 – Vacuum Control - OMAS Power ......................................................................................................... 1656
CZ056-50114 – Vacuum Pump Power .......................................................................................................................... 1657
CZ056-50116 – Capping Motor Encoder Cable ............................................................................................................ 1658
CZ056-50121 – Heater Cable ......................................................................................................................................... 1659
CZ056-50133 – Engine PCA to Engine Adaptor P ....................................................................................................... 1660
CZ056-50134 – Engine PCA to Engine Adaptor PCA Cable ........................................................................................ 1661
CZ056-50156 – Engine PCA to Engine Adaptor PCA Cable ........................................................................................ 1662
CZ056-50161 – WW Power in T Cable .......................................................................................................................... 1663
CZ056-50170 – TUR Sensor Cable ................................................................................................................................ 1664
CZ056-50183 – Temp Extension Curing ....................................................................................................................... 1665
CZ056-50202 – OMAS Controller to Sensor Cab ......................................................................................................... 1666
CZ056-50218 – AC Parton to Parton ............................................................................................................................. 1667
CZ056-50219 – DC Parton to Parton ............................................................................................................................ 1668
CZ056-50220 – Tokaheart-slinky Long ........................................................................................................................ 1669
CZ056-50221 – ATX to Slinky Power Cable .................................................................................................................. 1670
CZ056-50222 – Formatter Output Data Cable ............................................................................................................ 1671
CZ056-50231 – AC Connector to Partons .................................................................................................................... 1672
CZ056-50232 – DC Connector to Partons .................................................................................................................... 1673
CZ056-50252 – CAN B Bus Cable ................................................................................................................................... 1674
CZ056-50281 – Curing Fan Cable .................................................................................................................................. 1675
K4G10-50013 – E-box to E-cabinet PCA Cable ........................................................................................................... 1676
Q6702-50003 – SOL Cable ............................................................................................................................................. 1677
Q6703-50031 – Data Cable Luna-Luna ........................................................................................................................ 1678
xiv ENWW
Index ......................................................................................................................................................................................................... 1679
ENWW xv
xvi ENWW
For HP-authorized personnel only
1 Using this manual
● Purpose
● Chapters
● Readership
ENWW 1
Purpose
This service manual provides the procedures and information necessary to troubleshoot mechanical faults and
print-quality problems, perform diagnostic tests and calibrations, and service the HP Latex 1500 Printer.
For information about using the printer, see the user guide.
Chapters
1: Using this manual
The purpose of this chapter is to make a summary, chapter by chapter, of the contents of this service manual.
2: Printer systems
Use this chapter as a reference for technical information about the subsystems, components, and how they
work together.
Of particular importance are the diagrams included for each subsystem of the printer. They can be useful for
both troubleshooting and disassembly.
3: Safety requirements
This is an industrial printer with high voltages, and it can be hazardous to service. This chapter explains how to
service the printer safely.
4: Troubleshooting
This chapter explains how to respond to various kinds of printer problems that you may encounter.
5: Diagnostics
Use this chapter whenever you need to perform a diagnostic test, service utility, or service calibration. This
chapter is meant to provide procedures and relevant information, not troubleshooting information, which is in
the troubleshooting chapters.
The procedures are described in full, so that you know any relevant values for the test, as well as information
about what the printer is actually doing during the test.
The goal of diagnostic tests is to locate the root cause of the problem and the corresponding system error code
or message that will provide you with the logical steps to resolution.
Some diagnostic tests or calibrations must be performed after removing a component.
6: Service parts and diagrams

The purpose of this chapter is to detail all of the available service parts of the printer. This information is
presented in tables, organized by subsystem, and includes the following:
● Official service part names
● Part numbers
● Illustrations of the service parts
2 Chapter 1 Using this manual ENWW

Use this chapter whenever you need to order a service part.
7: Removal and installation

This chapter provides procedures for removing and installing service parts. Each service part has a removal
procedure detailed in this chapter, and installation procedures and notes are included as needed.
Useful information such as access notes and screw types (head sizes) are provided to help you work efficiently.
Whenever you remove or replace a component, check the Service Calibration Matrix at the beginning of the
chapter, which tells you the tests, utilities, and calibrations that must be performed after removing or replacing a
component, and in what order.
8: LogMeIn rescue
This chapter describes how to use LogMeIn rescue, a customer troubleshooting tool to obtain support remotely
without the need of a service visit.
9: Moving the printer

The printer is large and, depending on the scenario, will require special care if you wish to move it. This chapter
covers the four primary moving scenarios:
● Within the same site, over flat ground
● Within the same site, over ramps or stairs (the printer must be lifted)
● To a different site, with no possibility of freezing
● To a different site, with possibility of freezing, which can damage the tubes, causing ink leakages (the ink
must be removed, as it is water-based and can freeze).
10: Service maintenance

This chapter describes the various maintenance operations that should be performed when the printer has
completed 5 million cycles of operation.
Readership
The primary readers of this service manual are HP service engineers, although secondary readership may
include resellers. All procedures must be performed by HP service engineers, except those clearly marked
otherwise.
ENWW Readership 3
2 Printer systems
● Electrical system: E-cabinet
● E-box
● Substrate path
● Universal mounting beam
● Impelling system
● Pen to Rib Space (PRS)
● Ink system
● Carriage
● Service station
● Printhead cleaning system
● Drying
● Curing
● Vapor removal
● Printer status beacon
● Subsystem block diagrams
● Accessories
4 Chapter 2 Printer systems ENWW

Electrical system: E-cabinet

Functionality
The e-cabinet is the power distribution centre for the whole printer. It is an enclosure located on the right side of
the printer where all the power electrical components are located.
The e-cabinet has 2 input AC power lines:
● The IPS power line (single phase)
NOTE: This line is optional; the printer can be configured with a single power cord.
● The main power line to power the rest of the machine (three phase); e-box, heaters, DC and AC power
supplies.
The main power is switched on or off through the main printer switch, and the IPS power is switched on or off
through the IPS.
All the AC loads are single phase rated for 200–240 V AC. The main power line is separated inside the e-cabinet
into three single-phase lines. The following power input configurations are supported:
● High line voltage: a 380–415 V line-to-line system (220–240 V line-to-neutral) separated into:
L1-N, L2-N, L3-N
● Low line voltage: a 200–240 V line-to-line system separated into:
L1-L2, L2-L3, L3-L1
The separation into three single-phase lines is done through the configuration cross-connectors in TB-1, TB-2,
TB-3, and TB-4. For high line voltage mains a neutral is required, for low line voltage a neutral wire is not needed
(and should never be installed).
Through the TB-1, TB-2, TB-3, TB-4, and the configuration cross-connectors, one of the phases of the main
power can be connected to the single-phase input, so that the printer can be powered by a single power cord.
See the installation guide and site preparation guide for details and specifications.
The picture below shows an example of the terminal block configured:
ENWW Electrical system: E-cabinet 5

Simplified diagram and general electrical explanation

The following simplified block diagram shows an electrical overview of the e-cabinet components and the link
with the external subsystems.

ENWW
ACB-1 ACB-4
Main Switch K-1 20A
TB-1 50A 63A TB-4 RCD-1
40A ACB-5
30mA 20A
Drying
Mains 3 o 2 RCD-2
Phases 40A
30mA
ACB-6
RCD-3 20A
40A
30mA
ACB-7
20A
TB-1
Mains 2 ACB-8
Curing
Phase (Opt) 20A
L-1
L-2
L-3
TB-2
TB-3
ACB-2 24VDC
IPS IEC1
GABI & Frenadol
K-2
63A DC PSU-8
LED’s
IPS
IEC2
SCREEN
24VDC
J1 – 24V
D&N DC PSU-6
System IEC5 PPS
J2 – 24V
eBox IEC3
Drying
TB-5
24VDC
DC PSU-7 J4 – 32V
Aux IEC4
TUR
J5 – 32V
SVS
24VDC
DC PSU-2 J6 – 32V
WW
13A
J8 – 42V
RCBO-1 30mA
eCabinet CARR
32VDC
DC PSU-3 J9 – 42V
PCA MA
J10 – 42V
Power Power MI
Jumper Jumper
42VDC
DC PSU-1
J12 – 42V
MO
J13 – 42V
SAX
TF2 TF1 42VDC
DC PSU-5 J16 – 24V
CURING 2
J18 – 24V
120V 24VDC CURING 1

230V
DC PSU-4 J19 – 24V
ISS
Interlocks
Rearm
J20 – 24V
Button
Safety Blue
Relay Light
VAPOR
Door Fan Door Fan
1 2
Vapor
Removal
Rearm PUMP1
Light
Emergency
STOP
Vacuum
Pump
PUMP2
HP Latex 1500 PS eCabinet

Simpliﬁed BD

input line into three 200–240 V single-phase lines. There is a pilot light on each of these lines (L-1, L-2, and L-3)
Through the installation and configuration terminal blocks (TB-1, TB-2, TB-3, and TB-4), the e-cabinet splits the
7
to provide visual feedback. The configuration is done by the installation cross-connectors; see the installation
guide for further information on how to connect and configure the e-cabinet for each supported power system.
As a result of all the loads being single phase, the printer is an unbalanced three-phase load when connected to
a three-phase power line. The average power consumption is distributed as evenly as possible among the three
phases, but it will never be perfectly balanced.
Main switch and PC switch

Whether there is an independent single-phase line for the IPS or only the main power line, the main switch will
not switch the IPS on or off; the IPS AC power is switched on or off through the IPS main switch.
NOTE: Note that the IPS is a standard PC and should be turned off through the operating system, not by
switching off the AC power.
AC protections: ACBs and RCDs (GFIs)

Through the AC protections, the three single-phase lines coming from TB-1, TB-2, TB-3, TB-4, and through the
main switch.
● 3 lines for the curing system, with ACB and RCD (GFI) protection on each line
● 2 lines for the drying system, with ACB and RCD (GFI) protection on each line
● 1 line for the vacuum and vapor pumps protected by the RCBO
This separation of the AC lines allows us to identify better where a problem with the AC part comes from.
Safety circuit and contacts

There are 2 contacts that switch the AC power of several systems. They are controlled through the safety relay,
see Safety relay activation and safety elements on page 20 for further information.
Power jumper and power transformer

Power autotransformers TF-1 and TF-2: TF-1 is used to adapt the 200–240 V power input to a 230 V power
output. The power jumper selects the appropriate contacts of the autotransformer and must be chosen
depending on the mains nominal voltage (see the installation guide for more information). The transformer
powers the vacuum and vapor removal pumps. TF-2 is used to feed the vacuum pump and power input to a 127
V and is fuses protected (output and input).
● 3 lines for the curing system, with ACB and RCD (GFI) protection on each line
● 2 lines for the drying system, with ACB and RCD (GFI) protection on each line
DC power and the e-cabinet PCA

There are 7 AC/DC power supplies that supply power to most of the electrical components of the machine
(motors, valves, fans, solenoids, electronics).
The DC power coming out of the AC/DC power supplies is connected to the e-cabinet PCA which has a power
input for each PSU. The e-cabinet PCA’s main role is to distribute and monitor the DC power to the printer
subsystems; it also provides power and monitors the safety circuit.
Detailed electrical diagram

The following is a complete wiring diagram of the e-cabinet.

ENWW
Instalation AC-6AWG AC-6AWG AC-6AWG SAX BRAKE Contactor
TB-1 Terminal Blocks
[16mm2] [16mm2] [16mm2] AC-14AWG ACB-4
6x WDU16 TB-4 [2.5mm2] 20A Drying
K-1 L307
PPS MOTOR CONTROL
L305
3
6x WDU16 RCD-1..3
3 Phase 5 Wires 380-415V 63A
N105
40A/30mA N113
GABI
1
L3 4 L306
OR L3 L300 L300 2 1 L302 L302 L304 L305
7
L301 L303
2 N105
ACB-5
3 Phase 4 Wires 200-240V
1 3
L2 L2 L200 L200 4 3 L202 N106
L307
N104
L205
5
6
RCD-1 20A N113
3
OR L201 L203
L1 6 5 L207 L207
L1 L202 L204 L206 Drying
L100 L100 L102 4
3
N112 N112 AC
1 Phase 3 wires 240V L101 L103 L205 N107 Drying
1
N 8 7 2
N1 N100 N136 N107
1 3
1
N108
N101 RCD-2
L0 33 34 L102 L104
K2-A1 K2-A11
23 24
K-2 L113-1 4
Molex 43938-2101
N0 K1-24 L106
K1-23 N102 N137
1 63A 1 2 N110
AC-14AWG Male pins
1 3
ACB-1 N132-1
M8 PE STUD A1 A2 SW2-D1 RCD-3 [2.5mm2]
L1M
50A
N132 1 2 N132-1
SW2-D2
3 4
ACB-6
L113 L113-1
N1M
5 L306
20A
N102 6
3
N100 1 AC-12AWG
N103 L308 L308
7 8 [4mm2] N106 N114 N114
1
L208 Curing
TB-11 ACB-7 N115 AC
33 34
L108 Curing
1 Phase 3 1x WDU16 23 24 K2-24
20A N116
K2-23
L206 L208
3
wires 100-240V Molex 43938-2101
A1 A2 K2-A2 TB-10
K2-A11 N108 N115
Curing
1
2x WDU 2.5 AC-14AWG Male pins
AC-14AWG ACB-8
BR_Feedback
[2.5mm2]
[2.5mm2] 20A
L106 L108 FREN-
SAX-BRK-
SAX-BRK+
N116 FREN+
BR_Contactor
M4 PE STUD N110
1
SAX-BRK-
DC-16AWG
[1.5mm2]
SAX-BRK+
1 24V PSU
AC-12AWG AC-16AWG AC-12AWG PSU LPS
[4mm2] [1.5mm2] [4mm2] CONN3
24V PSU-LPS +
AC-14AWG GND PSU-LPS -
[2.5mm2] Housing
PSU-8
Molex
L1M
N1M
39-01-2026
AC-14AWG Pins:
AC-16AWG TB-9 [2.5mm2] Molex
1 3
ACB-2 TB-2 [1.5mm2] 2x WDU 2.5 2x 39-00-0082
10A 2 4 6x WDU16 L-3
L301
L-2 TB-3
L201 1
6x WDU16 DC-22AWG [0.34mm2]
L-IEC2
N-D&N
N-IEC1
N-IEC2
L-IEC1
L-D&N
L101 L303 L312 L312
4x TWISTED PAIRS
L-1 L313
L109
N101 N128 N128 N130

1 N119
K2-24
L203 L213 L213 L214 K2-23
K1-24
K1-23
N129 N129 N131 FREN+
FREN-
J53
Contactors
AC-12AWG
L103 L-PUMPS
L-D&N [4mm2]
D&N N103 N-PUMPS
N-D&N 1 TB-5
System PE-D&N AC-14AWG
20xSIK DC-10AWG [6mm2]
~400W [2.5mm2]
Laird TWISTED PAIR
6xWDU4 28A2736-0A2
M4 PE STUD AC-14AWG L Laird
L119 24V PSU
IEC-5 PSU-6 N
28A0807-0A2
N125
2xWQV4 [2.5mm2] PE PSU6 +
L113 L114 PE- PSU6 PSU6
24V PSU6 -
AC-12AWG
N132 N133 GND PSU6
L-IEC1 [4mm2] Short connection to
PSU holder screw TDK Laird
IPS PE-IEC1
28A2736-0A2
CN1
L115 L115 L119 ALM + ON/OFF

L116 CTRL PSU6
N120 PSU6
N120 N125
600W
N-IEC1
M4 PE STUD N134
CN3
L117 L117 L120

PSU-6
IEC-1 L118 PSU-5
N121 AC-14AWG DC-22AWG [0.34mm2]
N121 N126
L-IEC2 N123 TWISTED PAIRS
Laird [2.5mm2]
L109 L110 L110 L111
L112 28A2736-0A2 DC-10AWG [6mm2]
IPS PE-IEC2
24V PSU Laird
N119 N122 L
N122 N127 L120 28A0807-0A2 TWISTED PAIR
1 PSU-7
N124 N126 N
Screen PSU7 +
PE- PSU7 PE 24V PSU7
L116 L121 PSU7 -
N-IEC2
M4 PE STUD GND
N134 N135 PSU7
IEC-2 Short connection to
L-IEC3 L118
N-IEC3 N123 28A2736-0A2
CN1
** FUSES ** ** FUSES ** CTRL PSU7

ALM + ON/OFF
L-IEC4 L112 600W PSU7
AC-14AWG FP1: 8A#~5x20 FP11: 8A#~5x20
CN3
[2.5mm2] N-IEC4 N124

FP2: 8A#~5x20 FP12: 8A#~5x20 PSU-7
PSU-6
AC-14AWG DC-22AWG [0.34mm2]
FP3: 8A#~5x20 FP13: 8A#~5x20 [2.5mm2] TWISTED PAIRS
Laird
FP4: 8A#~5x20 FP14:8A#~5x20 28A2736-0A2 24V PSU DC-10AWG [6mm2]
L111 L
Laird TWISTED PAIR
WQV 4 FP5: 8A#~5x20 FP15: 4A#~5x20 N127 PSU-2 N
28A0807-0A2
L-PUMPS
N-PUMPS
PE- PSU2 PE
FP6: 8A#~5x20 24V PSU2 +
PSU2
FP16: 4A#~5x20 PSU2 -
FP7: 8A#~5x20 Short connection to GND

FP17: 4A#~5x20 PSU2
1 3 PSU holder screw
FP8: 8A#~5x20 FP18: 4A#~5x20 TDK
ACB+RCD
FP9: 8A#~5x20 FP19: 2A#~5x20 600W CTRL
FP10: 8A#~5x20 FP20: 2A#~5x20 PSU-2
L-IEC3
RCBO-1 AC-14AWG
eBox 13A/30mA Laird [2.5mm2]
PE-IEC3 28A2736-0A2 32V PSU
HPPN: K4T88-80258 L313 L
N130 PSU-3 Laird
N
4
2
PE- PSU-3 28A0807-0A2
PE
N-IEC3
32V PSU3 +
PSU3
PSU3 -
IEC-3 Short connection to GND PSU3
AC-14AWG PSU holder screw TDK
[2.5mm2] DC-10AWG [6mm2]
L-TF1
L-TF2
N-TF2
N-TF1
300W
M4 PE STUD TWISTED PAIR
L-IEC4
AC-14AWG PSU-3
Aux
PE-IEC4 Laird [2.5mm2]
28A2736-0A2
L214 L
PSU-1 42V PSU Laird
N-IEC4 N131 N
PE- PSU1 28A0807-0A2
PE
PSU1 +
42V PSU1
IEC-4
Trafo #1 PSU1 -
Vapor Removal Short connection to GND PSU1

eCabinet PCA
PSU holder screw DC-10AWG [6mm2]

AC-14AWG Pump TDK
Laird
240V
230V
220V
210V
200V
Com.
[2.5mm2] TWISTED PAIR
M4 PE STUD DC-22AWG [0.34mm2] TB-6 28A2736-0A2
CN1
600W PSU1
TWISTED PAIRS 7x WDU4 CTRL PSU1
ALM + ON/OFF
CN3
1x WPE4 AC-14AWG PSU-1

AC-14AWG
2xZQV4/2 [2.5mm2] DC-22AWG [0.34mm2]
[2.5mm2]
L-PJ1
Laird TWISTED PAIRS
28A2736-0A2 Laird
L114 L 42V PSU
AC-14AWG TF-1 PSU-5 N
28A0807-0A2
N133
TF1-240V 42V PSU5 +
PE- PSU5 PE PSU5
[2.5mm2] 240V PSU5 -
TF1-230V GND PSU5
230V L-PUMP1
Short connection to
DC-22AWG TF1-220V DC-10AWG [6mm2]
220V PSU holder screw
[0.34mm2] TF1-210V
TDK Laird TWISTED PAIR
210V 28A2736-0A2
CN1
TF1-200V PSU5
Trafo #2 200V 600W PSU5
CTRL ALM + ON/OFF
Vacuum Pump
CN3
PL-4 PSU-5 DC-22AWG [0.34mm2]

PY1 L4-X1
Pump #1
eStop TB-7 TWISTED PAIRS

2700VA AC-14AWG Laird
3x WDU4 28A0807-0A2
0V TF1-N1 Laird PSU4 +
PE- P1
[2.5mm2]
L-P1
3
L-TF1
X1
N-TF1
N-P1
L-PJ1
L-PUMP1
1x WPE4 28A2736-0A2 24V PSU PSU4 -
PSU4
eSTOP-
DC-22AWG [0.34mm2] L121 L
SFW - eSTOP+ PSU-4 24V
K2-A2
SR-A2
N135
PSU4
SR-A1
eSTOP+
4x SIK (2A fuse – 5x20 size) N
K2-A1
X2
TWISTED PAIRS PE- PSU4 PE GND DC-10AWG [6mm2]
4
SFW – eSTOP- 1xZQV4/2
PE- TF1
240V
230V
220V
210V
200V
Com.
Safety wiring 1 TWISTED PAIR
Laird
Short connection to 28A2736-0A2
CN1
L4-X2
TDK ALM + ON/OFF
1 AC-14AWG PSU holder screw PSU4
PY2
TB-8 PSU4
[2.5mm2] 600W CTRL
CN3
1x WDU 2,5
FT-13
FT-13
TF1-N2
DC-22AWG [0.34mm2]
TF1-N1
PE- TF1
L-PJ2
4x WDU 2.5 (1-2) PSU-4
GND
24V
TF-2 TWISTED PAIRS
IL_FB
TF2-240V
** FUSES ** L4-X1
Interlock-
Interlock+
ESTOP_FB
EN Light
SW2-D2
L4-X2
SW2-D1
PY1
PY2
L5-X1
235V
SR-A1
SR-A1+
TF2-230V
FT-21: 2A#5x20 J42
225V DC-22AWG [0.34mm2]
TF2-220V FT-22: 2A#5x20
200V TWISTED PAIRS
L5-X1
FT-23: 2A#5x20
13 23 33 41
127V L-PUMP2
A1 Y1 Y2 FT-24: 2A#5x20
110V SAFETY
ASSY
J44
Safety Relay L-5 Pump #2
PNOZX1 AC-8AWG DC-AWG22 [0.34mm2]

[6mm2] TWISTED BUNDLE
220VA
Interlock – SFW1
A2 14 24 34 42 0V TF2-N1 Interlock – SFW2
PE- P2
J48
L-P2
L-TF2
N-TF2
N-P2
L-PJ2
L-PUMP2
L5-X2
PE-LEFT Interlock – SFW3
Interlock – SFW4 J50
Interlock – SFW5
L5-X2
PE- TF2
Interlock – SFW6
SR-A1+
PCA-1
SW2-A2
J51
SR-A2
SR-14-34
SR-14-34
SW2-A2
1
FT-21 FT-22 FT-23 FT-24
FAN
M6 M6
DC-22AWG
FT-23
FT-21
DC-AWG22 [0.34mm2]
FT-23
FT-21
TF2-N2
TF2-N1
PE- TF2
[0.34mm2] M6 PE STUD M6 PE STUD TWISTED BUNDLE
VCC-FAN
GND-FAN
DC-22AWG
FAULT-FAN
DC-22AWG [0.34mm2]
TWISTED BUNDLE
LEFT/RIGHT MAIN BOX [0.34mm2]
Interlock DOOR
chain
Front door1
Interlock – SFW1
Interlock – SFW2
Interlock-
Loading table
Interlock+
Interlock – SFW3
Interlock – SFW4
FAN-2 FAN-1
Interlock – SFW5
AC-14AWG
Interlock – SFW6
[2.5mm2]
Tyco 350767-1
Female pins
L-P1
VAPOR
N-P1
PUMP
PE- P1
L-P2
N-P2 VACUUM
PUMP
PE- P2
eCabinet
Tyco 350767-1
Male pins
HP Latex 1500 PS
Rev.12 eCabinet
- HP Conﬁdential -

9
Internal Components
The interior of the e-cabinet contains the following components:
● Installation and configuration terminal block (TB-1, TB-2, TB-3, and TB-4)
● Main switch ACB-1
● Automatic and residual circuit breakers (ACB-1 to ACB-9)
● Contactors (K-1 to K-2, activation through safety relay)
● Safety relay (controlled by the emergency stops and enable button)
● 7 AC/DC power supplies (PSU-1 to PSU-7)
● E-cabinet PCA
● 1 power transformer (TF-1, vapor removal)
● 1 power transformer (TF-2, vacuum pumps)
● Fan (FAN-1 and FAN-2)
General view
AC and DC areas
This is a general view of the AC and DC power spatial distribution. Inevitably, some AC and DC cables share a
stretch of their routing, but in general they are as separated as possible.

AC input

AC power supplies, contacts, and distribution blocks

Safety circuit, power transformer, and PCA
DC power supplies

PSU configuration
There are seven AC/DC power supplies that supply power to most of the electrical components of the machine
(motors, valves, fans, solenoids, electronics…).
These power supplies have various output voltages and are powered on/off in different moments. Here is a
summary of the PSUs:
Input side Output PCA side
PSU# e-Cabinet PCA Cable

Power Voltage Connector Subsystem Fuse Connector
MA Motor 25A J9 LY195
MI Motor 25A J10 LY209
1 600 42V J41 MF Motor 25A J11 Accessory
MO Motor 25A J12 LY210
Carriage PCAs 15A J8 LY145
e-Cabinet PCA 4A — —
IDS 5A J19 LY206

2 600 24V J36
Vapor 15A J20 LY193
Removal PCA
Not used 10A J7 —
Webwipe 5A J6 LY188
3 300 32V J47 SVS-DD 5A J5 LY364
TUR PCA 5A J4 LY327
Not used — J3 —
Drying — J2 LY267
4 600 24V J46
PPS — J1 LY15
Not used — J14 —

5 600 42V J25
Scan motor 25A J13 LY207
Curing 25A J18 LY192

6 600 24V J34 electronics
Not used 3A J17 —
Curing 25A J16 LY192

7 600 24V J35 electronics
Not used 3A J15 —
8 100 24V e-Cabinet PrintZone NA NA LY389

metal LEDs

15 Electrical system: E-cabinet ENWW
TO ACB-2
TO ACB-1
N0 1
1
2
3
4
TB-5
L0 2
0
WQV 4
TB-1
N1 3 N1
HPPN: K4T88-80258
6x WDU16
L1 4 L1
L2 5 L2
L3 6 L3
N119 N124
1
N122
L110
L109
N102 2
N137 L112
N132-1 1 N1
N123
3
L102 L104 N121
2 L1
L113-1
L117
TB-4
4
L118
3 N136
N120
5
4 L204 N134
L202 L2
6x WDU16
L115
6
N104 L116
TB-5
5
L312 FP1 L313
20xUT6
L302 6 L304
PSU
L3 N128 N130
6xWDU4
2xWQV4
FP2
L213 FP3 L214
N103 1 N1 N-PUMPS
N129 FP4 N131
L113 L114
L103 2 L-PUMPS FP5
L1
N133
N132 FP6
L119
3 N129 L115 FP7
TB-3
N120 FP8 N125

L203 4 L213 L117
L2 FP9 L120
N121 FP10 N126
6x WDU16
5 N128
L110 FP11 L111
N127
N122 FP12
L312
L303 6 L3 L116 FP13 L121
N134 FP14 N135
L1-X1
N101 1 N1 N119 L-IEC3 FP15 L118
L1-X2 N-IEC3 FP16 N123
L101 2 L1 L109 L-IEC4 FP17 L112
N-IEC4 FP18 N124
3 L2-X1
TB-2
L-LPS1 FP19 L-LPS
N-LPS
L201 4 L2-X2 N-LPS1 FP20
L2
L3-X1
HP Latex 1500 PS V12 eCabinet
6x WDU16
5
Terminal blocks design and cabling
N-LPS
L3-X2
L301 6 L3 L-LPS PE_P1
PE-TF1 1
2 L-PUMP1
TB-6
FT-13 3
4 L-PJ1
L-TF1
1x WPE4
7x WDU4
TF-1-N1 N-TF1
2xZQV4N/2
FT-13 L-P1
TF-1-N2 N-P1
Trafos
PE-TF2 1 PE_P2
2 L-PUMP2
FT-23 3
FT-21 4 L-PJ2
TB-7
FT-21 FT-21 L-TF2

N-TF2
4x UT6
TF-2-N1 FT-22
FT-23 FT-23 L-P2
1x WPE4
3x WDU4
TF-2-N2 FT-24 N-P2

1xZQV4N/2
ESTOP_FB 1 eStop+ SFW-eSTOP-

SFW-eSTOP+
TB-8
24V 2 eStop- eSTOP+

eSTOP-
Interlock+ Ilock+ 3
N103 SR-A1
N100
TB-11
1 Interlock-
N102 K2-A1
IL_FB Ilock- 4
SR-A2
1x WDU 2.5
GND 5 K2-A2
Safety wiring
1x WDU16
4x WDU 2.5 (2)
SAX-BRK+ 1 TO BRK contactor GABI-1 1 ECAB_CONTACTOR_1L1
SAX-BRK- 2 TO BRK contactor GABI-2 2 ECAB_CONTACTOR_2T1
TB-9
FREN+ 3 GABI-3
TB-10
TO BRK contactor fdback 3 ECAB_CONTACTOR_3L2
FREN- 4 GABI-4
TO BRK contactor fdback 4 ECAB_CONTACTOR_4T2
2x WDU 2.5
2x WDU 2.5
Terminal block cabling details
E-cabinet exterior and user interface

Figure 2-1 IPS PC side (1 of 2)

Figure 2-1 IPS PC side (2 of 2)

Figure 2-2 AC protections detail

Figure 2-3 Rear details (AC I/O interface)

Figure 2-4 E-box side
The side nearest to the e-box is the DC power output and signals interface.
In case of a blown fuse, an alert will be shown by the Internal Print Server indicating which fuse needs to be
replaced.
Safety relay activation and safety elements

When the printer is turned on, the potentially dangerous systems (heaters and motors) are not powered up. To
enable power to these systems there is a safety circuit controlled by a safety relay.

The systems whose power is controlled by the safety circuit are:
● Substrate axis motors
● Printhead PCAs
● Print to Paper Space (PPS)
● Service station
● TUR PCA (SOL shutter)
● Scan-axis motor
● Drying AC power
● Curing AC power (heaters)
● Vacuum pumps
● Vapor removal
In order to enable the safety relay, three conditions must be satisfied:
● None of the 4 emergency stop buttons must be pressed.
● The printer firmware must be active and must allow enabling the power (indicated by blinking the Enable
button).
● The user must press the blue Enable button on the side of the e-cabinet.
The power-up sequence is as follows:
● The printer starts booting up by switching on the main switch or starting up the e-box through the Internal
Print Server.
● Among other checks, while starting up the printer checks the status of the emergency stop buttons. If one
or more buttons are pressed, it waits for the user to release them (a message is displayed by the Internal
Print Server).
● When all the initial checks have been passed, the printer waits for the user to press the Enable button (the
button blinks and the Internal Print Server displays a message).
● Once the Enable button has been pressed, the safety relay activates the power to all systems, and the
printer continues its start-up sequence until it is ready to print.
Emergency stop
If one or more emergency stop buttons are pressed, the safety relay will deactivate and cut power to all the
potentially dangerous systems. Once it has been deactivated, the safety relay can only be reactivated with user
intervention, and the three conditions stated above must be satisfied again.
Safety interlocks
There are two safety interlock switches located one at the front door and the other at the loading table. Those
switches control the power of the carriage motor and the heaters in the curing and drying systems. If either of
those interlocks is activated by opening a door, the power to those systems will be cut off. However, the safety

relay will not be deactivated, so when the door is closed the systems will be powered on again without further
user intervention.

E-box
Functionality
The E-box is the main processing and control system in the printer. It is a metal enclosure located at the rear
right of the printer where main electronics are located.
Components
The interior of the e-box contains the following components:
● Formatter: The formatter is the motherboard of the printer, similar to a PC motherboard. Its main functions
are the processing (formatting) of printing data coming from the Internal Print Server and the coordination
ENWW E-box 23
of printer subsystems. The formatter provides a SATA connector to the hard disk drive, PCI express
connections to the four engine PCAs, and a network interface to the Internal Print Server PC.
● Hard disk: The hard disk holds most of the printer’s data, including the firmware. However, key data such as
product number, serial number, and calibration values are also replicated in an internal memory of the IDS
AIR PCA in order to have redundancy protection. Therefore, if the hard disk drive fails, it can be replaced by
a new one, and key data are automatically copied from the IDS AIR PCA to the new hard disk. Similarly, if
the IDS AIR PCA breaks, it can be replaced by a new one, and key data are automatically copied from the
hard disk to the IDS AIR PCA.
It is important to understand what this means in practical terms: the hard disk and IDS cannot be replaced
simultaneously and can be replaced only by new ones. If hard disk or IDS are not new (e.g. they come from
another printer), the appropriate service procedures must be followed, otherwise data may be inconsistent.
● ATX power supply: The power supply for the e-box is a standard ATX unit, similar to a PC ATX power supply.
● E-box fan: In order to prevent the e-box from overheating, there is a fan located on the lid of the enclosure,
electrically connected to the formatter board.
● Printer ID PCA: Contains printer identification. When replacing the Engine PCA, take care not to lose it.
● Engine PCAs: The main controller of the printer. It is responsible for all the processes performed in real-
time, and is the ultimate controller of all electromechanical systems. The Engine PCA controls all substrate-
path components (drive roller, spindle motors, substrate-advance sensor, etc.), and all non-substrate-path
components (carriage, scan-axis motor, print-head cleaning assembly, service station, etc.). Attached to
this board is the Printer ID PCA. The engine boards control the real-time routines, namely:
– Converting the image format to data compatible with the printheads
– Sending the above information to the printheads at the correct speed
– Running the real-time servo controls for the position and speed of the mechanical actuators
– Communicating with other electronics boards that control delegated actuators and sensors
There are four identical engine boards directly connected to the hard disk drive. The following functionality
map summarizes each board controlling tasks:
Engine PCA 1
– Scan axis brushless motor (J101 DNK)
– Carriage DPE compensation
– Regular Line sensor and optional Day and Night carriage Line sensor
– Carriage1 (pen 1-2)
– Bulli Drying (J161 CAN)
– DD (J131 ODD)
– 2 Turbofalcon + SOL + Tetris
– 5x web wipe (J151 MICCI2)
– 2x capping (A130 4x) (J152 MICCI2)

– ELA Reset
– ELA Rst feedback
Engine PCA 2
– Carriage 2 (pen 5-6)
– Bulli Curing (J261 CAN)
– Vapor Removal Patron (J262 CAN)
– DD (J231 ODD)
– 2 Turbofalcon + primers
– PPS (4x luna PCA) (J251 MICCI2)
– IDS1 + IDS2 (J241 I2C)
– ELA Reset
Engine PCA 3
– MA brushless PCA (J301 DNK)
– MI brushless PCA (J302 DNK)
– MO brushless PCA (J303 DNK)
– MF brush less PCA (J304 DNK)
– MO (J322 ENC)
– MF (J323 ENC)
– OMAS1 (J381)
– DD (J331 ODD)
– 2 Turbofalcon
– 1 LUNA PCA for TUR sensors + 2 MF switches + 1 pinch wheel sensors + window sensor + 2 Luna for
Curing (J351 MICCI2)
– E-cabinet PCA (J341 I2C)
– Vacuum PCA 1 + CANA (J381 I2C)
– ELA Reset
– Vacuum PZ (J371)
ENWW E-box 25
Engine PCA 4
– OMAS2 (J481)
– DD (J431 ODD)
– 2 Turbofalcon
– Vacuum PCA 2 + CANA (J481 I2C)
– ELA Reset
– Vacuum VR + buzzer + TUR sensor (J471)
● Engine adaptor PCAs: The engine adaptor boards are responsible for:
– Converting the electrical signals coming from/going to the engine boards to suitable voltage levels
required by the machine.
– Sourcing/controlling and measuring the logic power needed by the subsystems.
– Monitoring signals for enhanced machine diagnosis.
There are four identical engine adaptor PCAs connected to each of the engine boards via flat cables and to
the e-box interconnect via board-to-board connections.
● E-box interconnect PCA: The e-box interconnect PCA centralizes the connectors for the cables going to all
the subsystems (except the printheads). It also has LEDs that enable visual diagnosis without accessing the
interior of the e-box enclosure.
See Troubleshooting without system errors on page 370 for details about connections and diagnostic
LED’s.
● Fiber-optics PCA: The fiber-optics PCA multiplexes the image information generated by the four engine
boards and sends it to the printheads through a single optical fiber.

General block diagram

For a diagram that shows a general overview of the electronic interconnections between the printer subsystems
see the subsystem block diagrams for more details: Figure 2-17 E-box on page 91 and Figure 2-16 Drying
Subsystem on page 90.
ENWW E-box 27
Substrate path
Functionality
The substrate path includes all the elements responsible for providing a smooth and accurate motion of the
substrate, and therefore ensuring a consistent and controlled substrate advance.
Components (roll-to-roll configuration)

The components included in the substrate path are:
● Input spindle, transmission, and motor (rear)
● Drive roller, transmission, substrate advance motor, encoder disc, and encoder PCA
● Pinch mechanism
● Print platen and substrate advance sensor
● Diverters and bottom plate
● Output spindle, transmission, and motor (front)
NOTE: Substrate input, output, and floor motors include a resistor in the electrical line used to dissipate energy
during the braking process and ensure the integrity of the electrical components.
Theory of operation (roll-to-roll configuration)

● The substrate roll is mounted on the rear spindle and is collected on the front spindle. Each of the spindles
has its own transmission and motor.
● The substrate goes from the rear spindle over the drive roller, over the print platen, over the diverter, and
onto the front spindle. The print platen is designed for minimal resistance against the substrate’s advance,
and includes suction holes for the vacuum.
● Vacuum is applied to keep the substrate flat on the print platen. There are different vacuum levels
depending on the substrate used. The vacuum level is determined automatically during the loading of the
substrate.
● The substrate is advanced by the motor of the drive roller. The drive roller system advances the substrate
under control. The encoder disc and encoder PCA provide feedback on the substrate advance.
● There is a pinch mechanism to prevent the substrate from slipping against the drive roller. The pinch
mechanism is composed of 22 covered pinch submodules, assembled along a beam also known as the
loading table.
This beam is articulated to the side walls of the bottom structure and is manually actuated. The movement
is assisted by a pair of torsion springs and two clamps fix the beam in the top position.
ENWW Substrate path 29

● Pinch bump: Installed on a new support to prevent the part from bending.

● The substrate-advance sensor is an optical sensor, located underneath the print platen. It takes pictures of
the back of the substrate as it moves across the platen. These pictures evaluate the precision of the
substrate movement. The evaluations result in a set of values that describe the substrate advance error
and are used to make automatic precision adjustments while the substrate is being printed.
NOTE: The substrate-advance sensor cannot see the fibers on certain substrates, such as transparent
substrate or very dark substrates. In these cases, the sensor is disabled automatically.
The image from the sensor is deformed under high temperature conditions and the relative distances
measured are inexact, producing wrong substrate advances and print-quality problems such as banding or
graininess.
The sensor’s field of view is a rectangle of 5 × 1 mm aligned with the direction of substrate movement. The
area of the picture used to perform image recognition on paper fibers is in the central 4 mm, so two
identical fiducials are marked at the extremes of the field of view without impacting in the images used to
recognize the substrate.
The glass on which the fiducials are printed has almost no thermal expansion and the fiducials keep their
relative position.
By comparing the current fiducial distance with the initial one, the optics system thermal deformation is
compensated.

● There are 2 diverters: the upper and the lower diverter. The bottom plate is supported between both
diverters. Diverters are composed of small plastic wheels that create a rolling surface effect. The diverters
create an angle in the substrate path after the print zone. This bends the substrate and thus isolates
possible wrinkles in the curing area from the print zone.
Dual roll accessory

The use of dual-roll spindles enables the printer to print on two different rolls of substrate at the same time,
significantly improving the productivity of the printer.
An integrated differential system is used to keep the same tension in both rolls of substrate mounted on the
same spindle, regardless of the width or diameter of each roll.
However, for optimum results, it is recommended that both rolls have the same width and diameter.
To fix both cores to the spindle, two independent air cameras need to be pressurized via two air valves located at
both ends of the spindle. For more information on dual-roll usage, see the user guide.

NOTE: Differential cannot be replaced independently!
NOTE: For Optimum IQ, the dual roll must be used in Roll to Roll Configuration Dual Roll in Roll to Free Fall
configuration may not work (Output tensions cannot be compensated)
Subsystem power and control

Substrate path motors are brushless motors powered with 42 V coming directly from the dedicated connectors
in the e-cabinet PCA.
There are also four dedicated data cables coming from the e-box interconnect PCA, one for each of the motors:
Media Input, Media Output, Media Advance, Media Floor (not included, accessory). Encoder cables go from the MI,
MO and MF motors to the e-box interconnect PCA. The MA motor has a separate analog encoder disc and PCA to
process the motor position. This analog encoder PCA is connected to the OMAS & VACUUM controller PCA.

The platen vacuum pump is powered with AC power coming from the e-cabinet PCA. Note that the AC power is
not distributed through the e-cabinet PCA so the power cable comes from a connector in the e-cabinet back
panel. The pump is controlled by the Vacuum PCA.
Power and data cables for the Vacuum Ctrl PCA come from the e-box interconnect PCA. The vaccum PCA and the
OMAS PCA are connected with a power cable, and data cable and the Substrate Advance encoder signal. The
OMAS sensor is connected to the OMAS PCA.
Note that although the OMAS & Vacuum PCA are 2 different boards, the service part is the same assembly.
See Figure 2-10 E-stops and Interlocks on page 84.
Substrate side plates (MIMO)

The HP Latex 1500 has had both input and output side plates replaced with new ones, with the following
differences: The Media Output Transmission now has a 90 degrees transmission assembly included and the
Media Output Motor is positioned vertically.

Universal mounting beam

The HP Latex 1500 Printer has a new guide in the curing beam used to mount the slitters and the front LED
lights.
● In-line slitters are a new accessory on the HP Latex 1500. The vertical cutters (4) allow the substrate to be
cut in the direction of the substrate advance.
IMPORTANT: The in-line slitters should be removed from the universal mounting beam when they are not
being used. Before loading the substrate make sure they are not installed into the beam.
CAUTION: Do not use the Ink Collector Kit when the in-line slitters are installed, as the cutting position can
damage the protector of the kit. You are recommended to uninstall the in-line slitters when working with
the ink collector.
● LED proofing lights: New optional accessory for the HP Latex 1500. LED proofing lights include 2 sets of
lights:
– Front light: Mounted underneath the Universal mounting beam (UMB), illuminating print output for
frontal visual assessment.
ENWW Universal mounting beam 35

– Back light: Two strips of LEDs illuminating from the rear of the substrate output, provides an on-
printer light source for visual assessment of backlit prints; no need to stop the printer to view in a
light box.
The LED proofing lights can easily be managed and switched on from the IPS.
CAUTION: LED proofing lights can reach high temperatures; take caution when approaching and
working close to LED strips.

Impelling system
Functionality
The scan-axis impelling system is responsible for providing controlled motion to the carriage across the scan
axis, for the purposes of printing and moving the printheads into a position where they can be serviced and
maintained.
It also includes the delivery system, which is composed of the ink tubes and cables going through the chain to
the carriage.
Components
● The scan-axis motor, located on the right side of the printer, drives the belt that moves the carriage.
Like the substrate-path motors, the scan-axis motor includes a resistor in the electrical line used to
dissipate energy during the braking process and ensure integrity of the electrical components. The resistor
also acts as a safety brake in case any interlock or e-stop is activated (for example, window is opened).
● The shaft support (blue piece), is located on the right side of the printer and helps to support tension
generated by the motor shaft belt.
● The scan-axis impelling belt is connected to the carriage on both sides, and runs from the scan-axis motor
to the scan-axis belt tensioner. The motor drives the belt, which in turn moves the carriage back and forth.
ENWW Impelling system 37

● The scan-axis belt tensioner, located on the left side of the printer, acts as a pulley support for the scan-
axis impelling belt opposite the motor. Two springs mounted between the pulley and scan-axis sideplate
maintain tension on the belt. When the tensioner and belt length are correctly adjusted, one mark has to be
visible from both sides on the tensioner pins.
● The scan-axis encoder strip is a plastic strip running the length of the scan axis. As the carriage is moved
back and forth by the scan-axis impelling system, an encoder sensor mounted on the carriage reads the
encoder to determine the speed and position of the carriage. This feedback is then used to control the
scan-axis motor movements.
● The carriage chain assembly contains the 7 ink tubes to control the carriage component. It is designed to
allow a controlled bending radial while the carriage moves back and forth and also protects the ink tubes
and power/data lines housed inside. The following pictures show the cables/tubes distribution inside the
chain and in the carriage clamp. Note that the fiber-optics cable is routed independently through the lower
side of the clamp.

Theory of operation
Carriage movement
A belt is attached to each side of the carriage. The belt is driven by the scan-axis motor mounted on the right
side of the printer. On the left side of the printer, the scan-axis belt tensioner acts as a pulley support for the
belt, using a simple spring mechanism to maintain tension on the belt.
Belt tension
Force is applied to the belt by springs on the left side of the printer.

The scan-axis motor is a brushless motor powered with 42 V coming directly from a dedicated connector in the
e-cabinet PCA.
ENWW Impelling system 39

There is also a dedicated data cable coming from the e-box interconnect PCA. The scan axis encoder signal is
connected to the printhead interconnect board. See Figure 2-9 E-cabinet PCA on page 83 and Figure 2-17 E-
box on page 91 for details.

Pen to Rib Space (PRS)

Functionality
The scan-axis PRS system raises and lowers the complete top scan structure (including carriage, service station,
and printhead cleaning system) in order to place it at different heights, keeping the correct alignment between
the scan axis and the bottom structure before, during, and after these movements. When the scan structure is
higher than the normal printing position, the PRS has to withstand its weight.
This changes the distance between the substrate path and the carriage assembly, allowing the user to load
substrate and print on substrates of different thicknesses.
The PRS selectable positions are as follows:
● Normal printing position is the nominal printing position and is calibrated and set at the manufacturing line
at 2.3 mm (0.09 in). When the scan axis is in this position, the complete assembly is set onto the side walls.
● Custom position is used to print on the thicker substrate types. It is a customer-selectable setting.
● Loading position is the highest selectable position; it is used to load substrate. The default setting is 40 mm
(1.57 in). This movement can be cancelled.
● Ink collector position check the user guide.
Components
The PRS system is composed of two independent lifter assemblies, which work together in order to raise and
lower the printer’s top structure.
● Each lifter assembly is composed of the following parts:
ENWW Pen to Rib Space (PRS) 41

1. Lifter motor (linear actuator Linak LA23)
2. Column guide
3. Column shaft
4. Encoder strip assembly (linear encoder)
5. Encoder sensor assembly
6. Part of the column shaft
7. Top guide
8. Bottom support

● The PRS home position flag detects when its PRS unit has reached its lowest position, also known as the
homing position. The flags are located at both sides of the scan beam.
Theory of operation
The linear actuator Linak LA23 (linear motor) raises and lowers the top structure. The top structure is guided by
two column shafts.

The homing of the system (home position flag activated) is the movement that releases the load in the linear
actuator from the top structure weight. The top structure rests on contact surfaces in the bottom structure, it
defines the print position for flexible medias. It also represents the absolute zero.
Engage process
The engage movement is the process where the Linear Actuator starts to lift until it touches the scan beam, and
is ready to raise.
The home position is the normal printing position. Upwards movements to the higher printing positions can be
performed accurately.

Each PRS motor has its own Motor Drive PCA. The subsystem is powered with 24 V coming from the e-cabinet
PCA.

There is a data cable coming from the e-box Interconnect PCA to control the motors movement. This cable
arrives to the first Motor Drive PCA and the other lifter PCA’s are connected in series.
The liner encoder is a line counter used to position the PRS system. It is a signal control.

Ink system
Functionality
The Ink Supply Module (ISM) is located on the left side of the printer and delivers a continuous supply of ink to
the printheads. It tracks and determines when an ink cartridge needs to be replaced. The system is designed to
allow ink cartridge replacement while printing (hot swap).
Components
● Ink cartridges
● Printheads
● TRS
● The intermediate ink tanks, located at the left side of the ink system compartment.
● The air circuit module, located at the left side the intermediate tanks, provides the air pressure needed to
pressurize the intermediate ink tanks and send ink to the printheads.
● The air pressure bottle prevents cross-contamination of ink when a broken bag occurs inside an
intermediate ink tank. The bottle also works as a cushion device for the air pressurization system.
● The seven ink pumps, located at the back of each supply support, move the ink from the supplies to the
intermediate tank.
● The Evalves NO, located on the lower tray, manages the flow of ink to obtain precise pressure measures.
● Seven ink pressure sensors.PIP (pressure in printer)are used to measure the ink pressure in each ink line.
New service parts require a service procedure to enter calibration values manually.
● The ink cartridge connector set connects the ink system to the ink cartridges. The ink connectors also read
the acumen data from the cartridges, and can detect whether the connector is correctly inserted.
● There is one IDS INK PCA (Freya) board and one IDS AIR PCA (Paz) board controllling the entire ink system.
● One ink leakage sensor, located in the lower tray.
Theory of operation
Ink supply hot swap
The printer allows the user to change the ink cartridge while the printer is printing, as it is actually using the ink
stored in the intermediate tanks.
Intermediate tank operation

The intermediate tanks are constantly pressurized during printing to provide the correct ink flow to the
printheads.
Once the quantity of ink falls below a certain threshold, the printer calculates the amount of ink fired from the
printheads and resupplies the intermediate tank with ink, while at the same time the flow of ink to printheads is
maintained.

Low ink cartridge detection

The pressure sensor detects the pressure in the ink line. When the supply is finished, the pressure sensor
detects that there is no ink flowing from the supply and declares it as empty.
Control of ink to the intermediate tanks

When the ink pumps activate the ink flow from the supplies to the intermediate tanks, refilling them. When the
intermediate tanks are completely filled, there is an increase in pressure detected by the ink pressure sensors
and the refill stops. Each time the ink pressure sensor reads the pressure in the line, the Evalve NO closes for a
very short time in order to assure the accuracy of the measure.
Air system functionality: the intermediate tanks push the ink to the printheads
The system has two air pumps. The air pressure is distributed using an air bottle with air tubes going to the
tanks. Each tank has a bag inside that holds the ink. In order to send the ink to the printheads, the air pumps
push air into the enclosed space of the tanks around the bags to pressurize them and force ink out.
ENWW Ink system 47

The air pressure is constantly monitored by an air pressure sensor located on the IDS AIR PCA (Paz). The system
is able to depressurize with the relief valves located in the air system.
Intermediate tank broken bag detection

In the event of a broken bag in an intermediate ink tank, the ink system uses the air pressure bottle to prevent
cross-contamination of inks.
Pip sensor:
When a broken bag is detected by the sensor located inside the ink pressure sensor, the relief valve opens to
release the air pressure of the system. The ink goes at maximum flow and falls into the bottom of the bottle,
preventing cross-contamination of colors.
Air pressure system circuit:

Ink cartridge LED indicators
● Red: Connector connected to the cartridge, but communication problem with the Acumen. Cannot use the
cartridge.
● Orange blinking: Ink cartridge empty.
● White blinking: Filling intermediate ink tank or reading Acumen. Do not disconnect!
● White: Functioning correctly, no problem.
● No LED: Connector not connected.
ENWW Ink system 49


The ISM is powered with 24 V coming from the e-cabinet PCA. The power cables arrives at the ISM connection
panel, from which the power cable goes to the IDS INK PCA (Freya) located at the left side of the ISM behind the
IDS AIR PCA. The data cable comes from the e-box, interconnect PCA to the ISM connection panel, and then a
LAN cable goes to the IDS INK PCA (Freya). From there, the IDS AIR PCA (Paz) PCA is connected in series.

Carriage
Functionality
The carriage performs the actual printing on the substrate. It contains the printheads and printhead control
electronics, the printhead primer system, two arrays of aerosol extraction fans, the Scan Axis encoder sensor,
the line sensor, the sensor for the Day and Night accessory and the spectrophotometer.
Components
The picture below shows a top view of the carriage with its components. Note how the printheads are numbered
by the printer firmware. All related system errors use these numbers.
Theory of operation and component interconnection

Printheads
The printheads fire ink onto the substrate to perform the actual print. Each printhead is controlled by the
dedicated carriage printhead interconnect PCA.
● Each printhead contains two colors (except the optimizer).
● Each printhead prints a maximum swath width of 108 mm (4.25 in).
● The printheads have five dies, and each die has 2112 nozzles (10,560 total nozzles per printhead). The dies
are divided into two arrays of nozzles (1056 nozzles per array, one for each color).
There is one array of color printheads, three printheads in total, one of each type (C/K, M/Y, lc/lm). There is a
fourth printhead for the optimizer, which is fired before the colored inks, which has multiple benefits:
ENWW Carriage 51
● It helps to achieve print-quality requirements at a high throughput.
● It allows lower temperature, which in turn allows increased substrate versatility.
● It helps to achieve color consistency when tiling.
Primer assembly
Each printhead houses a primer assembly that is responsible for squeezing ink out of the printhead nozzles to
remove clogging and maintain printhead health.
Each primer assembly includes an air pump that pushes air into a bag inside the printhead regulator. When this
bag is inflated, the ink channel is opened, the ink pressure received in the printhead pushes the ink out of
printhead through the nozzles. This is called ‘priming’.
Carriage interconnect PCA
There is one Carriage Interconnect PCA located in the rear part of the carriage (covered by a sheet metal
enclosure with numbered holes that allows visibility of the LEDs in order to diagnose without enclosure
removal). It receives 42 V from the e-cabinet. It is responsible for:
● Distributing the required power to all the printhead interconnect boards (42 V).
● Powering the primer pumps (3V3 generated by the board).
● Connection with the SOL (the SOL sensor is also known as "colorimeter" and "spectrophotometer").

Carriage power management PCA board (aka vega)
There is one Carriage power management PCA located in the rear part of the carriage (covered by a sheet metal
enclosure). It is responsible for:
● Powering Carriage Interconnect and Carriage Fiber Optics (aka Slinky) PCAs.
● Powering aerosol extraction fans.
● Powering the primer pumps (3V3 generated by the board).
● Powering PCA cooling fan placed at the carriage rear right side.
Printhead interconnect boards
There are four printhead interconnect boards, one for each printhead. Each one receives 42 V from the carriage
interconnect board. They are responsible for:
● Generating the required voltage for each printhead.
● Sending control and printing data to printheads.
● Processing the line sensor signal (printhead interconnect 2) and the Day and Night accessory sensor
(printhead interconnect 1).
ENWW Carriage 53
● Controlling the printhead priming. Printhead interconnect 1 controls priming for printheads 1&4; printhead
interconnect 2 controls priming for printheads 2&3.
● The scan-axis encoder signal passes through printhead interconnect 1 and then goes to Carriage fiber-
optics PCA.
The are two types of printhead interconnect PCA, one for the color printheads (aka sepia) and a different one for
the Optimizer printhead (aka squid).
Printhead PCA support

● Printhead interconnect PCA covers
● Clips: 2 clips between the pen pocket and the board cover (in the case of removal/replacement of any of
the print-head interconnect PCAs, remove these clips to avoid damage to the PCA electrical connectors on
insertion/extraction)
Carriage fiber-optics PCA (aka slinky)

This PCA demultiplexes the printing data coming from the fiber-optics and sends the data to each printhead
interconnect board.
It receives 12 V from the AerosolPCA and it is connected to the fiber-optics coming from the box through the
dynamic chain.

Spectrophotometer (aka SOL)
The spectrophotometer is used to perform color calibrations. There is a control board (Sensors Interconnect PCA)
within the spectrophotometer assembly (The sensor is connected to this PCA and this PCA is connected to the
Carriage Interconnect PCA already mentioned above).
Line sensor (aka TETRIS)
The line sensor is used to:
● Detect the edge of the substrate.
● Detect printed line positions in order to perform various calibrations:
– Automatic printhead alignment
– Automatic substrate advance calibration
– Service station calibration
Day and Night sensor (accessory)
This sensor is physically the same as the line sensor but is used for a different application called Day and Night
(D&N); print an image on both sides of transparent/translucid substrate with good image registration on both
sides so the image can be illuminated from the rear at night and show live colors without a double image. When
printing the first side image some fiducials for later reference are included. Once the first side image is printed
ENWW Carriage 55
the output is loaded back into the input side so that the first images are underneath the new print side. The D&N
sensor now measures the position of the previously printed reference fiducials to then print the new image
exactly in position with the previously printed underneath image. The sensor can detect the fiducials since media
is transparent/translucid and is illuminated from below by a LED light array that is placed under the print platen.
Carriage encoder
The carriage encoder set reads the scan-axis encoder strip to determine the position of the carriage on the scan
axis. The scan-axis encoder signal passes through printhead interconnect 1 and then goes to the Carriage Fiber-
Optics PCA.
Aerosol fan assemblies and aerosol filters

There are two arrays of fans at both sides of the printheads. The fans and filters remove aerosol (ink particles)
from the print path to maintain good print quality and component health. The aerosol system is controlled and
powered by the Carriage power management PCA.
Carriage oiling foam retainers

The carriage oiling foams lubricate and clean the rods to make the carriage ball bearings that support the
carriage roll correctly (a perfect roll is the aim, but in practice microslippages occur between ball bearings and
rods, so the clean lubricating film avoids dry friction in the microslippages, and helps avoid wear and increases
roll system life).
There are four foams with scrapers (to move away dirt from bearing path). They are placed at the left and right
of the carriage for the front and the rear rod.


As the carriage is one of the main processing centers in the printer and contains the electronics for several
subsystems, all the above explanations refer to the carriage electric and electronic interactions.
See the subsystem block diagram for more details: Figure 2-12 Carriage Subsystem on page 86.
ENWW Carriage 57
Service station
Capping
Functionality
The service station capping is an assembly located on the right side of the printer. It is composed of one
platform, carried without motor and transmission. Movement comes from the carriage.
Capping is the process of sealing the printheads while they are not in use, to keep the printhead’s nozzles in
good condition.
Components
Capping station sled assembly
● The capping station sled assembly slides and moves the cap rail from the carriage movement.
● The printhead capping module is the mechanical part that seals the printheads.
Theory of operation
The capping procedure
The printheads must be sealed when they are not printing to prevent ink from drying and clogging the nozzles.
The capping procedure is as follows:

1. The printheads are capped by moving the capping station into position underneath the carriage.
2. The capping station moves until the capping module posts come into contact with the carriage bottom
base plate, underneath the printheads.
3. The upper part of the capping station rises into position (shown in red below), pushing the rubber caps up
to seal the printheads. The capping station is forced upwards, capping the printheads.
4. The service station continues to move, pushing the capping head up to seal the printheads.
NOTE: To manually move the carriage, the servo must be deactivated. This happens if the interlocks open
and/or the printer turns off.
NOTE: To return the carriage to homing position, reinitialize the carriage from the IPS.
ENWW Service station 59

Installation
1. Put the carriage into service position.
2. Compress the 4 snaps ready to inert them.
3. Insert making sure the pin enters into the hole.
4. Ensure the other pin enters correctly into the Slot.
5. Verify that the SK cap assembly is correctly positioned inside the sled.

Drop detection
Functionality
The drop detection station is an assembly located on the right side of the printer, in between the web wipe and
the capping station. It has its own motor and transmission.
Drop detection identifies possibly blocked nozzles, allowing the printer to apply the appropriate algorithms to
compensate and maintain print quality.
Components

Drop-detector platform
● The drop-detector motor and transmission is mounted under the drop detector base and drives the
assembly with a belt. It is controlled by an independent motor drive PCA.
● There is one drop-detector sensor for each printhead, each of which is connected to a Drop Detector PCA.
Each Drop Detector PCA is directly connected to the e-box engine PCAs
● The encoder strip and sensor are used during drop detection to ensure that the drops of ink are fired in the
correct place. The strip is located inside the base on the right hand side.
Theory of operation
Drop detection procedure
The drop detection platform system contains 4 drop-detector modules, one for each printhead. Each drop
detector has a window with an LED on one side and a photoreceptor on the other.
The printer sequentially fires drops of ink from each nozzle into the window, through the signal path. This
generates a disturbance in the signal that detects whether the nozzle was fired correctly or not.
Any nozzles that did not fire correctly three times in a row are then disabled, allowing the printer to compensate
and maintain print quality by using the other nozzles. This is the error-hiding algorithm.
The drop detection station motor is controlled through a motor PCA attached on the left bracket of the capping
station. This motor PCA receives 32 V from the e-box interconnect PCA.

There are 4 drop-detector PCAs. Each one has a dedicated flat cable coming from the e-box interconnect PCA.
Each PCA controls 1 drop-detector sensor.
The linear encoder signal goes to the 4 DD PCAs via a single cable.
See Figure 2-15 Drop Detector (SVS) on page 89.

Printhead cleaning system

Functionality
The printhead cleaning system is designed to clean the printheads and absorb ink during the priming and ink-
spitting procedures. The subsystem absorbs ink and cleans the printheads with a cloth roll that is impregnated
with non-volatile PEG liquid.
This roll is moved from an input (top roller) to an output collecting roller (bottom roller), while the cloth is
impelled by the advance of the delivery system pressed with the pinch roll, in a similar way to the substrate path.
There is a rubber blade that moves up and down, lifting the cleaner roll to ensure that the printheads make
proper contact with the cloth.
Components
● The input roll holds the new printhead cleaner roll before it is fed through the roll path. The input roll is
powered by its own motor to maintain uniform tension, and its encoder helps to calculate the remaining
amount of cloth on the roll.
The cleaner roll cores are easily fastened into place and removed using the blue lock at the cap holder.
● The output roll receives the used printhead cleaner roll. The output roll is also powered by its own motor to
maintain uniform tension, and its encoder helps to calculate the remaining amount of cloth on the input
roll.
The cleaner roll cores are easily fastened into place and removed using the blue lock at the cap holder.
● The printhead cleaner roll is moved through the roll path by the drive roller. The pinchwheel mechanism
presses the roll against the drive roller to ensure good contact. The drive roller includes teeth that grip the
roll to help pull it through the path. The drive roller is powered by the advance motor through a gearbox
system.

The pinchwheel mechanism must be opened and closed in order to load and unload a roll. It is important to
ensure that the pinchwheels are correctly closed, otherwise the printer may report false substrate jams
and/or printhead crashes.
● The rubber wiper moves up and down, lifting the cleaner roll to ensure that the printheads make proper
contact with the cloth.
The up/down motion has two main positions. The engage position is the upper position calibrated for
correct printhead cleaning operation, and the disengage position is the lower resting position of the rubber
wiper.
● Each of the four motor systems has its own PCBoard to control its behavior and movement:
– Advance motor and advance motor encoder
– Input motor and input motor encoder
– Output motor and output motor encoder
– Engage motor and engage motor encoder
Theory of operation
Printhead wipe
A printhead wipe is a printhead cleaning procedure in which the rubber wiper is set to the correct height, and the
carriage passes over the printhead cleaner, from right to left, without stopping (but making contact and being
cleaned).
This routine can be done before or after printing, and also while printing:
● If an image printing is larger than 152 cm (60 in), a dynamic wipe is performed every two swaths.
● If the image is smaller than that, a dynamic wipe is performed every four swaths.
When printing, this routine is performed every two swaths: that is, every time the carriage is over the cleaning
assembly.
Spitting
In order to ensure the good health of the nozzles, the carriage is moved over the printhead cleaning assembly,
and the system performs a spitting operation in which all the nozzles spit a small amount of ink over the surface
of the wiping cloth. There are two spitting modes:
One spit is performed:
ENWW Printhead cleaning system 65

● On the right, every time the carriage is over the cleaning assembly, after wiping.
● On the left, every time the carriage is over the left spitoon
Priming
Priming is performed in order to ensure good nozzle health and to prevent the nozzles from becoming blocked
with dried ink. Ink floods out of the printhead onto the wiper cloth. This procedure can be performed by selecting
the option in the Internal Print Server.
The priming procedure is also performed on new printheads once they are installed, or when a hard cleaning is
launched from the Internal Print Server.

The printhead cleaning roll subsystem is powered with 32 V coming from the e-cabinet PCA. There is a LAN data
cable that comes from the e-box interconnect PCA to the first motor drive PCA and from there the four PCAs are
connected in series.

Drying
Functionality
The drying system provides controlled heat to the substrate while it is over the print zone, to evaporate water
from the ink vehicle. Together with the latex optimizer, this heat helps in the dot fixing to prevent bleed and
coalescence.
Heat is provided by hot airflow from chambers located inside the scanbeam.
Components
Components are placed on the scanbeam. The drying system is composed of two symmetrical modules
centered in the scanbeam.
Each drying module has the following components:
● 1 drying pressure chamber
● 4 fans
● 4 heaters
● 12 diffusers
● 4 temperature sensors
ENWW Drying 67
Each drying module is controlled though a dedicated drying enclosure PCA located at the carriage tower. Two AC
power cables come from the e-cabinet AC converters to the drying PCAs (one of them over the scan beam
through the dynamic chain) to power each of the modules.
For more information see the block diagram Figure 2-16 Drying Subsystem on page 90.
Theory of operation
The substrate over the print is heated by forced convection, its power level is regulated in close-loop mode. Each
one of the modules is controlled independently and the PWM level can be set individually.
Sensors placed in chambers are used for monitoring and operating temperature.

All the power and data cables for the drying subsystem come from the e-box and e-cabinet over the scanbeam.
The drying heaters are powered with AC power coming from the AC/AC converters. Each drying PCA is powering
two different drying chambers. The drying fans are powered with 24V coming from the drying PCA.
For more information see the block diagram Figure 2-16 Drying Subsystem on page 90.

Figure 2-5 Drying closure PCA 3 and 4. IDS Side
Figure 2-6 Drying enclosure PCA 1 and 2. Service Side
ENWW Drying 69
Curing
Functionality
The curing system provides controlled heat and airflow to the ink and substrate after the print zone. This causes
the latex particles to coalesce and form a continuous film on the substrate. Ink pigments are encapsulated inside
this film.
The complete module can be moved horizontally to allow substrate loading. Two latches fix the module in the
printing position.
The lower beam can be also considered as part of the vapor removal system as it collects vapors coming from
curing process that condense into a waste bottle located inside the ISM. For more details of the vapor removal
system, see the vapor removal section.
Components
The curing system is composed of 6 base modules.
Each base module has the following components:
● 2 heater/fan assemblies

● 2 temperature sensors
● 1 curing PCA, with 2 pressure sensors
ENWW Curing 71
● 1 perforated plate
Each heater/fan assembly is controlled independently, so that the system has 12 functional chambers.
Theory of operation
The temperature of each of the 12 air chambers is controlled by means of a closed-loop system that adjusts the
power provided to the heater to reach the target temperature. This hot air passes through the perforated plates
located at the rear of each base module and reaches the ink on the substrate to allow film formation.
The air is recirculated to reduce power consumption. However, a net airflow exists from the print zone to the
lower beam to collect excess vapor. See the vapor removal section for more details.
The following picture shows the cross section of a base module:
During the warm-up phase, extra power is applied to the heaters and the airflow is set to the minimum. During
the cool-down phase, the heaters are turned off and the airflow is set to the maximum.
Each heater/fan module has a safety thermostat to avoid overheating. The thermostat opens at 110°C and its
state is monitored by the PCA. Apart from the heater power and temperature monitoring, each fan has
independent power control and diagnosis through the curing PCA. The air pressure is monitored inside each
functional chamber to ensure that the system is working correctly.
The base modules turn on and off automatically, depending on the substrate width, to optimize power
consumption by the system.


Curing Module Clamps
The HP Latex 1500’s clamps to open and close the curing module are located beneath the window:
Closed:
Open (curing module opened):
To open the curing module,the window needs to be raised first.
CAUTION: Before you close the front window, ensure that the clamps are closed and the curing module is in
place.
Power and control per module
Two power cables are connected to each curing PCA (six PCAs in total):
ENWW Curing 73
● One AC cable to power the heaters (two heaters per module)
● One DC cable to power the fans (two fans per module)
Each resistor-fan assembly is connected to the PCA with two cables, the AC for the resistor and the DC for the
fan.
One data cable arrives to each module to control it.
Two temperature sensors (one per chamber) are connected to each curing PCA.
Each curing PCA has a 24 V fan to keep it refrigerated.
Power and control for the whole subsystem
Power (DC and AC) and data cables enter and exit each curing PCA to connect all six in series.
The curing cable routing is as follows:
AC power
Three AC cables come from the e-cabinet back panel to the entrance connector of the subsystem. From there:
● One AC cable goes to Curing PCA 1. Curing PCAs 1 and 4 are connected in series.
● The second AC cable goes to Curing PCA 2. Curing PCAs 2 and 5 are connected in series.
● The third AC cable goes to Curing PCA 3. Curing PCAs 3 and 6 are connected in series.
DC power
Two DC cables come from the e-cabinet PCA to the entrance connector of the subsystem. From there:
● One DC cable goes to Curing PCA 1. Curing PCAs 1, 2, and 3 are connected in series.
● The other DC cable goes to Curing PCA 4. Curing PCA 4, 5, and 6 are connected in series.
Data
One LAN cable comes from the e-box interconnect to module 1. From there all the modules are 00connected in
series.

Vapor removal
Functionality
The vapor removal system removes, condenses, and collects the low-volatile co-solvents (VOCs) evaporated
during the curing process in a controlled way. This provides a comfortable working environment and prevents
uncontrolled condensations on the printer elements, thus maintaining printer performance and reliability.
Components
The system is composed of the following elements:
● Curing lower beam
● Heat exchanger
● Impaction filter (demister pad)
● Vacuum blower
● Waste bottle
● Silencer
ENWW Vapor removal 75

Theory of operation
The curing beam is designed with a pattern of decreasing holes to extract the same airflow along the length of
the beam. The vapor is driven through the interior of the curing lower beam by a vacuum pump located in the
ISM. Some of the VOCs condense by wall contact along the beam, but mainly through a heat exchanger and
demister pad located in the ISM. The condensates are driven to a 10 l container (waste bottle) through a drainage
system.

The heat exchanger is composed of 4 fans that blow ambient air through the airflow coming from the curing
beam. This lowers the temperature of the airflow and causes its condensation.
After the heat exchanger, there is a demister element to get rid of the high mass particles, which may still be
airborne, by impaction. Those particles, together with the condensate formed in the plates of the exchanger, are
drained into a bottle.
The exhaust air temperature should be similar to the ambient temperature to avoid any visible vapor formation
leaving the control system.


The vapor removal pump is powered with AC power coming from the e-cabinet PCA. Note that the AC power is
not distributed through the e-cabinet PCA, so the power cable comes from a connector in the e-cabinet back
panel. The blower is controlled by the vapor removal vacuum PCA, which is connected to the e-box interconnect
with a data and a power cable. A power transformer in the e-cabinet ensures that the power is correctly supplied
to the vapor removal pump.
The 24V cable to power the fans goes from the e-cabinet PCA to the ISM connection panel. The control data
cable goes from the e-box interconnect PCA to the ISM connection panel.
The PCA data and power cables are connected from the ISM connection panel to the vapor removal PCA. The
blower power cable is connected from the ISM connection panel to the blower. The subsystem is controlled in an
open loop, providing constant PWM.
For more information see the block diagram Figure 2-21 TUR (Pinch Switch & SLIT SOL) and VR Subsystems
on page 95.

Printer status beacon

The Printer Status Beacon is an intuitive light signaling system to quickly identify the status of the printer from a
distance. It is connected to the IPS PC.
Subsystem block diagrams

The following pages show the electrical and electronic subsystem block diagrams:
● Figure 2-7 E-cabinet on page 81
● Figure 2-8 PS e-cabinet terminal blocks installation on page 82
● Figure 2-9 E-cabinet PCA on page 83
● Figure 2-10 E-stops and Interlocks on page 84
● Figure 2-11 E-stops and Interlocks (MR version only) on page 85
● Figure 2-12 Carriage Subsystem on page 86
● Figure 2-13 Curing Subsystem on page 87
ENWW Printer status beacon 79

● Figure 2-14 Printzone + Day and Night LEDs and Beacon Subsystems on page 88
● Figure 2-15 Drop Detector (SVS) on page 89
● Figure 2-16 Drying Subsystem on page 90
● Figure 2-17 E-box on page 91
● Figure 2-18 IDS (Ink Delivery System) on page 92
● Figure 2-19 PPS Subsystem on page 93
● Figure 2-20 SA, Media Path, OMAS and Vacuum Subsystems on page 94
● Figure 2-21 TUR (Pinch Switch & SLIT SOL) and VR Subsystems on page 95
● Figure 2-22 WW Subsystem on page 96
● Figure 2-23 Motor drive PCA on page 97

ENWW
[16mm2] [16mm2] [16mm2] AC-14AWG ACB-4
K-1 L307
PPS MOTOR CONTROL
L305
3
6x WDU16 RCD-1..3
N105 N113
40A/30mA GABI
1
L306
OR L3 2 1 4
L3 L300 L300 L302 L302 L304 L305
7
L301 L303
2 N105
ACB-5
1 3
L2 L2 L200 L200 4 3 L202 N106
L307
N104
L205
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5
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4
L203
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L1 6 5 L207 L207
L100 L100 L102 4
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N112 N112 AC
1
N 8 7 2
N1 N100 N136 N107
1 3
1
N108
N101 RCD-2
L0 33 34 L102 L104
K2-A1 K2-A11
23 24
K-2 L113-1 4
Molex 43938-2101
N0 K1-24 L106
K1-23 N102 N137
1 63A 1 2 N110
AC-14AWG Male pins
1 3
ACB-1 N132-1
M8 PE STUD A1 A2 S W2-D1 RCD-3 [2.5mm2]
L1M
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S W2-D2
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ACB-6
L113 L113-1
N1M
5 L306
20A
N102 6
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N100 1 AC-12AWG
N103 L308 L308
7 8 [4mm2] N106 N114 N114
1
L208 Curing
TB-11 ACB-7 N115 AC
33 34
L108 Curing
1x WDU16 23 24 K2-24
20A N116
K2-23
1 Phase 3
L206 L208
3
wires 100-240V Molex 43938-2101
A1 A2 K2-A2
TB-10
K2-A11 N108 N115
Curing
1
AC-14AWG ACB-8
B R_Feedback
[2.5mm2]
[2.5mm2] 20A
L106 L108 FRE N-
S AX-B RK -
S AX-B RK +
N116 FRE N+
B R_Contactor
M4 PE STUD N110
1
S AX-B RK -
DC-16AWG
[1.5mm2]
S AX-B RK +
1 24V PSU
[4mm2] [1.5mm2] [4mm2] CONN3
24V P SU-LP S +
AC-14AWG GND P SU-LP S -
[2.5mm2] Housing
PSU-8
Molex
L1M
N1M
39-01-2026
AC-14AWG Pins:
1 3
ACB-2 TB-2 [1.5mm2] 2x WDU 2.5 2x 39-00-0082
10A 2 4 6x WDU16 L-3
L301
L-2 TB-3
L201 1
L-IE C2
N-D&N
N-IE C1
N-IE C2
L-IE C1
L-D&N
L101 L303 L312 L312
4x TWISTED PAIRS
L-1 L313
L109
N101 N128 N128 N130

1 N119
K2-24
L203 L213 L213 L214 K2-23
K1-24
K1-23
N129 N129 N131 FRE N+
FRE N-
J53
Contactors
AC-12AWG
L103 L-P UM PS
L-D&N [4mm2]
D&N N103 N-P UM PS
N-D&N 1 TB-5
System P E-D&N AC-14AWG
~400W [2.5mm2]
Laird TWISTED PAIR
6xWDU4 28A2736-0A2
L119 24V PSU
IEC-5 P SU-6 N
28A0807-0A2
N125
2xWQV4 [2.5mm2] PE P SU6 +
L113 L114 P E- P SU6 P SU6
24V P SU6 -
AC-12AWG
N132 N133 GND PSU6
L-IE C1 [4mm2] Short connection to
IPS P E-IE C1
28A2736-0A2
CN1
L115 L115 L119
ALM + ON/OFF
L116 P SU6
CTRL
N120 P SU6
N120
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600W
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L117 L117 L120

IEC-1 PSU-6
L118 PSU-5
N121 N126
L-IE C2 N123 TWISTED PAIRS
Laird [2.5mm2]
L109 L110 L110 L111
L112 28A2736-0A2 DC-10AWG [6mm2]
IPS P E-IE C2
24V PSU Laird
N119 N122 L
1 P SU-7
N124 N126 N
Screen P SU7 +
P E- P SU7 PE 24V P SU7
L116 L121 P SU7 -
N-IE C2
M4 PE STUD GND
N134 N135 PSU7
L-IE C3 L118
N-IE C3 N123 28A2736-0A2
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** FUSES ** ** FUSES ** CTRL P SU7

ALM + ON/OFF
L-IE C4 L112 600W P SU7
AC-14AWG FP1: 8A#~5x20 FP11: 8A#~5x20
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[2.5mm2] N-IE C4 N124

FP2: 8A#~5x20 FP12: 8A#~5x20 PSU-7
PSU-6
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L111 L
Laird
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WQV 4 FP5: 8A#~5x20 FP15: 4A#~5x20 P SU-2
TWISTED PAIR
L-P UM PS
28A0807-0A2
N-P UM PS
P E- P SU2 PE
FP6: 8A#~5x20 24V P SU2 +
P SU2
FP16: 4A#~5x20 P SU2 -

FP17: 4A#~5x20 PSU2
FP8: 8A#~5x20 FP18: 4A#~5x20 TDK
ACB+RCD
FP9: 8A#~5x20 FP19: 2A#~5x20 600W CTRL
FP10: 8A#~5x20 FP20: 2A#~5x20 PSU-2
L-IE C3
RCBO-1 AC-14AWG
P E-IE C3 28A2736-0A2 32V PSU
HPPN: K4T88-80258 L313 L
N130 P SU-3 Laird
N
4
2
P E- P SU-3 28A0807-0A2
PE
N-IE C3
32V P SU3 +
P SU3
P SU3 -
[2.5mm2] DC-10AWG [6mm2]
L-TF1
L-TF2
N-TF2
N-TF1
300W
L-IE C4
AC-14AWG PSU-3
Aux
P E-IE C4 Laird [2.5mm2]
28A2736-0A2
L214 L
P SU-1 42V PSU Laird
N-IE C4 N131 N
P E- P SU1 28A0807-0A2
PE
P SU1 +
42V P SU1
IEC-4
Trafo #1 P SU1 -

eCabinet PCA

AC-14AWG Pump TDK
Laird
240V
230V
220V
210V
200V
Com.
CN1
600W P SU1
TWISTED PAIRS 7x WDU4 CTRL P SU1
ALM + ON/OFF
CN3

AC-14AWG
2xZQV4/2 [2.5mm2] DC-22AWG [0.34mm2]
[2.5mm2]
L-P J1
Laird TWISTED PAIRS
28A2736-0A2 Laird
L114 L 42V PSU
AC-14AWG TF-1 P SU-5 N
28A0807-0A2
N133
TF1-240V 42V P SU5 +
P E- P SU5 PE P SU5
[2.5mm2] 240V P SU5 -
TF1-230V GND PSU5
230V L-P UM P1
Short connection to
[0.34mm2] TF1-210V
210V 28A2736-0A2
CN1
TF1-200V P SU5
Trafo #2 200V 600W P SU5
CTRL ALM + ON/OFF
Vacuum Pump
CN3

P Y1 L4-X1
P ump #1

3x WDU4 28A0807-0A2
0V TF1-N1 Laird P SU4 +
P E- P1
[2.5mm2]
L-P1
3
L-TF1
N-TF1
X1
N-P1
L-P J1
L-P UM P1
1x WPE4 28A2736-0A2 24V PSU P SU4 -
P SU4
eS TOP-
DC-22AWG [0.34mm2] L121 L
S FW - eS TOP+ P SU-4 24V
K2-A2
S R-A2
N135
PSU4
S R-A1
eS TOP+
K2-A1
P E- P SU4
X2
TWISTED PAIRS PE GND DC-10AWG [6mm2]
4
S FW – eS TOP- 1xZQV4/2
P E- TF1
240V
230V
220V
210V
200V
Com.
Laird
CN1
L4-X2
TDK ALM + ON/OFF
1 AC-14AWG PSU holder screw P SU4
P Y2
P SU4
TB-8 [2.5mm2] 600W CTRL
CN3
1x WDU 2,5
FT-13
FT-13
TF1-N2
DC-22AWG [0.34mm2]
TF1-N1
P E- TF1
L-P J2
4x WDU 2.5 (1-2) PSU-4
GND
24V
TF-2 TWISTED PAIRS
IL _FB
TF2-240V
** FUSES ** L4-X1
Int erlock -
Int erlock +
E STO P_FB
E N Light
S W2-D2
L4-X2
S W2-D1
P Y1
P Y2
L5-X1
235V
S R-A1
S R-A1+
TF2-230V
FT-21: 2A#5x20 J42
225V DC-22AWG [0.34mm2]
TF2-220V FT-22: 2A#5x20
200V TWISTED PAIRS
L5-X1
FT-23: 2A#5x20
13 23 33 41
127V L-P UM P2
A1 Y1 Y2 FT-24: 2A#5x20
110V S AFE TY
A SS Y
J44
Safety Relay L-5 P ump #2

220VA
Int erlock – S FW1
A2 14 24 34 42 0V TF2-N1 Int erlock – S FW2
P E- P2
J48
L-P2
L-TF2
N-TF2
N-P2
L-P J2
L-P UM P2
L5-X2
P E-LE FT Int erlock – S FW3
Int erlock – S FW4 J50
L5-X2
P E- TF2
Int erlock – S FW6 PCA-1
S R-A1+
S W2-A2
S R-A2
J51
S R-14-34
S R-14-34
S W2-A2
1
FT-21 FT-22 FT-23 FT-24
FA N
M6 M6
DC-22AWG
FT-23
FT-21
DC-AWG22 [0.34mm2]
FT-23
FT-21
TF2-N2
TF2-N1
P E- TF2
V CC -FA N
GND-FA N
DC-22AWG
FA ULT-FA N
DC-22AWG [0.34mm2]
TWISTED BUNDLE
Interlock DOOR
chain
Front door1
Int erlock -
Loading table
Int erlock +
FAN-2 FAN-1
AC-14AWG
[2.5mm2]
Tyco 350767-1
Female pins
L-P1
V AP OR
N-P1
P UM P
P E- P1
L-P2
V ACUUM
N-P2
P UM P
P E- P2
eCabinet
Tyco 350767-1
Male pins
Lyra PS Rev.12 eCabinet

Apr. 2016

Figure 2-7 E-cabinet
81
ENWW Chapter 2 Printer systems 82
Abr. 2016
N0 N0
N0 1 N0 1
L0 L0 2 L0 L0 2
TB-1
N N1 3 N1 3
L1 L1 4 L1 L1 4
L2 L2 5 L2 L2 5
FROM WQV16
L3 6 L3 6
L3 L3
N0 1 N0 1
2
1
L0 2 L0
1
N N1 3
1
N1 3
3
L1 L1 4 L1 L1 4
L2 L2 5 L2 L2 5
L3 6 L3 6
L3 L3
Star
Delta
Lyra – PS eCabinet
Terminal blocks installation
6 L3 6 L3
5 5
4
4 L2 4 L2
7
6
3 3
4
2 L1 2 L1
1 N1 1 N1
6 L3 6 L3
5 5
FROM WQV16
4 L2 4 L2
6
3 3
4
2 L1 2 L1
1 N1 1 N1
6 L3 6 L3
TB-2 + TB-3 + TB-4
5 5
4
4 L2 4 L2
6
3 3
4
2 L1 2 L1
1 N1 1 N1
Figure 2-8 PS e-cabinet terminal blocks installation
ENWW
[16mm2] [16mm2] [16mm2] AC-14AWG ACB-4
K-1 L307
PPS MOTOR CONTROL
L305
3
6x WDU16 RCD-1..3
N105
40A/30mA N113
GABI
1
L3 4 L306
OR L3 L300 L300 2 1 L302 L302 L304 L305
7
L301 L303
2 N105
ACB-5
1 3
L2 L2 L200 L200 4 3 L202 N106
L307
N104
L205
5
6
RCD-1 20A N113
3
OR L201 L203
L1 6 5 L207 L207
L100 L100 L102 4
3
N112 N112 AC
1
N 8 7 2
N1 N100 N136 N107
1 3
1
N108
N101 RCD-2
L0 33 34 L102 L104
K2-A1 K2-A11
23 24
K-2 L113-1 4
Molex 43938-2101
N0 K1-24 L106
K1-23 N102 N137
1 63A 1 2 N110
AC-14AWG Male pins
1 3
ACB-1 N132-1
M8 PE STUD A1 A2 SW2-D1 RCD-3 [2.5mm2]
L1M
50A
N132 1 2 N132-1
SW2-D2
3 4
ACB-6
L113 L113-1
N1M
5 L306
20A
N102 6
3
N100 1 AC-12AWG
N103 L308 L308
7 8 [4mm2] N106 N114 N114
1
L208 Curing
TB-11 ACB-7 N115 AC
33 34
L108 Curing
1 Phase 3 1x WDU16 23 24 K2-24
20A N116
K2-23
L206 L208
3
wires 100-240V Molex 43938-2101
A1 A2 K2-A2 TB-10
K2-A11 N108 N115
Curing
1
AC-14AWG ACB-8
BR_Feedback
[2.5mm2]
[2.5mm2] 20A
L106 L108 FREN-
SAX-BRK-
SAX-BRK+
N116 FREN+
BR_Contactor
M4 PE STUD N110
1
SAX-BRK-
DC-16AWG
[1.5mm2]
SAX-BRK+
1 24V PSU
[4mm2] [1.5mm2] [4mm2] CONN3
24V PSU-LPS +
AC-14AWG GND PSU-LPS -
[2.5mm2] Housing
PSU-8
Molex
L1M
N1M
39-01-2026
AC-14AWG Pins:
1 3
ACB-2 TB-2 [1.5mm2] 2x WDU 2.5 2x 39-00-0082
10A 2 4 6x WDU16 L-3
L301
L-2 TB-3
L201 1
L-IEC2
N-D&N
N-IEC1
N-IEC2
L-IEC1
L-D&N
L101 L303 L312 L312
4x TWISTED PAIRS
L-1 L313
L109
N101 N128 N128 N130

1 N119
K2-24
L203 L213 L213 L214 K2-23
K1-24
K1-23
N129 N129 N131 FREN+
FREN-
J53
Contactors
AC-12AWG
L103 L-PUMPS
L-D&N [4mm2]
D&N N103 N-PUMPS
N-D&N 1 TB-5
System PE-D&N AC-14AWG
~400W [2.5mm2]
Laird TWISTED PAIR
6xWDU4 28A2736-0A2
L119 24V PSU
IEC-5 PSU-6 N
28A0807-0A2
N125
2xWQV4 [2.5mm2] PE PSU6 +
L113 L114 PE- PSU6 PSU6
24V PSU6 -
AC-12AWG
N132 N133 GND PSU6
L-IEC1 [4mm2] Short connection to
IPS PE-IEC1
28A2736-0A2
CN1
L115 L115 L119 ALM + ON/OFF
L116 CTRL PSU6
N120 PSU6
N120 N125
600W
N-IEC1
M4 PE STUD N134
CN3
L117 L117 L120
PSU-6
IEC-1 L118 PSU-5
N121 N126
L-IEC2 N123 TWISTED PAIRS
Laird [2.5mm2]
L109 L110 L110 L111
L112 28A2736-0A2 DC-10AWG [6mm2]
IPS PE-IEC2
24V PSU Laird
N119 N122 L
1 PSU-7
N124 N126 N
Screen PSU7 +
PE- PSU7 PE 24V PSU7
L116 L121 PSU7 -
N-IEC2
M4 PE STUD GND
N134 N135 PSU7
L-IEC3 L118
N-IEC3 N123 28A2736-0A2
CN1
** FUSES ** ** FUSES ** CTRL PSU7

ALM + ON/OFF
L-IEC4 L112 600W PSU7
AC-14AWG FP1: 8A#~5x20 FP11: 8A#~5x20
CN3
[2.5mm2] N-IEC4 N124

FP2: 8A#~5x20 FP12: 8A#~5x20 PSU-7
PSU-6
Laird
L111 L
Laird TWISTED PAIR
WQV 4 FP5: 8A#~5x20 FP15: 4A#~5x20 N127 PSU-2 N
28A0807-0A2
L-PUMPS
N-PUMPS
PE- PSU2 PE
FP6: 8A#~5x20 24V PSU2 +
PSU2
FP16: 4A#~5x20 PSU2 -

FP17: 4A#~5x20 PSU2
FP8: 8A#~5x20 FP18: 4A#~5x20 TDK
ACB+RCD
FP9: 8A#~5x20 FP19: 2A#~5x20 600W CTRL
FP10: 8A#~5x20 FP20: 2A#~5x20 PSU-2
L-IEC3
RCBO-1 AC-14AWG
PE-IEC3 28A2736-0A2 32V PSU
HPPN: K4T88-80258 L313 L
N130 PSU-3 Laird
N
4
2
PE- PSU-3 28A0807-0A2
PE
N-IEC3
32V PSU3 +
PSU3
PSU3 -
[2.5mm2] DC-10AWG [6mm2]
L-TF1
L-TF2
N-TF2
N-TF1
300W
L-IEC4
AC-14AWG PSU-3
Aux
PE-IEC4 Laird [2.5mm2]
28A2736-0A2
L214 L
PSU-1 42V PSU Laird
N-IEC4 N131 N
PE- PSU1 28A0807-0A2
PE
PSU1 +
42V PSU1
IEC-4
Trafo #1 PSU1 -

eCabinet PCA

AC-14AWG Pump TDK
Laird
240V
230V
220V
210V
200V
Com.
CN1
600W PSU1
TWISTED PAIRS 7x WDU4 CTRL PSU1
ALM + ON/OFF
CN3

AC-14AWG
2xZQV4/2 [2.5mm2] DC-22AWG [0.34mm2]
[2.5mm2]
L-PJ1
Laird TWISTED PAIRS
28A2736-0A2 Laird
L114 L 42V PSU
AC-14AWG TF-1 PSU-5 N
28A0807-0A2
N133
TF1-240V 42V PSU5 +
PE- PSU5 PE PSU5
[2.5mm2] 240V PSU5 -
TF1-230V GND PSU5
230V L-PUMP1
Short connection to
[0.34mm2] TF1-210V
210V 28A2736-0A2
CN1
TF1-200V PSU5
Trafo #2 200V 600W PSU5
CTRL ALM + ON/OFF
Vacuum Pump
CN3

PY1 L4-X1
Pump #1
3x WDU4 28A0807-0A2
0V TF1-N1 Laird PSU4 +
PE- P1
[2.5mm2]
L-P1
3
L-TF1
X1
N-TF1
N-P1
L-PJ1
L-PUMP1
1x WPE4 28A2736-0A2 24V PSU PSU4 -
PSU4
eSTOP-
DC-22AWG [0.34mm2] L121 L
SFW - eSTOP+ PSU-4 24V
K2-A2
SR-A2
N135
PSU4
SR-A1
eSTOP+
K2-A1
X2
TWISTED PAIRS PE- PSU4 PE GND DC-10AWG [6mm2]
4
SFW – eSTOP- 1xZQV4/2
PE- TF1
240V
230V
220V
210V
200V
Com.
Laird
CN1
L4-X2
TDK ALM + ON/OFF
1 AC-14AWG PSU holder screw PSU4
PY2
TB-8 PSU4
[2.5mm2] 600W CTRL
CN3
1x WDU 2,5
FT-13
FT-13
TF1-N2
DC-22AWG [0.34mm2]
TF1-N1
PE- TF1
L-PJ2
4x WDU 2.5 (1-2) PSU-4
GND
24V
TF-2 TWISTED PAIRS
IL_FB
TF2-240V
** FUSES ** L4-X1
Interlock-
Interlock+
ESTOP_FB
EN Light
SW2-D2
L4-X2
SW2-D1
PY1
PY2
L5-X1
235V
SR-A1
SR-A1+
TF2-230V
FT-21: 2A#5x20 J42
225V DC-22AWG [0.34mm2]
TF2-220V FT-22: 2A#5x20
200V TWISTED PAIRS
L5-X1
FT-23: 2A#5x20
13 23 33 41
127V L-PUMP2
A1 Y1 Y2 FT-24: 2A#5x20
110V SAFETY
ASSY
J44
Safety Relay L-5 Pump #2

220VA
Interlock – SFW1
A2 14 24 34 42 0V TF2-N1 Interlock – SFW2
PE- P2
J48
L-P2
L-TF2
N-TF2
N-P2
L-PJ2
L-PUMP2
L5-X2
PE-LEFT Interlock – SFW3
Interlock – SFW4 J50
Interlock – SFW5
L5-X2
PE- TF2
Interlock – SFW6
SR-A1+
PCA-1
SW2-A2
J51
SR-A2
SR-14-34
SR-14-34
SW2-A2
1
FT-21 FT-22 FT-23 FT-24
FAN
M6 M6
DC-22AWG
FT-23
FT-21
DC-AWG22 [0.34mm2]
FT-23
FT-21
TF2-N2
TF2-N1
PE- TF2
VCC-FAN
GND-FAN
DC-22AWG
FAULT-FAN
DC-22AWG [0.34mm2]
TWISTED BUNDLE
Interlock DOOR
chain
Front door1
Interlock – SFW1
Interlock – SFW2
Interlock-
Loading table
Interlock+
Interlock – SFW3
Interlock – SFW4
FAN-2 FAN-1
Interlock – SFW5
AC-14AWG
Interlock – SFW6
[2.5mm2]
Tyco 350767-1
Female pins
L-P1
VAPOR
N-P1
PUMP
PE- P1
L-P2
N-P2 VACUUM
PUMP
PE- P2
eCabinet
Tyco 350767-1
Male pins
HP Latex 1500 PS
Rev.12 eCabinet

Figure 2-9 E-cabinet PCA
83
84
eSTOP 3 eSTOP 4
Rear Left Rear Right
eCAB TB8-3
eSTOP4-1 eSTOP4-2 eSTOP-
eSTOP3-2 TB8-3
eSTOP3-1
K4T88-50253 K4T88-50254 TB8
K4T88-50167 K4T88-50168 TB8-1
eSTOP3-2 SFW eSTOP4-1 SFW eSTOP4-2 SFW
eSTOP3-1 SFW eCAB TB8-1
3 4 eSTOP- SFW
Interlock 3
(Loading Table)
Chapter 2 Printer systems

J44
ILOCK3-2 ILOCK3-1
K4T88-50169 ECABINET PCA
(K4T88-60441)
ILOCK3
ECAB INTERLOCK 1
K4T88-50247 INTERLOCK 1
J48
FW: Interlock1_fb
3 4
eCAB ILOCK- TB8-4 TB8-4

TB8
2 1
eCAB ILOCK+ TB8-3 TB8-3
K4T88-50252
Interlock 2 Interlock 1
(Window) (Window)
K4T88-50166
ILOCK2-1 ILOCK1-2 ILOCK1-1
ILOCK2-2
K4T88-50170 K4T88-50246
ECABINET PCA
K4T88-50171 (K4T88-60441)
ILOCK1 eCAB INTERLOCK 2

K4T88-50172 J50 INTERLOCK 2
FW: Interlock2_fb

J51
FW: Interlock3_fb
eCAB TB8-2
eSTOP2-2 SFW eSTOP2-1 SFW eSTOP1-2 SFW eSTOP1-1 SFW eSTOP+ SFW TB8-2
K4T88-50165 K4T88-50164 TB8
K4T88-50251 K4T88-50250
TB8-2
eSTOP2-2
2 eSTOP2-1 eSTOP1-2
1 eSTOP1-1 eCAB
TB8-2
eSTOP+
eSTOP 2 eSTOP 1
Front Left Front Right
12V DC Cable LABEL eCabinet
24V DC
32V DC
42V DC
220V AC
DATA
HP Latex 1500 – eSTOPs & INTERLOCKS
ENWW
Figure 2-10 E-stops and Interlocks
eSTOP 3 eSTOP 4
ENWW
Rear Left Rear Right
eCAB TB8-3
eSTOP4-1 eSTOP4-2 eSTOP-
eSTOP3-2 TB8-3
eSTOP3-1
K4T88-50253 K4T88-50254 TB8
K4T88-50167 K4T88-50168 TB8-1
eSTOP3-2 SFW eSTOP4-1 SFW eSTOP4-2 SFW
eSTOP3-1 SFW eCAB TB8-1
3 4 eSTOP- SFW
Interlock 3
(Loading Table)
J44
ILOCK3-2 ILOCK3-1
(K4T88-60441)
ILOCK3
ECAB INTERLOCK 1
J48
FW: Interlock1_fb
3 4
eCAB ILOCK- TB8-4 TB8-4

TB8
2 1
eCAB ILOCK+ TB8-3 TB8-3
K4T88-50252
Interlock 1
(Window)
K4T88-50166
ILOCK1-2
ILOCK1-1
(K4T88-60441)
K4T88-50171

K4T88-50172 J50 INTERLOCK 2
FW: Interlock2_fb
J51 INTERLOCK 3
FW: Interlock3_fb
eCAB TB8-2
eSTOP2-2 SFW eSTOP2-1 SFW eSTOP1-2 SFW eSTOP1-1 SFW eSTOP+ SFW TB8-2
K4T88-50165 K4T88-50164 TB8
K4T88-50251 K4T88-50250
TB8-2
eSTOP2-2
2 eSTOP2-1 eSTOP1-2
1 eSTOP1-1 eCAB
TB8-2
eSTOP+
eSTOP 2 eSTOP 1
Front Left Front Right
12V DC Cable LABEL
24V DC eCabinet
32V DC
42V DC

220V AC
DATA
HP Latex 1500 – eSTOPs & INTERLOCKS
Figure 2-11 E-stops and Interlocks (MR version only)
85
86
TETRIS SENSOR 2
(K0Q45-60085) front
TETRIS 2
KAT88-50162
FIBER OPTICS PCA

(CZ056-60360) P4 – KAT88-50015
(SLINKY) P3 – KAT88-50015
P2 – KAT88-50015
PH1 PH2 PH3 PH4

FALCON FALCON FALCON FALCON
J18 (FO) K4T88-50019 FO PCA PH2 J8 PH - OPT PH - CK PH - YM PH - LmLc
PH2 J6

FO PCA PH3 J10 PH OPT PCA
PH COLOUR PCA
FO PCA PH1 J11 PH1 J13 PH OPT PCA (CZ056-60002) PH COLOUR PCA PH COLOUR PCA PH COLOUR PCA
FO PCA PH4 J9 (CZ056-60016) (CZ056-60016) (CZ056-60016)
P1 – KAT88-50016 J13 J6 J13 J13
FW ID FW ID FW ID FW ID
J6 Horus6 J13
PH OPT PCAPH1 J6 3 0 1 2
eBox Horus7 Horus0 Horus2 Horus4
J9
J8
J10
J11
Horus1 Horus3 Horus5
J18 (FO) Primer Assy Primer Assy Primer Assy Primer Assy
K4T88-60376 K4T88-60376 K4T88-60376 K4T88-60376
TETRIS SENSOR 1
KAT88-50009
J2
J5
J5
J2
J5
J2
J7
J2
J5
(K0Q45-60085) rear
P2 J24
FO PCA J26
P2
P3
TETRIS 1
Solenoid
K4T88-60379
Primer
K4T88-60380
Solenoid
K4T88-60379
Primer
K4T88-60380
Solenoid
K4T88-60379
Primer
K4T88-60380
Solenoid
K4T88-60379
Primer
K4T88-60380
PH COLOUR PCA PH3 J13

J26

FIBER OPTICS PCA (CZ056-60360) PRIMER
PRIMER PCA PH3 J5 PRIMER
PH COLOUR
PCA PH3 J5
PH COLOUR
PH COLOUR
PCA PH4 J2
PRIMER PH4
PCA PH3 J2
PH COLOUR
DAY & NIGHT PH2 PH3

[Y/M]
PH1
[C/K]
[OPT]
ACCESSORY
PCA PH2 J5
PH COLOUR
Optical Encoder
PH COLOUR
PCA PH2 J2
PH OPT PCAPH1 J5
Assy K4T88-60186 (with D&N LED BAR)
K4T88-50003
PH OPT PCAPH1 J2
K4T88-50008 K4T88-50004
ECABINET PCA (K4T88-60441)
Optical sensor PN 1990-1512
include cable K4T88-50001
K4T88-50010 K4T88-50005
K4T88-50001
K4T88-50004
K4T88-50003
K4T88-50008
K4T88-50003
ECAB 42V CARR

K4T88-50004
K4T88-50003
42V CARR P1 KAT88-50014

CARRINT J30
CARR POWERPCA J17 CARRINT J26

K4T88-50239
CARRINT J15
CARRINT J1
K4T88-50240
CARRINT J34
CARRINT J13
CARRINT J33
CARRINT J7
CARRINT J2
CARRINT J9
CARRINT J11
CARRINT J27
CARRINT J28
CARRINT J14
P2
P3
SOL ENCLOSURE
P1
Aerosol
AEROSOL (spectrophotometer)
Fan Assy 2 FAN
K0Q45-60064 CARRIAGE
J1
J9
J2
J7
J14
J26
J30
J34
J13
J33
J15
J11
J28
J14
J27
eCabinet
B
K4T88-50068 AEROSOL CARRIAGE INTERCONNECT
CARR POWER FAN 2 Q6702-50003
PCA (CZ056-60155)
PCA
AEROSOL SOL
CARR POWER
FAN 1 Interconnect
PCA K4T88-50248 PCA
K4T88-50068 (Q6702-60181)
Aerosol
Fan Assy 1
A J16
K0Q45-60064 SOL SENSOR
AEROSOL J36 K4T88-50136
CARR
B FAN
POWER
CARRIAGE CARRINT J36
PCA J16
CARR POWERPCA J3 CARR INT J32
J3 P2 P1 J32
Cooling Fan J17
K4T88-50143
K0Q45-60174 CARRIAGE POWER

(incl. cable
K4T88-50145) MANAGEMENT PCA
(KOQ45-60057) P3 J35
J1 P1
CARR INT J35
CARR POWER PCA J1
12V DC Cable LABEL K4T88-50020
24V DC Carriage
32V DC
42V DC
220V AC
DATA
HP Latex 1500 – Carriage Subsystem
ENWW
Figure 2-12 Carriage Subsystem
ENWW
Curing
GND
Cables
CZ056-50019 CZ056-50019 CZ056-50019

K4T88-50091
6x CZ056-50124 6 x CZ056-50213
CZ056-50219 CZ056-50219
24V_IN 24V_OUT 24V_IN 24V_OUT 24V_IN 24V_OUT

J11 J16 J7 AC_IN J11 J16 J7 AC_IN J11 J16 J7 AC_IN
J13
J13
J8 24V J8 24V J8 24V J13
24V_FAN_CURING
24V_FAN_CURING
24V_FAN_CURING
ID 1 ID 2 ID 3
SVS side
AC_IN_Link J3 AC_IN_Link J3 AC_IN_Link J3
EBOX INTERCONNECT PCA
(CZ056-60005) J12 CURING PCA J12 CURING PCA J12 CURING PCA
(CZ056-60008) (CZ056-60008) (CZ056-60008)
CURING PCA
ID1 J12 24V AC 24V AC 24V AC
FAN Heater FAN Heater FAN Heater
Curing J1 J1 J1
eBox J261 Curing
J14
J13
J10
J14
J13
J10
J14
J13
J10
J261_CAN KAT88-50128
P1
P1
P1
P1
P1
P1
CZ056-50183 CZ056-50183
CZ056-50183
CZ056-50281 CZ056-50121 CZ056-50121
CZ056-50121
CZ056-50281
CZ056-50281
CZ056-50231
FAN PCA FAN PCA FAN PCA
P3
P3
P3
P3
P2
P2
P2
P2
P3
P3
P2
P2
eBox CZ056-80381 CZ056-80381 CZ056-80381
(include cable) (include cable) (include cable)
CZ056-50218
CZ056-50218
CZ056-50218
Temp Temp Temp Temp Temp Temp

Sensor Sensor Sensor Sensor Sensor Sensor
CZ056-60068CZ056-80068 CZ056-60068CZ056-80068 CZ056-60068CZ056-80068
Fan/Heater Assy Fan/Heater Assy Fan/Heater Assy Fan/Heater Assy Fan/Heater Assy Fan/Heater Assy
eCab AC Curing K4T88-60210 K4T88-60210 K4T88-60210 K4T88-60210 K4T88-60210 K4T88-60210
AC K4T88-50123
Aerial AC Curing
CZ056-50019 CZ056-50019
CZ056-50232
eCab Curing-1
24V P2 CZ056-50219 CZ056-50219
P1
K4T88-50124
24V_IN 24V_OUT 24V_IN 24V_OUT 24V_IN 24V_OUT
24V P3 Aerial DC Curing J11 J16 J7 AC_IN J11 J16 J7 AC_IN J11 J16 J7 AC_IN
J13
J13
J13
eCab Curing-2
CAN Termination
J27
eCabinet J8 24V J8 24V J8 24V 1258-0283
24V_FAN_CURING
24V_FAN_CURING
24V_FAN_CURING
ID 4 ID 5 ID 6
AC_IN_Link J3 AC_IN_Link J3 AC_IN_Link J3
J12 CURING PCA J12 CURING PCA J12 CURING PCA

(CZ056-60008) (CZ056-60008) (CZ056-60008)
IDS side
24V AC 24V AC 24V AC

FAN Heater FAN Heater FAN Heater
J1 J1 J1
J14
J13
J10
J14
J13
J10
J14
J13
J10
P1
P1
P1
P1
P1
P1
Addressing CZ056-50183 CZ056-50183 CZ056-50183

- Set on aerial cable connected to J13. CZ056-50281 CZ056-50281
- Jumper cable cut ’1' CZ056-50121 CZ056-50121 CZ056-50121
- Jumper cable ‘0’ CZ056-50281

- A0 is the LSB FAN PCA FAN PCA FAN PCA
P3
P3
P3
P3
P3
P3
P2
P2
P2
P2
P2
P2
CZ056-80381 CZ056-80381 CZ056-80381

- ‘001’ refers to ID 1 (‘000’ not accepted’) (include cable) (include cable) (include cable)
- ‘111’ refers to ID 7
- Example: ‘011’ PCA ID 3
Temp Temp Temp Temp Temp Temp
Sensor Sensor Sensor Sensor Sensor Sensor
J13
CZ056-60068CZ056-80068 CZ056-60068CZ056-80068 CZ056-60068CZ056-80068
Fan/Heater Assy Fan/Heater Assy Fan/Heater Assy Fan/Heater Assy Fan/Heater Assy Fan/Heater Assy
W_A2 ‘0’ K4T88-60210 K4T88-60210 K4T88-60210 K4T88-60210 K4T88-60210 K4T88-60210
24V_FAN_CURING
W_A1 ‘1’
W_A0 ‘1’
Curing
12V DC Cable LABEL

24V DC
32V DC
42V DC
220V AC
HP Latex 1500 – Curing Subsystem #6 #5 #4 #3 #2 #1
DATA

Figure 2-13 Curing Subsystem
87
88
BEACON LIGHT BEACON
(K4G10-60138)
IPS SEMAPHORE
1
K4T88-50289
3
K4T88-50290
IPS
BEACON AERIAL BEACON AERIAL

2
(CZ056-60005)

EEBox J471 VAC
J471 K4T88-50189 TUR
PPA J471 LED BOX J5 eCabinet-for-LED (P4P91-60014)
P4P91-50001 J5
3 x LED BAR (OUTPUT LIGHTS)
EEBox J371 VAC 3 (J8J14-60005)
LED BOX J3
LED BOX J4
J371 K4T88-50118 Vacuum J3 P4P91-50004 OL LED BAR1
J4
LED BOX J7
PPA J371
J7
J1
P4P91-50002
OL LED BAR2
P4P91-50003
MOTOR DRIVE PCA
Right side MOTOR DRIVE
(Q6702-60953)
LED BAR (DUAL SIDE) LED bar PCA J3 D&N
eBox Micci Bus
(P4P91-60018) 2 P2 J1Termination
P4P91-50005 P4P91-50003 P1 J3 1254-3650
8121-0795 Luna PCA Right MicciBus 21 OL LED BAR3
Side LED bar D&N LED BAR
P4P91-50006
ID 7
left side P2 J4
Luna PCA left LED bar
(P4P91-60019)
Side LED bar P2 J1
DAY & NIGHT LEDS (ACCESSORY) MOTOR DRIVE OUTPUT LIGHTS (ACCESSORY)
PCA J1 D&N
CZ056-50016
eCab PZ Connect the

LEDS Micci Bus
MOTOR DRIVE MOTOR DRIVE PCA Termination
LPS PSU Termination
PCA P2 TUR (Q6702-60953) if D&N not
1254-3650
DIN TUR MOTOR DRIVE PCA J1 PZ connected
CZ056-50019 J1 P2 J1
eCabinet MOTOR DRIVE
K4T88-50243 PCA J3 PZ
J3 MicciBus 21
MOTOR DRIVE
PCA J3 PZ MOTOR DRIVE
ID 6
PCA J4
LUNA Addressing J4 A K4T88-50244

PPS
- Brown A0 PRINTZONE LEDS D&N LED BUTTON MEDIALOAD
BUTTON B C D
- Red A1 BUTTON
- Orange A2
- Blue A3
LED BAR (PRINTZONE)
- Jumper cable cut  ’1' K4T88-50243 1 (K4T88-60296)
- Jumper cable  ‘0’
- A0 is the LSB
- ‘0001’ refers to ID 1 (‘000’ not accepted’)
PZ LED BAR
- Example: ‘0011’  PCA ID 3
PRINTZONE LEDS DAY & NIGHT LEDS PPS MEDIA LOAD
BUTTON BUTTON BUTTON
(K4T88-60409) (K4T88-60409) (K4T88-60410)
12V DC Cable LABEL PRINTZONE LEDS
24V DC
32V DC
42V DC
220V AC
DATA
HP Latex 1500– PRINTZONE + DAY & NIGHT LEDs and BEACON Subsystems
ENWW
Figure 2-14 Printzone + Day and Night LEDs and Beacon Subsystems
ENWW
DD 1 DD 2 DD 3 DD 4
Assy. K4T88-60163 Assy. K4T88-60163 Assy. K4T88-60163 Assy. K4T88-60163
DROP DETECTOR DROP DETECTOR DROP DETECTOR DROP DETECTOR
P1
P2
P3
P4
DD 1 K4T88-50013 K4T88-50013 DD 4
DD 2 DD 3 Encoder Assy
CZ056-60278
K4T88-50013 P5
LE Encoder
eCAB SVS K4T88-50013 K4T88-50013

32V SVS Aerial 1
LE
P10
Assy include cable
Aerial 1
K4T88-50151
DM2 CH1
DM1 DM3 CH1 DM 4 CH1
DM1 CH1 K4T88-50151 K4T88-50151
DM4
DM2 DM3
eCabinet
P6
P7
P8
P9
P2
P3
P4
P5
DropMux DropMux DropMux DropMux
J1
J1
J1
J1
P1
P1
P1
P1
PCA #1 PCA #2 PCA #3 PCA #4
P1 J5 P1 J5 P1 J5 P1 J5
(CZ056-60005) DROP MUX PCA #1 DROP MUX PCA #2 DROP MUX PCA #3 DROP MUX PCA #4
(CZ056-60013) (CZ056-60013) (CZ056-60013) (CZ056-60013)
Fusion 1 – CK Fusion 2 – YM Fusion 3 – LmLc Fusion 4 – OPT

eBox J131 DD K4T88-50154 (Flat Cable Twisted)
(Engine PCA 1) (Engine PCA 3) (Engine PCA 2) (Engine PCA 4)
J131
eBox J331 DD
J331 K4T88-50154 (Flat Cable Twisted)
eBox J231 DD
ODD
eBox J431 DD
(Optical Drop Detector)

MOTOR DRIVE PCA Bump switch Assy
(Q6702-60953) MOTOR DRIVE (CZ056-60301)
PCA J4 DD Bump switch
MOTOR DRIVE K4T88-50142 c Switch
eBox J152 DD PCA J4 DD MicciBus xx
J_152 K4T88-50155 J4
ID 2 J4 A K4T88-50142
Assy include cable
J3 A MOTOR DRIVE
Micci Bus PCA J3 DD
Termination P2
eBox 1254-3650
K4T88-50142 A
K4T88-50227 K4T88-50142 DD Motor DD Motor
12V DC Cable LABEL AERIAL 2 AERIAL 2 (K4T88-60016)
24V DC Drop Detector (SVS)
32V DC
42V DC
220V AC
DATA
HP Latex 1500 – Drop Detector (SVS)

Figure 2-15 Drop Detector (SVS)
89
90
K4T88-50030
Q6703-50031
#8 #7 #6 #5 #4 #3 #2 #1 PCA ID1
PCA ID2
DRYING PCA ID1 J11 DRYING PCA ID1 J16 DRYING PCA ID1 J7 DRYING PCA ID2 J11 DRYING PCA ID2 J7
24V_IN 24V_OUT 24V_IN 24V_OUT
J11 J16 J7 AC_IN J11 J16 J7 AC_IN
PCA ID3
PCA ID4
J13
J13
J8 24V DRYING PCA ID1 J3 J8 24V
24V_FAN_CURING
24V_FAN_CURING
ID 1 ID 2
AC_IN_Link J3 AC_IN_Link J3
J12 DRYING PCA J12 DRYING PCA

DRYING PCA ID1 J12 (K4T88-60386) DRYING PCA ID2 J12 (K4T88-60386)

DRYING PCA ID1 J1 24V AC DRYING PCA ID2 J1 24V AC
FAN Heater FAN Heater
J1 J1
J14
J13
J10
J14
J13
J10
K4T88-50224 DRYING PCA ID1 K4T88-50038 DRYING PCA ID2
P1
P1
P1
P1
DRYING PCA ID1 J10 DRYING PCA ID2 J10

J13 J13
TEMP1 K4T88-50226 TEMP1 K4T88-50041
EBOX INTERCONNECT K4T88-50225 K4T88-50044
PCA(CZ056-60005) TEMP2 FAN2 HEATER2 TEMP2 FAN2 HEATER2
FAN1 FAN1
eBox J161 HEATER1 HEATER1
Drying FAN PCA
P3
P3
P3
P3
P2
P2
P2
P2
CZ056-80381
J161_CAN KAT88-50033 (include cable)
Temp Temp
Sensor Sensor
K4T88-80027 K4T88-80027
Temp Temp
Sensor Sensor
#1 K4T88-80027 #1 #2 #3 K4T88-80027 #3 #4
eBox
#2 Fan/Heater Assy Fan/Heater Assy #4 Fan/Heater Assy Fan/Heater Assy
K0Q45-60080 K0Q45-60080 K0Q45-60080 K0Q45-60080
Module 1&2 (SVS)
ECABINET PCA (K4T88-60441) KAT88-50035
KAT88-50031
eCAB DS-1
K4T88-50030
24V (J2) KAT88-50032
Q6703-50031
Aerial 4 DRYING PCA ID3 J11 DRYING PCA ID4 J11

DRYING PCA ID3 J7 DRYING PCA ID4 J7
AC K4T88-50163 K4T88-50029
Aerial 4 24V_IN 24V_OUT 24V_IN 24V_OUT
J11 J16 J7 AC_IN J11 J16 J7 AC_IN
J13
J13
eCAB AC
Drying
CAN Termination
J27
eCabinet J8 24V DRYING PCA ID3 J3 J8 24V 1258-0283
24V_FAN_CURING
24V_FAN_CURING
ID 3 ID 4
AC_IN_Link J3 AC_IN_Link J3
J12 DRYING PCA J12 DRYING PCA

Addressing DRYING PCA ID3 J12 (K4T88-60386) (K4T88-60386)
- Set on aerial cable connected to J13. 24V AC DRYING PCA ID4 J1 24V AC
DRYING PCA ID3 J1 FAN Heater FAN Heater
- Jumper cable cut ’1' J1 J1
- Jumper cable ‘0’
J14
J13
J10
J14
J13
J10
K4T88-50037 K4T88-50036
DRYING PCA ID3 DRYING PCA ID4
- A0 is the LSB J10 J10
P1
P1
P1
P1
- ‘001’ refers to ID 1 (‘000’ not accepted’) DRYING PCA ID3 DRYING PCA ID4
J13 J13
- ‘111’ refers to ID 7 TEMP2 TEMP2
K4T88-50040 K4T88-50039
- Example: ‘011’ PCA ID 3 K4T88-50043 K4T88-50042
TEMP1 FAN1 FAN2 HEATER2 TEMP1 FAN1 FAN2
HEATER1 HEATER1 HEATER2
FAN PCA
P3
P3
P3
P3
P2
P2
P2
P2
CZ056-80381
J13
Temp (include cable) Temp
Sensor Sensor
W_A2 ‘0’ K4T88-80027 K4T88-80027
Temp Temp
24V_FAN_CURING
W_A1 ‘1’ Sensor Sensor
W_A0 ‘1’ K4T88-80027 #6 #5 #6 K4T88-80027 #8 #7 #8
#5 Fan/Heater Assy Fan/Heater Assy
#7 Fan/Heater Assy Fan/Heater Assy
K0Q45-60080 K0Q45-60080 K0Q45-60080 K0Q45-60080
12V DC Cable LABEL

Module 3&4 (IDS)
24V DC
Drying
32V DC
42V DC
220V AC
DATA
HP Latex 1500 – Drying Subsystem
ENWW
Figure 2-16 Drying Subsystem
ENWW
TUR
PRINTZONE
VACUUM DAY & sensors
IDS LEDS
PCA NIGHT switch
VR fans TUR
LEDS
CARRIAGE eBox
K4T88-50118 K4T88-50189
P2 P1
K4T88-50019 (FO) eBox

P6 P5 physical
connection
to PHs
FIBER OPTICS PCA (CZ056-60360) K4T88-50286
P4 P3 K4T88-50106 K4t88-50287 CZ056-50163
Cooling Fan
CZ056-80269
includes cable J18 (FO)
This cable contains the K4T88-50259
address for Slinky on x P7 K4T88-50260
J26 the ebox
Not
J9
J8
J17
J11
J16
J10
J15
J14
J24 CZ056-50221 connected
PH1 PH3 PH4 PH2

OPT YM LmLc CK
ENGINE PCA 1 (K4T88-60085) ELA ENGINE ADAPTOR PCA1
J4 CZ056-50001 JT1 (CZ056-60332)
PCIE1X5
Board2Board conector PCI CONN
SYSFAN1
(SLOT 1) GpioFusion1 J_302 K4T88-50102
J_381 CAN
J_371 PWR
J_262 CAN
GpioEla1
J_471 PWR
J_481 CAN
Board2
J_351 MICCI2
J11 Board JP1 Encoder
FORMATTER PCA J8 CZ056-50001 JT2 conn ENC J_321 K4T88-50110
MI
J22
OMAS
(CZ056-60330) J20 JT3 PWR_IN
J_301 K4T88-50104
ENGINE PCA 2 (K4T88-60085) ELA ENGINE ADAPTOR PCA 2
J4 CZ056-50002 JT1 (CZ056-60332)
MA
PCIE1X4
(SLOT 3) GpioFusion3 GpioEla3
Board2 J_303 K4T88-50103
J11 Board JP1
J8 CZ056-50002 JT2 conn
J22
Encoder
OMAS
J20 JT3 PWR_IN Ebox INTERCONNECT PCA ENC J_322 K4T88-50109
PPA MO
CZ056-50252
(CZ056-60005)
J4 CZ056-50133 JT1 (CZ056-60332)
PCIE1X3
(SLOT 2) GpioFusion2 J_101 CZ056-50045
GpioEla2
Board2
J11 Board JP1 SAX
J8 CZ056-50133 JT2 conn
J22
OMAS
J20 JT3 PWR_IN
J_261 CAN K4T88-50128 CURING

PCIE1X2 J4 CZ056-50134 JT1 (CZ056-60332)
(SLOT 4)
GpioFusion4 GpioEla4 J_161 CAN K4T88-50033 DRYING
PCIE1X1 Board2
(SLOT 5) J11 Board
J_341 I2C
JP1
J_431 ODD
J_331 ODD
J_231 ODD
J_131 ODD
J8 CZ056-50134 JT2 conn

J_151 MICCI2
J_152 MICCI2
J_251 MICCI2
LAN
SATA 1
J20 JT3 PWR_IN SPI4 SPI2 SPI3 SPI1
MURALYRA
(K4T88-60086) eBox J341
CQ105-50010
IPS (PSU)
Picolit
HDD 746177-002
691917-002
CZ056-50222 (CZ056- CZ056-50003
K4G10-50013
60516)
K4T88-50154
eBOX
K4T88-50154
K4T88-50154
K4T88-50154
K4T88-50114
K4T88-50155
K4T88-50236
8121-1044
8121-0796
eCab eBox
8121-0796
K4T88-50413
ISS LAN ISS LAN
12V DC WW DD PPS DD
24V DC ECABINET PCA
Cable LABEL
eCabinet (K4T88-60441)
32V DC
42V DC
IPS eCabinet
220V AC
DATA
HP Latex – eBox

Figure 2-17 E-box
91
92
BLACK CYAN MAGENTA YELLOW Light CYAN Light MAGENTA OPTIMIZER
BISON
Acumen
2.X
Pumps Assy Pumps Assy Pumps Assy Pumps Assy Pumps Assy Pumps Assy Pumps Assy
Electrovalve 1 Electrovalve 1 (G2W18-64001) (G2W18-64001) (G2W18-64001) (G2W18-64001) (G2W18-64001) (G2W18-64001) (G2W18-64001)
(K0Q45-60241
Acumen (K4T88-50291)
(CZ056-60005)
Presence Sensor (K4T88-50292)


Electrovalve 2 Electrovalve 2 P2 P3 P4 P5 P6 P7 P8
(K0Q45-60241
P2
P2
P3
P3
P4
P4
P5
P5
P6
P6
P7
P7
P8
P8
eBox J481 IDS

Black 0 Cyan 1 Magenta 2 Yellow 3 Light Optimizer 6
J_481 CAN Light

Electrovalve 3 Cyan 4 Magenta 5
Electrovalve 3
(K0Q45-60241

K4T88-50286
Electrovalve 4 Electrovalve 4
(K0Q45-60241
Electrovalve 5 Electrovalve 5 K4T88-50177 External View (IDS front view)

(K0Q45-60241
K4T88-50179 Black Cyan Magenta
K4T88-50089
Line 0 Line 1 Line 2
K4T88-50178
Electrovalve 6 Light Light
Electrovalve 6 Yellow
eBox Cyan Magenta
Line 3 PIP sensor Assy (B4H70-60052)
(K0Q45-60241 Line 4 Line 5
Optimizer
Line 6 PIP PIP PIP PIP PIP PIP PIP
IDS INK IDS INK IDS INK Black Cyan Magen Yellow Lc Lm OPT
Electrovalve 7
PCA J16 PCA J13 PCA J2 ta
(K0Q45-60241
P2 P3 P4 P5 P6 P7 P8
IDS INK PCA J7 P1 P1 P1
Electrovalve 7
J16 J13 J2 Black 0 Cyan 1 Magenta Yellow Light Light Pre-
2 3 Cyan 4 Magenta treatment
IDS-VR J7 IDS INK 5 6
Interconnect PCA J14
K4T88-50090
IDS
Panel Interconnect J14 P1 K4T88-50176
IDS
Panel J4 IDS INK PCA (K0Q45-60153)
Interconnect
Panel IDS INK PCA J4 J15 LEAKAGE SENSOR
K4T88-50148 IDS INK Leakage Sensor (Q6702-50061)
J8
IDS INK PCA J9 J1 PCA 15 K4T88-50180
K4T88-50017 K4T88-50026 J10 JTAG CONNECTOR
IDS IDS INK PCA J10
J11
Interconnect IDS
Panel Interconnect
ECABINET PCA (K4T88-60441) Panel IDS INK PCA J11
4 x LED array
K4T88-50183 (0..3)
(K0Q45-60155)
IDS AIR PCA J2
IDS ECAB IDS IDS AIR PCA 4 x LED array
(4..7)
J2
(K0Q45-60112)
(K0Q45-60155)
2 x Air Pump (K4T88-60362) Air Pump 1
E
B
C
D
Temperature Pressure
Air Pump 2 sensor sensor LED PCA 0 LED PCA 3
E
B
C
D
eCabinet LED PCA 1 LED PCA 2 LED PCA 4

IDS AIR PCA J6 LED PCA 7
1 X Relief Valve (K4T88-60361) K4T88-50021 J6 A K4T88-50061
IDS AIR PCA J7 LED PCA 5 LED PCA 6
J7 A K4T88-50147
J4 IDS AIR PCA J15
IDS AIR PCA J10 BROKEN BAG 0
Relief Valve JTAG CONNECTOR J15 A K4T88-50237 B BROKEN
J10 IDS AIR PCA J14 BROKEN BAG 1 BAG
J14 A K4T88-50238 C
BROKEN BAG 4 BROKEN BAG 2 0-3
B BROKEN D
BROKEN BAG 5 BAG BROKEN BAG 3
C E
12V DC Cable LABEL BROKEN BAG 6 4-6
D
24V DC IDS
32V DC
42V DC
220V AC
DATA
HP Latex 1500 – IDS (Ink Delivery System)
ENWW
Figure 2-18 IDS (Ink Delivery System)
ENWW
(CZ056-60005)
Right Side (SVS) Left Side (IDS)
MOTOR DRIVE PCA #1 MOTOR DRIVE PCA #2

MOTOR DRIVE MOTOR DRIVE MOTOR DRIVE
(Q6702-60953) (Q6702-60953)
eBox J251 PPS PCA #1 J1 PPS PCA #1 P2 PPS PCA #2 J1 PPS
Micci Bus
J_251 MICCI2 P1 K4T88-50236 P2 J1 P2 K4T88-50235 P2 J1 P2 J1Termination
1254-3650
MicciBus xx MicciBus xx
P2 B K4T88-50055 P3 B K4T88-50230
Aerial A J3 A J3
Aerial ID 1 MOTOR Aerial
MOTOR
ID 2
DRIVE
DRIVE PCA P2 J4 PCA #2 P2 J4
MOTOR DRIVE MOTOR DRIVE
eBox #1
PCA #1 J3 PPS PCA #2 J3 PPS
MOTOR DRIVE MOTOR DRIVE
PCA J4 PPS PCA J4 PPS
LUNA Addressing LIFTER LIFTER

- Brown A0 (Motor + Encoder) (Motor + Encoder)
- Red A1 K4T88-60402 K4T88-60402
- Orange A2
- Blue A3
Encoder Encoder
- Jumper cable cut ’1' K4T88-50056 P1 K4T88-50056 P1
- Jumper cable ‘0’
Motor encoder Motor encoder
- A0 is the LSB
- ‘0001’ refers to ID 1 (‘000’ not accepted’) Motor Motor
- ‘0111’ refers to ID 7 B P2 B P2
K4T88-50054 Lifter Motor
Lifter Motor
PPS AERIAL PPS AERIAL

J2-2 J3-1
K4T88-50231 K4T88-50230
K4T88-50055 K4T88-50232
PPS AERIAL
K4T88-50054 J3-2
ECABINET PCA (K4T88-60441) PPS AERIAL
J2-1
C
A
A
C
eCab PPS
C
B
C
B
24V (J1) K4T88-50054

PPS SAFETY
PCA J2 K4T88-50234 K4T88-50234
ECAB CONTACTOR 1L1 PPS SAFETY
K4T88-50233 PCA J3
A
A
ECAB CONTACTOR 2T1

TB-9 ECAB CONTACTOR 3L2
J2
J3
ECAB CONTACTOR 4T2

PPS SAFETY PCA
(K4T88-60370)
PPS SAFETY
eCabinet PCA J1 P1 J1
12V DC Cable LABEL

24V DC PPS
32V DC
42V DC
220V AC
DATA
HP Latex 1500 – PPS Subsystem

Figure 2-19 PPS Subsystem
93
94
LED BOX J5 eCabinet-for-LED
J5
(J8J14-60013) CZ056-60175
(AM 80 OMAS EE ASSY)
DAY & NIGHT
EBOX INTERCONNECT PCA VACUUM CONTROL PCA OMAS Controller PCA
(CZ056-60005) eBox J371 VAC VAC PCA P4 (CZ056-60156) (CQ869-60170)
OMAS sensor
J_371 PWR K4G10-50003 K4T88-50118 P4 VAC PCA J3 OMAS CTRL P4 Assy
J3 (ENCODER) CZ056-50038 P4 (ENCODER) (CZ056-60173)
eBox J371 eBox J371 VAC
VAC PCA J2 Pressure
VAC PCA P3 OMAS CTRL P2
eBox J381 VACUUM VACUUM sensor P3 (CAN) CZ056-50039 P2 (CAN) CZ056-50202
J_381 CAN K4T88-50106 J2
P1 CZ056-50040 P7 (POWER)
P5 VAC PA P1 OMAS CTRL P7
EBOX J101 SAX
J_101 VAC PCA P5 J1 (ENCODER)

EBOX J302 MI VAC CTRL J1
J_302 K4T88-50117
EBOX J321 MI Vacuum

J_321 Pump
(3160-4238)
OMAS
VAC PUMP
CONTROL
EBOX J303 MO
J_303
CZ056-50036
EBOX J322 MO
VAC PUMP
J_322 CZ056-50114
VACUUM
J_301
SAX Motor
EBOX J301 MA SAX Brusless Motor Assy GND braid
K4T88-50185
eBox (K4T88-80031) CZ056-50213
K4T88-50102 SAX Motor
K4T88-50110
VAC PUMP
K4T88-50103 MI Motor
MI Brusless Motor Assy
ECAB VAC PUMP K4T88-50109 (K4T88-60346)
MI ENC
K4T88-50104 encoder
KAT88-50264
eCab TB10-3/4 BR Feedback
TB10-4 MI Motor
TB10-3 KAT88-50261 SAX brake
TB-10 A2 A1
TB10-2 eCab TB10-1/2 BR contactor R3 (K4T88-50249) MO Motor
TB10-1 MO Brusless Motor Assy
SAX RESISTOR OUT K4T88-50156 (K4T88-60346)
J53 MO ENC
SAX KAT88-50157 IN OUT encoder
ECAB SAX SAX RESISTOR IN R4
MI RESISTOR OUT
ECAB MI
MI KAT88-50158 IN OUT K4T88-50187 MO Motor
MI RESISTOR IN
CZ056-50130
ECAB MO MO RESISTOR IN MA Motor MA Brushless Motor Assy
MO KAT88-50160 IN OUT K4T88-50188 (CZ056-60167)
MO RESISTOR OUT MA ENC
analog encoder
CZ056-50130
MA K4T88-50186
ECAB MA MA Motor
eCabinet SAX & MEDIA PATH (MI – MA – MO)
12V DC Cable LABEL

24V DC
32V DC
42V DC
220V AC
DATA
HP Latex 1500 – SA & Media Path & OMAS & VACUUM Subsystems
ENWW
Figure 2-20 SA, Media Path, OMAS and Vacuum Subsystems
MOTOR DRIVE PCA J1 PZ
ENWW
CZ056-50019
PZ LEDs
EBOX INTERCONNECT PCA MOTOR DRIVE

MOTOR DRIVE PCA
(CZ056-60005) PCA P2 TUR
(Q6702-60953)
Not
MOTOR DRIVE PCA J1 TUR Connected
P2 I
J_351 MICCI2 K4T88-50190 P2 J1
MicciBus 21
A
P1
J3
(A) ID 5
eBox J262 VR SOL SLIT solenoid J4 A CZ056-50170
(C8926-60399) MF
J_262 CAN TOP
K4T88-50161 WINDOW MA PINCH LEVER PINCH
TUR PCA MF LATCH
Not LEVER
Connected B C
C
eBox J471 G F D Not
E Not
eBox J471 TUR SOL SLIT J A Connected
5V IN Connected
5V Not
J471 H
12V A eBox J471 TUR Connected
PWR
24V D
K4T88-50191 K4T88-50191
K4T88-50189
K4T88-50287
eBox
K4T88-50260 Mechanical Switch Mechanical Switch
Short Cable Short Cable
(CZ056-50169) (CZ056-50169)
eCabinet-for-LED
(J8J14-60013) J4 Pinch Switch Pinch Switch
LED BOX J4 Right (SVS) Left (IDS)
DAY & NIGHT PINCH SWITCH – SSLIT - TUR
K4T88-50161
eCAB TUR IDS-VR

Interconnect
TUR SNS B VR VR PCA J11
Panel 24V_IN 24V_OUT
eCAB VR INTERCON J11 J16 J7 AC_IN
CAN Termination
VR PCA NECT
J27
1258-0283
PANEL
J8 24V J36
VR LAN VR PCA
VR PCA J12 J37 (K4T88-60084) AC_IN_Link J3
VR PUMP K4T88-50125 K4T88-50182
J12 J36
eCAB
J13
eCabinet Vapor
24V AC
Removal VR Split VR Split FAN Heater
PUMP J1
K4T88-50073 ID 7
24V_FAN_CURING
J4
J14
J13
Addressing K4T88-50153
A
B
- Set on aerial cable connected to J13. Vapour Removal VR PCA J13

pump Blower VR PCA J14
- Jumper cable cut ’1' (K4T88-80040)
- Jumper cable ‘0’ VR Pump Panel K4T88-50159
VR Pump Panel
- A0 is the LSB Control
B
K4T88-50071
- ‘001’ refers to ID 1 (‘000’ not accepted’) K4T88-50075 AC
VR Pump VR Pump
- ‘111’ refers to ID 7 Filter
J13
W_A2 ‘0’
24V_FAN_CURING
W_A1 ‘1’
W_A0 ‘1’
FANS ARRAY (K4T88-60060)
12V DC Cable LABEL

VAPOUR REMOVAL
24V DC 5V DC
32V DC
42V DC
220V AC
DATA
HP Latex 1500 – TUR (Pinch Switch & SLIT SOL) & VR Subsystems

Figure 2-21 TUR (Pinch Switch & SLIT SOL) and VR Subsystems
95
96
MOTOR DRIVE PCA (Q6702-60953) MOTOR DRIVE PCA (Q6702-60953)
MOTOR DRIVE PCA ID5 J1 WW

P2 J1 P2 Q6703-50031 P2 J1 P2
EBOX INTERCONNECT PCA MOTOR DRIVE PCA ID5 J3 WW MOTOR DRIVE PCA ID4 J3 WW
(CZ056-60005)
KAT88-50114 P1 P1
J3 ID 5 J3 ID 4
(A) CZ056-50156 (A)
CZ056-50156
A J4 A J4
J_151 MICCI2 Aerial 6 WW MOTOR DRIVE PCA ID5 J4 WW Aerial 7 WW MOTOR DRIVE PCA ID4 J4 WW
eBox J151 WW

Q6703-50031
CZ056-50116 CZ056-50116
P3 (C)
P3 (C)
SVS Motor Assy SVS Motor Assy
(Motor + Encoder) (Motor + Encoder)
B
C
eBox Q1271-60564 Q1271-60564
Aerial 7 WW
Aerial 6 WW
Encoder Encoder
B B
WW Encoder Z WW Encoder MI
CZ056-50156 Motor CZ056-50156 Motor

P2 (B) P2 (B)
WW Motor Z WW Motor MI
MO MI
Aerial 5 WW Aerial 5 WW
NC
WW KAT88-50121 A CZ056-50161 F
Aerial 8 WW Aerial 9 WW
E
eCAB WW
D
Micci Bus MOTOR DRIVE PCA (Q6702-60953) MOTOR DRIVE PCA (Q6702-60953)
P3 (C)
P3 (C)
Termination
Aerial 8 WW 1254-3650 J1 Aerial 9 WW
P2 Q6703-50031 P2 J1 P2
eCabinet
CZ056-50156
CZ056-50156 P1 P1
J3 ID 1 MOTOR DRIVE PCA ID2 J3 WW J3 ID 2
(A) (A)
MOTOR DRIVE PCA ID1 J3 WW
LUNA Addressing A J4 A J4
- Brown A0
- Red A1 MOTOR DRIVE PCA ID1 J4 WW MOTOR DRIVE PCA ID2 J4 WW
- Orange A2
- Blue A3
- Jumper cable cut  ’1' CZ056-50116 CZ056-50116
SVS Motor Assy SVS Motor Assy
- Jumper cable  ‘0’ (Motor + Encoder) (Motor + Encoder)
- A0 is the LSB Q1271-60564 Q1271-60564
- ‘0001’ refers to ID 1 (‘000’ not accepted’)
Encoder Encoder
- Example: ‘0011’  PCA ID 3 B B
WW Encoder MO WW Encoder MA
CZ056-50156 Motor CZ056-50156 Motor

P2 (B) P2 (B)
WW Motor MO WW Motor MA
Z MA
12V DC Cable LABEL

Web Wipe
24V DC
32V DC
42V DC
220V AC
DATA
HP Latex 1500 – WW Subsystem
ENWW
Figure 2-22 WW Subsystem
ENWW
Motor Drive PCAs Layout Stand beam
Motor drive Motor drive Motor drive PPS Motor

PPS Motor
PCA PCA (Double- PCA (SOL drive PCA
drive PCA
(Printzone top sided day Solenoid) (ISS Side)
(SVS Side)
light and night Kit)
SVS ISS
buttons) PPS Safety Accessory
21
16 PCA 17 15 22
J251
DD
J351
J151
J152
Motor drive
PCA (DD
station)
First number 12
is the engine
PCA to which Printhead cleaning roll Motor Drive PCAs (SVS side) Printhead cleaning roll Motor Drive PCAs (ISS side)
it is connected
Motor drive PCA (Printhead

cleaning roll MA) Motor drive PCA (Printhead
Ebox Interconnect
12 cleaning roll Z engage)
PCA 11 The number under the Motor Drive
PCA is related to its ID in FW. Two
Motor Drive PCAs in the same bus
cannot have the same ID.
Motor drive PCA (Printhead
cleaning roll MI) Motor drive PCA (Printhead In some of the block diagrams the
14 cleaning roll MO) number shown as ID X for the Motor
15 Drive PCA corresponds to the last
number of the actual ID (for
example, if this is the Motor Drive
PCA 12, in the block diagram it may
say ID 2). This is the ID set in the J4
connector of each Motor Drive PCA.
The ID in the connector is set in

binary, a loop means 0 and a cut
cable means 1.

Figure 2-23 Motor drive PCA
97
Accessories
● Ink Collector
● Double-sided day and night kit
● Dual-Roll
● Slitters
● The substrate edge holders
● Roll-to-free-fall accessory
● Media saver

Ink Collector
The ink collector kit is an accessory for the HP Latex 1500 Printer designed to protect the printer from the ink
that falls through porous substrates (textile mesh, flag, and voile).
NOTE: Do not use the Ink collector kit when the in-line slitters are installed, the cutting position can damage
the protector of the kit. It is recommended to uninstall the in-line slitters when working with the ink collector.
Functionality
Before printing on porous substrates (textile mesh, flag, and voile), you must install the ink collector kit available
as an accessory, to protect the printer from the ink that falls through the substrate. The kit should be removed
before printing on non-porous substrates.
ENWW Accessories 99
Components
1 Ink collector container
2 Ink collector with two replaceable foams
3 Ink collector edge holders
4 Protector modules
NOTE: Instructions on how to mount and maintain this accessory can be found in the User guide.

Double-sided day and night kit

Functionality
This accessory provides the printer with the hardware and firmware necessary to print dual side using the
Double-sided Day and Night specific workflow.
The process for printing a job using double-sided day and night workflow is separated into 2 clear steps:
● Print Side A: First step. Similar to a normal print job procedure with the difference that some fiducials are
added on the plot contour that are read by the light sensor during the side B process for positioning the 2
sides of the plot perfectly.
● Print Side B: Second step. First, rewind side A using the IPS specific Double-side Day and Night mode. Then
install the platen protector and load the media. Printing side B, the platen light illuminates the rear part of
the media, enabling the light sensor situated on the carriage to read the fiducials printed on side A.
Specific Double-sided Day and Night edge holders are added with the kit to use in case of a crash.
Components
Kit contents:
● Printzone Backlight
2 LED profiles are situated between the Main Roller and Platen and used during Side B printing to retro-
illuminate the fiducials printed on Side A and to be able to center both sides of the Double-sided Day and
Night job.
ENWW Accessories 101

Both are composed of an aluminum profile with a 24 volt LED strip glued onto it. Left and right profiles
have an asymmetric position for the cable, facilitating the cable routing to both sides of the printer, and
away from printing area. The Right Platen Light has a sheet metal shim that is used to position both
profiles correctly.
Printzone Backlights are fixed to the printer using 4x M3 screws (0515-4880) per profile. After installation
a light diffuser is installed between the aluminum extrusions.
Power and connections:
● Power: 24V
● Connections: From printzone backlights profiles to Luna 317
● Printzone Backlight Left (P4P91-60019) is connected to Luna 317 (P4P91-50003 terminal)

using P4P91-50006 cable.
● Printzone Backlight Right (P4P91-60018) is connected to Luna 317 (P4P91-50003 terminal)

using P4P91-50005 cable.
● Day and Night Sensor
This sensor is physically the same as the line sensor but is used for a different application called Day and
Night (D&N); print an image on both sides of transparent/translucid substrate with good image registration
on both sides so the image can be illuminated from the rear at night and show live colors without a double
image. When printing the first side image some fiducials for later reference are included. Once the first side
image is printed the output is loaded back into the input side so that the first images are underneath the
new print side. The D&N sensor now measures the position of the previously printed reference fiducials to
then print the new image exactly in position with the previously printed underneath image. The sensor can
detect the fiducials since media is transparent/translucid and is illuminated from below by a LED light array
that is placed under the print platen.
● Line Sensor: Connected to Optimizer squid using K4T88-50009 cable.

● Output lights
Front light assembly
1. Turn off the printer and the power-enable switch.
2. Disconnect the LED_LAMP from the frontlight cable terminal.
TIP: For better access, open the curing module.

3. Extract the LED_LAMP from the 8 frontlight brackets along the universal mounting beam.
4. Remove the LED_LAMP (composed of 2 LED lamp modules, 1 LED lamp cable and 1 LED lamp plug)
from the printer.
5. If it’s necessary remove 8 x frontlight brackets that are along the universal mounting beam, removing
2x screws from each one.

6. If it’s necessary remove 1 x frontlight cable cover that is on the right side of the universal mounting
beam, removing 2x screws.
Front light installation
1. Mount the LED_LAMP. Join 2 x LED lamp modules. Connect the LED lamp cable on the right.
2. Reverse the removal process.
Back light assembly


2. Disconnect the 2 x LED_LAMPS from both the backlight cable terminals.
TIP: For better access, open the curing module.
3. Extract the 2x LED_LAMPS from the 8 backlight brackets below the curing module.
4. Remove the 2x LED_LAMPS (composed of 2 LED lamp modules, 1 LED lamp cable and 1 LED lamp
plug) from the printer
5. If it’s necessary remove 8 x backlight brackets that are below the curing module, removing 2 x screws
from each one.

Back light installation
1. Mount the 2 x LED_LAMP. For each one, join 2 x LED lamp modules. Connect the LED lamp cable on
the right side.
● Luna
An extra Luna PCA (Luna 317) must be installed to control DSDN workflow, it is situated on the stand beam,
near to Luna 316. The position is predefined, the Stand Beam comes with threaded holes to facilitate the
installation. It is fixed to the printer using 2 x M4 screws (0515-4862).
● Luna 317: Powered by DSDN eCabinet using cable P4P91-50003
● Lunes 317: Connected to Luna 316 using a LAN cable (CZ056-50016)
● LAN Terminal: Must be removed from Luna 316 and installed on Luna 317

● DSDN eCabinet, Structure and Cabling
A specific eCabinet with 3 power supply (24V) and 3 relays is used to power DSDN LED bars:
● Output Backlight top
● Output Backlight bottom
● Output Frontlight
It is situated over the IDS and fixed to the structure by a metallic support. The position for the DSDN
eCabinet is prefixed by 4 pre-existing holes on the right side printer structure. The DSDN eCabinet Support
is supported on the Printer eCabinet Top Panel.
● DSDN: Powered with 230V by Printer eCabinet using 8121-0795 power cable (J1 Socket)
● J3 Socket: Connected to Output Front and Backlights using P4P91-50004 cable
● J4 Socket: Connected to printer eBox J371 socket using P4P91-50002 cable

● J5 Socket: Connected to printer eBox J471 socket using P4P91-50001 cable
● J6 Socket: Spare (24V)
● J7 Socket: Connected to Luna 317 and Printzone Backlight using P4P91-50003 cable
● Button and label
DSDN kit comes with an extra button named “Backlights button” that controls:
● Output Backlight top
● Output Backlight bottom
This must be installed on the right side of the curing in a pre-existing hole. To install it is necessary to
remove the plastic cover, and connect to cable K4T88-50244 (pre-routed on printer, Curing Module).
The DSDN Kit comes with a label that must be installed on the Curing Module:
● Platen Protector
Qty: 2 per kit
Length: 60 inch
The Platen Protector should be used during side B printing in order to avoid scratching printed side A. There
is the possibility to install only 1 platen protector centered on the platen for media narrower than 63
inches. For media from 63 to 126 inches it’s necessary to install both platen protectors.
Components:
● Black fabric with 2 steel rods: glued on the extremes to give to give strength and consistency to the
assembly
● DN Protector Rib assembly:

● (1) 12x M3 screws (CH980-00069)
● (2) 5x Magnets
● (3) 1x DN Protector Rib (PPO + 20% GF Black Extrusion)
● (4) 10x Poliacetal washer (P4P91-80001)
● (5) 1x Left cover (Action Blue)
● Tensioner (PPO + 20% GF Black Extrusion):

Installation:
1. Drop the DN Protector Rib Assembly between the platen and Main Roller. Verify that magnet contact
is correct (the magnets should fix the position).
2. Cover the platen with the fabric.
3. Fix the fabric using the Tensioner Element.
NOTE: For more information on installation see the DSDN User Guide.
● Edge Holders
A specific MEH edge holder is used for the DSDN workflow to avoid media crashes with media narrower
than the platen protector width.

Components:
● Input side assembly:
● Output side assembly:
● Strip:
Installation:
1. Fix the DSDN Edge Holder “INPUT” side on the DN Protector Rib Assembly. Clipping Process.

2. Fix the DSDN Edge Holder “OUTPUT” side on the Tensioner Element. Use a flat Screwdriver.
NOTE: For more information on installation see the DSDN User Guide.
Dual-Roll
Maximizes productivity in unattended printing when SAB and other substrates up to 63in (1.6M) are used.
NOTE: When using dual-roll, roll-to-roll configuration is recommended for best performance.
Center support extra shims

Depending on the printer position, it may be necessary to increase the dual-roll center support height. There is
an extra shims kit to adjust the height of input-output center support. The kit comes with several shims and a
screw to adjust it.
Slitters
Slitters (see Universal mounting beam on page 35, In-line slitters blade replacement on page 1453, and Parts
and diagrams on page 599)
The substrate edge holders

The purpose of the substrate edge holders is to prevent the substrate edges from lifting up and jamming while
printing. If you experience this kind of problem while printing, you can try using the edge holders to overcome it.
The edge holders are highly recommended when printing on textile substrates.
NOTE: When printing with the Double-sided Day and Night Kit, specific edge holders are also needed.
NOTE: The edge holders are not recommended when printing on substrate that is more than 0.4 mm (0.016 in)
thick.

TIP: The edge holders may be easier to deploy if you raise the carriage beam (see “Set the carriage beam
position” in the user guide).
The correct position is illustrated below. The substrate should be free to move, and should not touch the ends of
the edge holder.
CAUTION: Wrongly positioned edge holders could severely damage the printheads and carriage.
NOTE: If the substrate is loaded with the right edge outside the 161 cm position on the spindle ruler, or the left
edge outside the −162 cm position, the edge holders cannot be used because there is not enough space for
them.
Roll-to-free-fall accessory
Functionality
The roll-to-free-fall accessory allows the user to cut and collect the substrate as the printer prints dynamically.
In the Roll-to-free fall configuration, the substrate goes from the input spindle over the main roller, the platen,
the front diverters and then to the tension roller; then it continues to the floor. The roll-to-free-fall roller has its
own pinch mechanism to keep the substrate under tension and to allow dynamic cutting.
The tension roller is moved using a motor in the IPS R2FF side plate.
You can load substrate on the spindle with the printed face inwards or outwards, in this case the spindle will turn
in the opposite direction.

In addition to this, the output spindle can be used as a substrate collector. This is the roll-to-collector
configuration. There is a distance-detecting sensor that controls the output motor when the output spindle is
working as a collector. It keeps the substrate loop within defined limits by means of an infrared measurement
system.
The loop shaper is part of the substrate collection system and gives shape to the loop of substrate that hangs
down from the substrate path. The length of the loop shaper can be changed by removing or adding sections in
order to work with various substrate widths.
The roll-to-free-fall and roll-to-collector configurations can be chosen in the Internal Print Server during the
substrate loading process.

Components
The roll-to-free-fall accessory elements are:
● Side plates (the IPS side plate includes the motor assembly).
● Pinch beam (includes an optical sensor with its PCA control in the middle position of the beam to help the
collection of the media when the collector assembly is enabled). In the IPS die there is the lever that
activates the pinch to get tension in the media.
● Rubber spindle.
● Substrate collector assembly.
● Cable and breaking resistor.

Power and connections

The roll-to-free-fall accessory is controlled through the Luna PCA 316 (already in the printer). In this PCA we
connect the latch sensor cables, Optical Sensor PCA control cable and the lever sensor cable.
The motor assembly is connected to the E-box Interconnect (data, power and control). The breaking resistor
cable connects the motor power cable with the E-box interconnect. The breaking resistor aim is to avoid
damages in the motor assembly.

Media saver
The HP Latex Media Saver preserves substrate and avoids substrate waste during loading. It saves time and
money, and increases production and efficiency. The media saver only supports substrate width between 48 and
63 inches. Dual roll is supported.

3 Safety requirements
● Printer safety features
● Hazards
● Accessories installation/assembly
● Safety Check
ENWW 119
Printer safety features

Any repair or maintenance operation, running diagnostics, or troubleshooting may require maintenance key, e-
cabinet key, mains switch key, IPS switch key, and Torx screwdriver set.
NOTE: After using the maintenance key to open a door, remember to lock it afterwards, and return the key to
safe and secure storage.
Warning labels
Label Explanation
Electric shock hazard
Heating modules operate at hazardous voltage. Disconnect power

source before servicing.
Caution! Double pole. Neutral fusing. Refer servicing to qualified

service personnel.
In case of operation of the fuse, parts of the printer that remain

energized may represent a hazard during servicing. Turn off the
printer using both Branch Circuit Breakers located in the Power
Distribution Unit (PDU) of the building before servicing.
Warning
High leakage current. Current leakage may exceed 3.5 mA. Earth
connection essential before connecting supply. Equipment to be
connected to earthed mains only.
See installation instructions before connecting to the supply.

Ensure that the input voltage is within the printer's rated voltage
range. The printer requires up to two dedicated lines, each
protected by a branch circuit breaker according to site preparation
requirements.
Read and follow the operating and safety instructions before

starting the printer.
Located on the e-cabinet.
Risk of burns. Do not touch the internal enclosures of the printer

drying and curing modules, universal support beam, and LED’s
array and enclosures when accessing substrate path.
Located on the curing modules and universal support beam
120 Chapter 3 Safety requirements ENWW

Label Explanation
Crush hazard. Do not touch PPS while moving. When substrate has
been loaded, the carriage descends into its normal position, and
could crush your hand or anything else left underneath it.
Located on each side of substrate path, close to PPS gear
Risk of trapped fingers. Do not touch gears while moving. Danger

that your hands may become trapped between gearwheels.
Located on each side of substrate path, and close to PPS gear
Hazardous moving part. Keep away from moving carriage

printhead. When printing, the printhead carriage travels back and
forth across the substrate.
Located internally on substrate path and on printhead cleaning roll

(web wipe); for maintenance/service personnel only
You are recommended to wear gloves when handling ink cartridges,

printhead cleaning cartridges and the printhead cleaning container.
Located on ink waste bottle and web wipe
Sound pressure level could exceed 70dB(A) in certain print modes.

Hearing protection may be required.
Located on rear side on left cover
ENWW Printer safety features 121

Label Explanation
Electric shock hazard. Disconnect power before servicing. Heating

modules and electrical cabinets operate at hazardous voltage.
Located internally on heating modules and electrical cabinets; for

maintenance/service personnel only
Hazardous moving parts. Keep away from moving fan blades.

Internal close to Vacuum Fan Blades and Dryer PCA cooling fan.
Located internally, close to vacuum fan blades and Dryer PCA

cooling fan; for maintenance/service personnel only
Risk of cutting your fingers. Do not touch in-line slitters during

printing.
Handle in-line slitters with care and store them safely in their box
when not being used with the printer.
Located on each side of the in-line slitters and close to carriage

encoder strip
Identifies the Protective Earth (PE) terminal for qualified electrician,

and bonding terminals for maintenance/service personnel only.
Earth connection essential before connecting supply.
Identifies the Protective Earth (PE) terminal for qualified electrician,

and bonding terminals for maintenance/service personnel only.
Earth connection essential before connecting supply.
Identifies the short-circuit breaking capacity of printer’s built-in

supplementary circuit breakers beside mains input terminal, for
qualified electrician and maintenance/service personnel only. Earth
connection essential before connecting supply.

Emergency stop buttons

There are four emergency stop buttons distributed around the printer. If an emergency occurs, simply push one
of the emergency stop buttons to stop all printing processes. A system error message is displayed, and the fans
turn at maximum speed. Ensure that all emergency stop buttons are released before restarting the printer.
Hazards
Electrical shock hazard
Description
Internal circuits use hazardous voltage capable of causing death or serious personal injury. Turn off the printer
using the branch circuit breakers located in the building's Power Distribution Unit (PDU) before servicing the
printer. The printer must be connected to earth at mains outlets only.
Particular attention must be paid to the drying and curing subsystem as well as the vapor removal subsystem,
which uses hazardous voltages. Even when the drying and curing subsystem and vapor removal are not
operating, there will still be parts of the electrical circuit with hazardous voltage levels.
Best practice
● Always perform the Safety Check before servicing the printer. See Safety Check on page 129.
● Fuses blown after being replaced may indicate malfunctioning electrical circuits within the system. Have
the system checked by qualified service personnel, and do not attempt to replace the fuse again.
ENWW Hazards 123

● Ensure you have the appropriate test equipment for the voltage range to be measured and proper
insulated leads before measuring the voltage at any test point.
● Be in a stable and reliable position for measuring any voltage safely.
● Before servicing the printer be sure to turn it off and use the provided mains switch keys to prevent the
printer being turned on inadvertently during servicing.
● Avoid unintentional short-circuits with conductive parts surrounding the test points.
● Ensure the test leads do not slip out of your hands when measuring voltages, and be careful not to touch
uninsulated parts accidentally.
Mechanical hazard
Description
● When the PPS is lowered, it can crush body parts if they are in the way.
● When the carriage moves, it can crush or cut body parts if they are in the way.
● Any moving printer components can potentially crush, cut, or seriously injure you.
Best practice
● Risk of cutting your fingers! Uninstall the In-line slitters when manipulating the curing module or accessing
the substrate path.
● Take care when using the air gun. When used for cleaning purposes, make sure to use it according to local
regulations since additional safety provisions may apply.
● Keep your clothing or body parts safe from moving parts of the printer.
● Avoid wearing loose clothing, jewelry like necklaces or bracelets, or any kind of hanging objects.
● If you have long hair, make sure that it is restrained.
● Take care that sleeves and gloves do not get caught in the mechanical parts of the printer.
● Stay clear of the printer when lowering the PPS.
● Stay clear of the print path when the carriage is moving.
● Be aware of the location of the emergency stop buttons.
● Also make sure that there are no tools obstructing the operation of the printer.
● Avoid standing close to the fans, which could cause injury and could also affect print quality (by obstructing
the air flow).
● Do not touch gears or moving rolls during printing.
● Do not operate the printer with covers bypassed.
● Do not touch the in-line slitters during printing.
● Handle the in-line slitters with care and store them safely in their box when not being used with the printer.

WARNING! Take care when opening the loading table and NEVER leave it unattended with both latches open as
it may open inadvertently and cause serious injuries. Always check the table has both latches properly closed.
Scan-axis encoder strip hazard

Description
The scan-axis encoder strip is very sharp, and can easily cut your hands when you work near it.
Best practice
● Wear protective gloves if you must touch the scan-axis encoder strip.
● Do not wear loose clothing or jewelry.
Burn hazard (drying and curing and vapor removal)

Description
The drying and curing subsystems and vapor removal, LED array supports, beam and enclosures of the printer
operate at high temperatures and can cause burns if touched.
Best practice
● Avoid direct contact with the drying and curing and vapor removal areas of the printer.
● Be careful when you work near the print path.
● If you must work near the drying and curing modules or vapor removal, make sure that they have
completely cooled down.
Lifting and handling

Description
Improper handling of heavy materials can lead to serious bodily injury.
Best practice
● When handling substrate rolls, care must be taken to avoid back strain and/or injury.
● Always use a forklift, pallet truck, or other handling equipment to lift substrates.
● Always wear personal protective equipment like boots and gloves.
● Follow any manpower instructions included in this service manual when you replace components. Many
components, such as the drive roller or the cover, require at least two people for removal.
ENWW Hazards 125

Fire Hazard
Description
Drying and curing subsystems operate at high temperatures.
Best practice
● Use the power supply voltage specified on the nameplate.
● Connect the power cords to dedicated lines, each protected by a branch circuit breaker.
● Do not manipulate the heating modules, unless required for servicing parts.
● Do not insert objects through slots in the printer.
● Do not use aerosol products that contain flammable gases inside or around the printer. Do not operate the
printer in an explosive atmosphere.
● Do not block or cover the openings of the printer.
● Follow any manpower instructions included in this service manual when you replace components. Many
components, such as the drive roller or the cover, require at least two people for removal.
● Do not attempt to modify the drying or curing module, the vapor removal or the e-cabinet, unless required
for servicing parts.
● Do not load substrates that cannot be used at an operating temperature above 125°C (257°F). Ensure that
the operating temperature of the substrate recommended by the manufacturer is not exceeded. If this
information is not available, ask the manufacturer.
● Proper maintenance and genuine HP consumables are required to ensure that the printer operates safely
as designed. The use of non-HP consumables (foams, filters, printhead cleaner roll, and inks) may present
a risk of fire.
● Do not load substrates with auto-ignition temperatures below 250°C (482°F). See note below. No ignition
sources are close to the substrate.
NOTE: Test method based on EN ISO 6942:2002: Evaluation of materials and material assemblies when
exposed to a source of radiant heat, method B. The test conditions, to determine the temperature when
the substrate starts ignition (either flame or glow) were: heat flux density 30 kW/m², copper calorimeter, K
type thermocouple.
Light radiation hazard

Description
Ultraviolet (UV) radiation can be emitted from the LED array in compliance with the requirements of the exempt
group of IEC 62471:2006, Photobiological safety of lamps and lamp systems.However, you are recommended
not to look directly at the output LEDs for a long time while they are on.

Best practice
● You are recommended not to look directly at the LED lights while they are on.
● After servicing parts, make sure to reassemble them properly.
Sound pressure level

Description
The sound pressure level could exceed 70 dBA in some print modes.
Best practice
● Hearing protection may be required.
Ink handling
Your printer does not use solvent inks and does not have the traditional problems associated with them.
However, HP recommends that you wear gloves when handling ink system components.
ENWW Hazards 127

Accessories installation/assembly
Description
Installation of accessories and their assembly processes may require access to areas with hazards described
previously in this manual or a combination of them.
Carefully read through all the potential hazards and always follow the best practices indicated in this manual
when preforming a service task.
Always perform the appropriate safety check before and after each service operation.
Best Practices
● Before installing the accessory, and for your own safety, ensure you have the appropriate tools, materials
and recommended personal equipment.
● Always adopt a stable and reliable position in order to work safely during accessory installation.
● Before installing the accessory, be sure to turn the printer off and use the mains switch keys provided to
prevent the printer being turned on inadvertently during the process.
● Before installing the accessory, be sure that the host printer is fixed in a reliable and stable position.
● If you must work near the drying and curing modules or printer vapor removal, make sure that they have
completely cooled down before you begin.
● If you must be exposed to internal printer sharp edges, be sure to wear protective gloves.
● Do not wear loose clothing or jewelry during accessory installation.
● After installing the accessory, make sure that all disassembled safety means are correctly reassembled to
guarantee safe printer use and accessory after installation.
● Check safety warning labels always remain in their intended location after accessory installation, if they are
not, replace them with a new one in the original intended position.
● Always perform the described safety check after accessory installation.

Safety Check
Description
The Safety Check must be performed before and after every service operation of the printer. From purging the
printer to replacing a single component, this Safety Check must always be performed.
Procedure
NOTE: The protective earth conductor is marked with a symbol.
1. If you intend to remove any components of the drying and curing system or the vapor removal, turn off the
main power switch and disconnect the printer from the Power Distribution Unit (PDU).
2. Check that the protective bonding conductor (green-and-yellow grounding cable) is well attached to the e-
cabinet doors.
3. Check that the protective earth conductor for single phase and three-phase (green-and-yellow grounding
cable) is well attached to the back panel of the e-cabinet.
4. Check that the protective bonding conductor (green-and-yellow grounding cable) is well attached to the
back panel of the e-cabinet.
single-phase input.
6. Check that the protective bonding conductor (green-and-yellow grounding cable) is well attached to printer
structure.
drying system.
curing system.
9. Check that the protective bonding conductor (green-and-yellow grounding cable in the power cord) is well
attached to the vacuum and vapour removal pumps.
10. Check that the protective bonding conductor (green-and-yellow grounding cable in the power cord) is well
attached to the e-box.
11. Check that safety interlock is not in bypass position.
12. Check that all emergency stop buttons are released.
13. Check that all RCCBs (GFIs) trip properly, by pressing the Test button.
14. Check that all doors and windows remain closed and in their original position.
ENWW Safety Check 129

15. Check that all safety warning labels remain in their intended positions and add any required labels on new
or removed parts.
16. Check that the in-line slitters locking mechanism is working properly; it must prevent the cutter blade being
reached when in "open" position.

4 Troubleshooting
● Troubleshooting with Print Care
● Print Care login and boot modes
● Troubleshooting system error codes
● Troubleshooting without system errors
● Printer calibration
● Basic printer check for correct printing
● Ink density vs number of paths
● Media path troubleshooting
● Image quality troubleshooting
● Printhead and ink cartridge troubleshooting
● How to extract and read the service plot
● Troubleshoot non-HP ink usage
ENWW 131
Troubleshooting with Print Care

When there is a problem with the printer, a system error is displayed in the Internal Print Server. See the
following sections for details about system error codes.
All the troubleshooting steps and corrective actions are described below. In many cases, a diagnostic test is
needed to determine the failure mode, and these tests are performed with the Print Care software. See How to
run a diagnostic test on page 535.
132 Chapter 4 Troubleshooting ENWW

Print Care login and boot modes

As someone authorized by HP to provide support for this printer, you can log into Print Care as ‘Engineer’ to gain
access to the special tools, diagnostics, and calibrations provided to support, diagnose, and repair the printer.
First use the Print Care Password Manager to generate a password: click Generate in the window below, then use
the generated password.
NOTE: The password is case-sensitive.
When the password is generated, access the Switch User menu from File ►Switch User. Insert ‘Engineer’ as User
Name and the generated password in the Password field.
The printer can be started in normal mode or diagnostic mode, from Printer tools ►Power options ►Boot
modes . Normal mode starts the printer normally, but diagnostic mode starts only a minimal part of the printer
engine for diagnostic purposes, so the diagnostics available can be different in each case. See Diagnostics
on page 533.
When the printer is started in diagnostics mode, you should see the window below on the screen of the built-in
computer.
ENWW Print Care login and boot modes 133

In diagnostic mode you may be able to run tests with parts detached from the printer, or run one subsystem
only and start the components required for this subsystem.
NOTE: To return the carriage to the capping position after working in diagnostic mode, you should restart the
printer in normal mode.
How to access logs for troubleshooting

This chapter describes how to access the various logs needed to troubleshoot issues in the Latex 3000 printer
series.
Enabling and accessing logs

1. Log in as an Engineer and enable logs through Print Care (PrC) by going to System diagnostics ►Utilities
►Get printer logs.

2. Copy the URL where the log files can be obtained.
NOTE: The path enabled is http://<engine_IP_addr>/hp/device/3432/8828/tmp/
3. Use Internet Explorer to access the URL given.
(In this example, the is192.168.88.88).
Which logs are required?

printer.log
System errors and most of the relevant information are stored on the printer.log file.

The printer.log file corresponds to the current open session on the printer.
log.xx.gz
Each time the printer is rebooted the latest printer.log file is compressed and renamed as log.XX.gz (where xx is a
number from 1 to 50; when 50 is reached the next file will be called log.1.gz) and a new file printer.log is created
for the current open session.
When troubleshooting an error that has occurred, both the current printer.log and the last saved log.xx.gz file are
needed.
TIP: Order the list of log.xx.gz files by Last modified to ensure they are the most recent.
engine.log and engine.log.xx.gz
These files track the main status of the printer during each operation (loading substrate, printing, and so on).
Current session operations are stored in the engine.log file and past sessions are compressed and renamed
engine.log.xx.gz.
The engine.log.xx.gz files correspond to the log.xx.gz of the same session.

Occasionally, R&D requests the engine.log and/or engine.log.xx.gz files. The corresponding log.xx.gz should also
be included.
MasterXML file
The MasterXML file also contains a great deal of relevant information about the printer status.
This file can be obtained through the “service information” option on the “information” menu in the IPS.
Additional specific logs
Scan Axis friction analysis test
Log in as an Engineer and run the log through Print Care (PrC) by going to Carriage Rail Cleaning ►Friction
Analysis.
During the friction analysis test, a screen of results is displayed.

The test also generates a file in the tmp folder, which can provide useful information to R&D: http://
<engine_IP_addr>/hp/device/3432/8828/tmp/scanAxisFrictionAnalysis.log.
System error 86.XX.XX:XX - Scan Axis error Codes
Log in as an Engineer and run the log through Print Care (PrC) by going to Scan Axis ►Scan axis analysis.
scanAxisHighestFrictionTrz*****.log and sscanAxisHighestFriction*****.log files are generated in the tmp folder.

Double-sided Day and Night Kit scanning issues
In case of having issues with the Double-sided Day and Night Kit, the files generated by the 90004 (or 90014)
diagnostic can be used.
Run the Scanning check 90004 (or 90014) diagnostic in the Double-sided Day and Night Menu. The files
ScanDataCalib_0.txt and ScanDataCalib_20.txt containing the results of the test will be generated in the tmp
folder.
Intermediate broken tanks issues
In the event of an IT broken bag signal (22.02.0X:06), abnormal intermediate tank refilling, or ink flow error, etc.,
the SupplyX.log files can be used. There are 7 files, one for each fluid (0 = K, 1 = C, 2 = M, 3 = Y, 4 = Lm, 5 = Lc, 6
= OP).

Troubleshooting system error codes

● Useful information
● Understanding system error codes
● Resolve a system error code
● 01. E-box error codes
● 10. E-cabinet error codes
● 11. Pipeline error codes
● 16. Curing error codes
● 17. Drying error codes
● 22. Ink delivery system error codes
● 30. Vapor removal error codes
● 41. Substrate path error codes
● 41. Substrate path (Roll-to-free-fall only) error codes (accessory)
● 43. Substrate vacuum system error codes
● 46. Printhead primer error codes
● 47. Printhead cleaning error codes
● 48. PPS error codes
● 49. Carriage aerosol removal error codes
● 50. OMAS error codes
● 52. Drop detector error codes
● 55. Carriage line sensor error codes
● 58. Carriage SOL error codes
● 59. Firmware error codes
● 61. Internal firmware error codes
● IPS PC Blue-Screen Errors related to AntiVirus Software
● 79. Miscellaneous error codes
● 86. Scan axis error codes
● 89. Illumination and buttons error codes
● 90. Double-sided Day and Night Kit (accessory) error codes

Useful information
When dealing with a system error, first obtain the following information:
● The model and serial number of the printer
● The firmware version that the printer is using (from the Internal Print Server: Utilities ►Statistics ►Code
rev.)
● The complete error code
● The service configuration print
● The current configuration print
● The name and version of the software application that the customer is using
NOTE: When reporting the system error code, ensure that you supply the full error code and the firmware
version.
Understanding system error codes

A system error code appears in the following format:
● XX.nn.mm:ff
The different parts of the code have the following meanings:
● XX: Subsystem in which the failure has been detected (see the subsystem error codes table below)
● nn: Service part in which the failure has been detected.
● mm: Service part index, if more than one such part is used: for example, it may be used to identify the ink
cartridge (color and number).
● ff: Type of failure: voltage too low, temperature too high, communications error, time-out, and so on.
XX code Subsystem
01 E-box
10 E-cabinet
11 Pipeline
16 Curing system
17 Drying
22 Ink delivery system
30 Vapor removal system
41 Substrate path
43 Substrate vacuum system
46 Printhead primers
47 Printhead cleaning roll
48 PPS
ENWW Troubleshooting system error codes 141

49 Carriage aerosol removal
50 Substrate-advance sensor (OMAS)
52 Drop-detector system
55 Carriage line sensor
58 Carriage color sensor (SOL)
59 Vapor extractor
61 Internal firmware
79 Miscellaneous
86 Scan axis
89 Illumination and buttons
90 Double-sided Day and Night Kit
Resolve a system error code

In this section “X” or “XY” means the index of the component, for instance for printhead position or curing
modules.
01. E-box error codes

This section lists e-box error codes together with error descriptions, causes, corrective actions, persistence
(whether they can be cleared), and severity.
01.01.00:01
Internal Print Server message
Electrical box fan does not spin. Some printer components could be damaged by overheating. If problem persists
call support and shut down the printer.
Description
The fan installed over the heatsink that cools down the CPU in the formatter board does not spin.
Causes in order of importance
a. The fan is broken.
b. The wire of the fan is disconnected from the formatter PCA.
c. The fan is not powered (red wire).
d. The fan does not properly receive the PWM signal (yellow wire).
Corrective actions
1. Check for the proper fan wire connection to the formatter PCA (CPUFAN1 connector).
2. Check, with multimeter, for supply voltage in pin 2 (5 V) of the CPUFAN1 connector in the formatter PCA.

3. Check, with multimeter, for PWM signal in pin 3 (between 1 and 3 V) of the CPUFAN1 connector in the
formatter PCA.
4. Install a new formatter PCA. See Formatter PCA (CZ056-67186) on page 809.
Severity
ADVISORY (continuable)
01.02.01:02
Engine PCA not properly connected or malfunctioning.
Description
Engine PCA #01 does not start up properly (during power on) or there is an error during start-up.
a. The engine PCA #01 is missing.
b. The contact with formatter PCA (BUS PCI express) fails.
c. The engine PCA #01 is damaged and is not performing properly.
Corrective actions
1. Check for PCA presence in proper slot.
2. Perform a visual check for proper assembly of the PCA.
3. Perform a physical check (push) of the PCA assembly.
4. Run the subsystem diagnostic (01005). See Table 5-21 E-box on page 585.
5. Install a new PCA. See Engine PCA (K4T88-67067) on page 805.
6. Call support.
Severity
SEVERE (non-continuable)
01.02.01:76
Engine PCA DRAM malfunctioning.

Description
Internal error in the engine PCA.
a. PCA tracks are damaged or broken.
b. Any component in the PCA is damaged or broken.
Corrective actions
1. Run subsystem diagnostic (01005). See Table 5-21 E-box on page 585.
2. Install a new engine PCA. See Engine PCA (K4T88-67067) on page 805.
Severity
01.02.02:02
Description
Engine PCA #02 does not start up properly (during power on), or there is an error during start-up.
c. The engine PCA #02 is damaged and does not perform properly.
Corrective actions
3. Perform a physical check of the PCA assembly (push).
6. Call support.
Severity

01.02.02:76
Description
Corrective actions
Severity
01.02.03:02
Description
Engine PCA #03 does not start up properly (during power-on), or there is an error during start-up.
c. The engine PCA #03 is damaged and doesn’t perform properly.
Corrective actions
3. Perform a physical check of the PCA assembly (push).

6. Call support.
Severity
01.02.03:76
Description
Corrective actions
Severity
01.02.04:02
Description
Engine PCA #04 does not start up properly (during power-on), or there is an error during start-up.

c. The engine PCA #04 is damaged and is not performing correctly.
Corrective actions
2. Visual check for proper assembly of the PCA.
3. Physical check of the PCA assembly (push).
6. Call support.
Severity
01.02.04:76
Description
Corrective actions
Severity

01.06.01:04
Engine PCA #1 to Engine Adaptor PCA 1 communication failure.
Description
There is a communication error between the engine adaptor PCA #01 and the engine PCA #01.
a. The flat cable between engine adaptor PCA and engine PCA is missing or not connected.
b. The flat cable is damaged or not properly connected.
c. The engine adaptor PCA supply cable is not connected (engine adaptor PCA not powered).
d. Any fuses of the engine adaptor PCA are blown.
Corrective actions
1. Visual check of the flat cable between the engine adaptor PCA and engine PCA (both ends).
2. Physical check of the flat cable (push both ends).
3. Visual check of the voltage LEDs on the engine adaptor PCA; if they do not illuminate, check the supply
cable and PCA fuses.
4. Install a new engine adaptor PCA. See Engine adaptor PCA (CZ056-67188) on page 802.
6. Call support.
Severity
01.06.01:10
Engine adaptor PCA #01 supply voltages out of range.
Description
The voltmeters in the engine adaptor PCA #01 sensed a voltage source (24V, 12V, 5V, or 3V3) out of its valid
range.

a. Any of the fuses of the engine adaptor PCA are blown.
b. The engine adaptor PCA is damaged or broken.
c. There is a short-circuit or an overcurrent consumption in at least one voltage source.
Corrective actions
1. Check the overcurrent LEDs on the side of the engine adaptor PCA (it must be off). See Board name: Engine
adaptor PCA on page 393.
3. Run subsystem diagnostic (01007) and Power Supplies (10004). See Table 5-21 E-box on page 585 and
Table 5-22 E-cabinet on page 586.
4. Call support.
Severity
01.06.02:04
Description
There is a communication error between the engine adaptor PCA #02 and the engine PCA #02.
Corrective actions

6. Call support.
Severity
01.06.02:10
Engine adaptor PCA #02 supply voltages out of range.
Description
range.
Corrective actions
4. Call support.
Severity
01.06.03:04

Description
There is a communication error between the engine adaptor PCA #03 and engine PCA #03.
Corrective actions
6. Call support.
Severity
01.06.03:10
Engine adaptor #03 supply voltages are out of range.
Description
range.

Corrective actions
4. Call support.
Severity
01.06.04:04
Description
There is a communication error between the engine adaptor PCA #04 and engine PCA #04.
Corrective actions
6. Call support.
Severity

01.06.04:10
Engine adaptor PCA #04 supply voltages are out of range.
Description
range.
Corrective actions
4. Call support.
Severity
01.60.00:01
Hard drive file data crash.
Description
Files found in the hard disk are corrupted
a. An unexpected shutdown of the printer corrupted the data on the hard disk.
b. The hard disk is broken or does not perform properly.

Corrective actions
1. Restart the printer.
2. Install a new hard disk drive. See E-box hard disk drive (K4T88-67268) on page 797.
3. Call support.
Severity
01.60.00:75
No free space left in printer hard disk.
Description
There is no space left in the internal hard disk; for some reason the hard disk does not clean the temporal data.
a. The hard disk does not perform properly.
b. Firmware error.
Corrective actions
Call support.
Severity
01.60.01:03
Default values in main and backup NVM.
Description
The data written on the hard disk do not match the data found in IDS (EE-PROM), or both are empty.
The hard disk drive and the IDS Air PCA board were replaced at the same time (and both were empty).

Corrective actions
Instead of replacing both parts (the IDS Air PCA and the hard disk drive) at the same time, replace the parts in
separate steps.
Replace one of the parts (the other part should be the old one, because it contains all the printer calibration
information). Then turn on the printer normally, and push the rearm button normally. Now the printer should
copy calibration data from the old part to the new part (for example, from the old IDS Air PCA board to the new
hard disk). Wait ten seconds and then turn off the printer normally.
Replace the other part (old to new). Then turn on the printer, and push the rearm button normally. Now the
printer should copy calibration data from the first new part to the second new part (for example, from the new
hard disk to the new IDS Air PCA board). The error should disappear.
Severity
01.60.02:03
Part number mismatch between main and backup NVM.
Description
The part number of the hard disk drive is not correct (wrong part).
The printer was assembled with the wrong hard disk drive.
Corrective actions
1. Ensure that the IDS Air PCA board and the hard disk drive are the correct parts for the printer.
2. Call support.
Severity
01.60.03:03
Serial number mismatch between main and backup NVM.
Description
The serial number of the hard disk is not correct.

The printer was assembled with the wrong hard disk.
Corrective actions
1. Ensure that the IDS Air PCA board and the hard disk drive are the correct parts for the printer.
2. Call support.
Severity
10. E-cabinet error codes

This section contains information about error messages specifically pertaining to e-cabinet subsystems.
10.01.01:01
Contactor K1 does not switch state
Description
The contactor K-1 is closed when it should be open, or open when it should be closed. K-1 should be open when
the printer starts (before pressing the rearm button), at any time the front door or the loading table are open,
and after pressing an emergency stop button.
a. Contactor fault
b. Feedback cable fault (from K-1 contacts 33/34 to e-cabinet PCA CONTACTORS connector)
c. 24 V DC control voltage not reaching A1/A2
d. E-cabinet PCA fault
e. A cable is damaged.
Corrective actions
1. Restart the printer. If the problem does not repeat, it is probably a firmware glitch.
2. Check that the cable from the 33/34 contacts of K-1 to the e-cabinet PCA is not damaged. If it is damaged,
install a new cable. This affects the other contactors as there is only one feedback cable for all of them.
Check that +24 V DC are present on the A1/A2 contacts; otherwise, check the control voltage cabling and
safety relay.
3. Install a new K-1 contactor. See E-cabinet contactor (K4T88-67211) on page 851.
4. Install a new e-cabinet PCA. See E-cabinet PCA (K4T88-67288) on page 880.

Severity
ADVISORY
10.01.02:01
Contactor K2 does not switch state
Description
The contactor K-2 is closed when it should be open, or open when it should be closed. K-2 should be open when
the printer starts (before pressing the rearm button), at any time the front door or the loading table are open,
and after pressing an emergency stop button.
a. Contactor fault
b. Feedback cable fault (from K-2 contacts 23/24 to E-cabinet PCA CONTACTORS connector)
c. 24 V DC control voltage not reaching A1/A2
d. E-cabinet PCA fault
e. A cable is damaged.
Corrective actions
1. Restart the printer. If the problem does not repeat, it is probably a firmware glitch.
2. Check that the cable from the 33/34 contacts of K-2 to the e-cabinet PCA is not damaged. If it is damaged,
install a new cable. This affects the other contactors as there is only one feedback cable for all of them.
Check that +24 V DC are present on the A1/A2 contacts; otherwise, check the control voltage cabling and
safety relay.
3. Install a new K-2 contactor. See E-cabinet contactor (K4T88-67211) on page 851.
Severity
ADVISORY
10.02.00:01
E-cabinet Pca malfunction.

Description
A malfunction on the e-cabinet PCA has been detected.
Surface mount fuse blown, internal component failure
Corrective actions
Severity
10.02.00:03
E-cabinet PCA not supported version
Description
The firmware detects an unknown PCA version.
a. Wrong version of the PCA installed, or outdated firmware that does not support the PCA
b. PCA malfunction
Corrective actions
2. If the error appears after installing a new e-cabinet PCA, ensure that the printer has the latest firmware
installed.
Severity

10.02.00:04
E-cabinet to e-box communication failure
Description
I2C communication malfunction. The e-box cannot communicate with the e-cabinet.
a. Communication cable not connected or misconnected
b. PSU-2 not working
c. PCA malfunction
Corrective actions
2. Check that the communication cable from the e-box to the e-cabinet is properly connected at both ends.
3. Check that PSU-2 is working and the PCA is receiving power (LEDs in the e-cabinet PCA should indicate
power presence on PSU-2 and +24V, +5V, +8V).
4. Check the internal connections inside the e-box and run all the e-box diagnostics. See Table 5-21 E-box
on page 585.
Severity
10.02.00:11
E-cabinet PCA 5V to ground voltage out of range
Description
E-cabinet PCA 5V to ground voltage is out of range.
E-cabinet PCA malfunction
Corrective actions

Severity
10.02.00:13
E-cabinet PCA 8V to ground voltage out of range
Description
E-cabinet PCA 8V to ground voltage out of range.
E-cabinet PCA malfunction
Corrective actions
Severity
10.02.00:15
E-cabinet PCA replaceable fuse blown
Description
The glass fuse on the inner face of the e-cabinet PCA (F24) has blown. This fuse powers the following
components: Safety relay, contactors, e-cabinet internal fan, rearm button light. Probably there is a short-circuit
in one of these parts or the associated cabling.
a. Fuse blown
b. PCA malfunction
Corrective actions
1. Install a new F24 fuse. See E-cabinet PCA fuse (K4T88-67209) on page 846.
2. Check for short-circuits:

a. Safety circuit (safety relay, contactors, and all associated cables)
b. E-cabinet fan and its cables
c. Rearm button light and its cables
Severity
10.02.00:20
E-cabinet temperature outside normal range
Description
The ambient temperature is too high inside the e-cabinet, if it keeps rising the printer will stop. The temperature
sensor is located on the e-cabinet PCA.
a. Ventilation grille filter clogged
b. Ventilation grille blocked externally
c. E-cabinet fan failure
d. Room temperature too high
Corrective actions
None mandatory, warning only.
Check that the fan works, the air intake is not blocked externally, and the air filter is not clogged.
Severity
Warning only—continuable
10.02.00:21
E-cabinet temperature outside safe range

Description
Ambient temperature too high in the e-cabinet.
a. Ventilation grille filter clogged
b. Ventilation grille blocked externally
c. E-cabinet fan failure
d. Room temperature too high
Corrective actions
1. Wait for the printer to cool down and then restart it.
2. Check that the e-cabinet fan is working, the air intake is not blocked, and the air filter is not clogged.
3. Ensure that the room temperature is inside the printer specifications.
4. If the fan is not working, install a new e-cabinet PCA. See E-cabinet PCA (K4T88-67288) on page 880.
Severity
10.02.00:41
E-cabinet PCA overcurrent
Description
The overcurrent protection for the external actuators powered by the e-cabinet PCA has been triggered. This
protection controls the power to the following components: Safety relay, contactors, e-cabinet internal fan,
rearm button light. Probably there is a short-circuit in one of these parts or the associated cabling.
a. Fault in a 24 V component external to the PCA
b. E-cabinet PCA fault
Corrective actions
2. Check for short-circuits:

a. Safety circuit (safety relay, contactors, and all associated cables)
b. E-cabinet fan and its cables
c. Rearm button light and its cables
Related parts
● E-cabinet PCA (K4T88-67288) on page 880.
● E-cabinet lamps kit (K4T88-67214) on page 859.
● E-cabinet contactor (K4T88-67211) on page 851
● E-cabinet safety relay (CZ056-67129) on page 820
Severity
10.03.01:01
E-cabinet PSU-1 no voltage or alarm signal asserted
Description
The PSU-1 is not supplying voltage, or its alarm signal is activated.
a. PSU-1 not receiving AC voltage
b. PSU-1 DC output cable or control cables disconnected or damaged
c. PSU-1 in fault mode (overcurrent, overvoltage, overtemperature)
d. PSU-1 end of life
e. PCA malfunction
Corrective actions
1. Check that the FP3 fuse is not blown.
3. Check that the PSU-1 feedback LED is on.
4. If the LED is lit, check the DC output cable, the control cables, and the PCA.
5. Install a new e-cabinet 48V PSU-1. See E-cabinet PCU 48V-600W (K4T88-67208) on page 841.
After installing the new part, adjust the output voltage to 42 V ±5%.

Severity
10.03.01:18
E-cabinet PSU-1 voltage too high
Description
The PSU-1 voltage read by the e-cabinet PCA is too high.
a. PSU-1 voltage too high
b. PCA malfunction
Corrective actions
2. Run the E-cabinet state diagnostic (10005), which returns the measured voltage among other values. See
3. Disconnect the DC output cable from the PCA.
4. Measure the PSU-1 output voltage with a voltage meter. If lower than 42 V +10%, it is probably a PCA
malfunction. If necessary, install a new e-cabinet PCA. See E-cabinet PCA (K4T88-67288) on page 880.
5. Otherwise, adjust the PSU-1 output voltage through its adjustment potentiometer with the help of a
voltage meter. Voltage must be within 42 V ±5%.
Severity
10.03.01:19
E-cabinet PSU-1 voltage too low

Description
The PSU-1 voltage read by the e-cabinet PCA is too low.
a. PSU-1 voltage too low
b. PCA malfunction
Corrective actions
4. Measure the PSU-1 output voltage with a voltage meter. If higher than 42 V −10%, it is probably a PCA
malfunction.
Severity
10.03.02:01
Description
e. PCA malfunction

Corrective actions
1. Check that ACB-6 is on.
3. Check that the PSU-2 feedback LED is lit.
5. Install a new e-cabinet 24V PSU-2. See E-cabinet PSU 24V-600W COSEL (K4T88-67205) on page 828.
6. Call support.
Severity
10.03.02:10
Description
E-cabinet PSU_2 ground to earth voltage out of range.
The subsystem powered by this PSU may be not properly earthed. The PSU-2 powers the IDS, the e-cabinet, and
the vapor removal subsytems.
Corrective actions
Check the earthing of the powered subsystems. See the ink system module and vapor removal subsystem
ground in Cables on page 1469.
Severity
SILENT
10.03.02:18
Description
The PSU_2 voltage read by the e-cabinet PCA is too high.

b. PCA malfunction
Corrective actions
malfunction.
Severity
10.03.02:19
Description
b. PCA malfunction
Corrective actions
malfunction.

Severity
10.03.03:01
Description
b. PSU-3 DC output cable disconnected
e. PCA malfunction
Corrective actions
1. Check that the FP1 and FP2 fuses are not blown.
4. If the LED is lit, check the DC output cable and the PCA.
5. Install a new e-cabinet 36V PSU-3. See E-cabinet PCU 36V-600W (K4T88-67207) on page 837. After
replacing the part, adjust the output voltage to 32 V ±5%.
Severity

10.03.03:10
Description
The subsystem powered by this PSU may be not properly earthed. The PSU-3 powers the printhead cleaning
system, the take-up reel, the PPS, and the service station.
Corrective actions
Check the earthing of the powered subsystems.
Severity
SILENT
10.03.03:18
Description
b. PCA malfunction
Corrective actions
6. Install a new e-cabinet 36V PSU-3. See E-cabinet PCU 36V-600W (K4T88-67207) on page 837. After
replacing the part, adjust the output voltage to 32 V ±5%.

Severity
10.03.03:19
Description
b. PCA malfunction
Corrective actions
After replacing the part, adjust the output voltage to 32 V ±5%.
Severity
10.03.04:01

Description
b. PSU-4 DC output cable disconnected
e. PCA malfunction
f. An overcurrent in the output 4_1 (Drying) caused the PSU-4 to enter fault mode
Corrective actions
4. If the LED is lit, check the DC output cable and the PCA.
▲ Run the Activate/deactivate outputs in diagnostic mode diagnostic (10009) and check if the error
appears when activating output 4_1 DRYING. If it does, there might be an output short-circuit. In this
case, look for the short-circuit and change the affected part. Alternatively, disconnect output 4_1
DRYING and reboot the printer. If the error does not appear anymore and different errors appear (such
as communication issues with PCA connected to the output), the output short-circuit might be
confirmed.
Severity
10.03.04:10
Description
The subsystem powered by this PSU may be not properly earthed. The PSU-4 powers the carriage 24 V
electronics.
Corrective actions
Check the earthing of the powered subsystems.

Severity
SILENT
10.03.04:18
Description
b. PCA malfunction
Corrective actions
Severity
10.03.04:19
Description

b. PCA malfunction
Corrective actions
Severity
10.03.05:01
Description
e. PCA malfunction
Corrective actions

Severity
10.03.05:10
Description
The subsystem powered by this PSU may be not properly earthed. The PSU-5 powers the scan-axis motor.
NOTE: In the case of this PSU, this error may appear as scan-axis motor braking, but it doesn't mean that the
scan-axis motor is faulty.
Corrective actions
Check the earthing of the powered subsystem. See the impelling ground braids in Cables on page 1469.
Severity
SILENT
10.03.05:18
Description
b. PCA malfunction

Corrective actions
Severity
10.03.05:19
Description
b. PCA malfunction
Corrective actions

Severity
10.03.06:01
Description
e. PCA malfunction
f. An overcurrent output 6_1 (Curing 1) caused the PSU-6 to enter fault mode
Corrective actions
1. Check that ACB-6 is on.
appears when activating output 6_1 CURYING 1. If it does, there might be an output short-circuit. In
this case, look for the short-circuit and change the affected part. Alternatively, disconnect output 6_1
CURING 1 and reboot the printer. If this error does not appear anymore and different errors appear
(such as communication issues with PCA connected to the output) the output short-circuit might be
confirmed.

Severity
10.03.06:10
Description
The subsystem powered by this PSU may be not properly earthed. The PSU-6 powers three curing PCAs and the
DS-2 control.
Corrective actions
Check the earthing of the powered subsystems. See Figure 2-20 SA, Media Path, OMAS and Vacuum Subsystems
on page 94; for more details, see the curing ground cables in Cables on page 1469.
Severity
SILENT
10.03.06:18
Description
b. PCA malfunction
Corrective actions

Severity
10.03.06:19
Description
b. PCA malfunction
Corrective actions
Severity
10.03.07:01

Description
e. PCA malfunction
f. An overcurrent in output 7_1 (Curing 2) caused the PSU-7 to enter fault mode
Corrective actions
appears when activating output 7_1 CURING 2. If it does, there might be an output short-circuit. In
this case, look for the short-circuit and change the affected part. Alternatively, you can disconnect
output 7_1 CURING 2 and reboot the printer. If this error does not appear anymore and different
errors appear (such as communication issues with PCA connected to the output) the output short-
circuit might be confirmed.
Severity
10.03.07:10
Description
The subsystem powered by this PSU may be not properly earthed. The PSU-7 powers three curing PCAs and the
DS-1 control.

Corrective actions
Check the earthing of the powered subsystems. See Figure 2-20 SA, Media Path, OMAS and Vacuum Subsystems
on page 94; for more details, see the curing ground cables in Cables on page 1469.
Severity
SILENT
10.03.07:18
Description
b. PCA malfunction
Corrective actions
Severity
10.03.07:19

Description
b. PCA malfunction
Corrective actions
Severity
10.04.11:10
E-cabinet MO fuse blown
Description
The Media Output motor 42 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that
subsystem or its power cabling.
MO motor 42 V fuse blown (F12)
Corrective actions
2. Shut down the printer (completely, main switch off), look for the short-circuit, and repair it. Then install a
new e-cabinet F12 fuse. See E-cabinet PCA fuse (K4T88-67209) on page 846.

Severity
Continuable (when in roll-to-floor mode this output is not used)
10.04.12:10
E-cabinet MF fuse blown
Description
The Media Floor motor 42 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that
MF motor 42 V fuse blown (F11)
Corrective actions
Severity
10.04.13:10
E-cabinet MI fuse blown
Description
The Media Input motor 42 V fuse in the e-cabinet PCA has blown. Probably there is short-circuit in that
MI motor 42 V fuse blown (F10)
Corrective actions

Severity
10.04.14:10
E-cabinet MA fuse blown
Description
The Media Advance motor 42 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that
MA motor 42 V fuse blown (F9)
Corrective actions
Severity
10.04.15:10
E-cabinet 42V CARR fuse blown
Description
The carriage 42 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that subsystem or its
power cabling.
Carriage 42V fuse blown (F8)
Corrective actions

Severity
10.04.21:10
E-cabinet ISS fuse blown
Description
The ISS 24 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that subsystem or its power
cabling.
ISS 24 V fuse blown (F19)
Corrective actions
Severity
10.04.22:10
E-cabinet VAPOR fuse blown
Description
The vapor removal 24 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that subsystem
or its power cabling.
Vapor removal 24 V fuse blown (F20)
Corrective actions

Severity
10.04.31:10
E-cabinet PPS fuse blown
Description
The PPS 32 V fuse in the e-cabinet has blown. Probably there is a short-circuit in that subsystem or its power
cabling.
PPS 32 V fuse blown (F7)
Corrective actions
Severity
10.04.32:10
E-cabinet WW fuse blown
Description
The printhead cleaning system 32 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that
Printhead cleaning system 32 V fuse blown (F6)
Corrective actions

Severity
10.04.33:10
E-cabinet SVS fuse blown
Description
The service station 32 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that subsystem
or its power cabling.
SVS 32 V fuse blown (F5)
Corrective actions
Severity
10.04.34:10
E-cabinet SOL Solenoid fuse blown. Replace fuse. If the problem persists, call support.
Description
The SOL Solenoid 32V fuse in the e-cabinet PCA (labeled as TUR) has blown. Probably there is a short-circuit in
that subsystem or its power cabling.
SOL Solenoid 32V fuse (J4, labeled as TUR) blown (F3)
Corrective actions

Severity
Continuable (if the spectrophotometer is not in use, this fuse is not needed)
10.04.35:10
E-cabinet PSU-3-5 fuse blown
Description
The unused 32 V fuse has blown.
Unused 32 V fuse blown (F3)
Corrective actions
As this fuse is not used, no action is needed.
Severity
Continuable
10.04.35:40
E-cabinet PSU-3-5 power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
Unused 32 V switch in the e-cabinet PCA is overloaded.
Unused 32 V switch overload
Corrective actions
As this output is not used, no action is needed.
Severity
Continuable

10.04.41:10
E-cabinet Drying fuse blown. Replace fuse. Run subsystem diagnostic. If the problem persists, call support.
Description
The Drying 24V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that subsystem or its
power cabling.
Drying 24V fuse blown (F2)
Corrective actions
Severity
10.04.42:10
E-cabinet PPS fuse blown. Replace fuse. Run subsystem diagnostic. If the problem persists, call support.
Description
The PPS 24V fuse has blown. Probably there is a short-circuit in that subsystem or its power cabling.
PPS 24V fuse blown (F1)
Corrective actions
Severity
Continuable

10.04.51:10
E-cabinet SAX fuse blown
Description
The scan-axis motor 42 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that
SAX 42 V fuse blown (F13)
Corrective actions
Severity
10.04.52:10
E-cabinet PSU-5-2 fuse blown
Description
The unused 42 V fuse has blown.
Unused 42 V fuse blown (F14)
Corrective actions
As this fuse is not used, no action is needed.
Severity
Continuable

10.04.61:10
E-cabinet CURING-1 fuse blown
Description
The curing-1 24 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that subsystem or its
power cabling.
Curing-1 24 V fuse blown (F18)
Corrective actions
Severity
10.04.62:10
E-cabinet AC/AC converter 2 fuse blown. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The DS-2 24 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that subsystem or its
power cabling.
DS-2 24 V fuse blown (F17)
Corrective actions
Severity

10.04.71:10
E-cabinet CURING-2 fuse blown
Description
The curing-2 24 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that subsystem or its
power cabling.
Curing-2 24 V fuse blown (F16)
Corrective actions
Severity
10.04.72:10
E-cabinet AC/AC converter 1 fuse blown. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The DS-1 24 V fuse in the e-cabinet PCA has blown. Probably there is a short-circuit in that subsystem or its
power cabling.
DS-1 24 V fuse blown (F15)
Corrective actions

Severity
10.05.11:40
E-cabinet MO switch overload. Run subsystem diagnostic. If problem persists, call your support representative.
Description
The Media Output motor 42 V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in that
MO motor 42 V switch overload
Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the MO motor system and
cabling, and repair it. Probably the root cause is in the motor.
Alternatively, you can use a diagnostic (10007 or 10009) to turn the PCA power outputs off and on while
investigating the short-circuit. See Table 5-22 E-cabinet on page 586.
Severity
Continuable (when in roll-to-floor mode this output is not used)
10.05.13:40
E-cabinet MI power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The Media Input motor 42 V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in that
MI motor 42 V switch overload

Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the MI motor system and
Severity
10.05.14:40
E-cabinet MA power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
E-cabinet MA power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
MA motor 42 V switch overload
Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the MA motor system and
Severity
10.05.15:40
E-cabinet 42V CARR power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.

Description
The carriage 42 V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in that subsystem or
its power cabling.
Carriage 42 V switch overload
Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the carriage 42V-powered
PCAs and their cabling, and repair it.
Severity
10.05.21:40
E-cabinet ISS power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The ISS 24 V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in that subsystem or its
power cabling.
ISS 24 V switch overload
Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the ISS and its cabling, and
repair it.
Severity

10.05.22:40
E-cabinet VAPOR power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The vapor removal 24 V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in that
Vapor removal 24 V switch overload
Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the vapor removal system
and its cabling, and repair it.
Severity
10.05.31:40
E-cabinet PPS power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The PPS 32 V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in that subsystem or its
power cabling.
PPS 32 V switch overload

Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the PPS and its cabling, and
repair it.
Severity
Continuable
10.05.32:40
E-cabinet WW power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The printhead cleaning system 32 V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in
that subsystem or its power cabling.
Printhead cleaning system 32V switch overload
Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the printhead cleaning
system and its cabling, and repair it.
Severity
10.05.33:40
E-cabinet SVS power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.

Description
The SVS 32 V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in that subsystem or its
power cabling.
SVS 32 V switch overload
Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the service station and its
cabling, and repair it.
Severity
10.05.34:40
E-cabinet SOL solenoid power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The Spectrophotometer Solenoid PCA 32 V switch in the e-cabinet PCA is overloaded. Probably there is a short-
circuit in that subsystem or its power cabling.
Spectrophotometer Solenoid PCA 32 V switch (labeled as TUR) overload
Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the Spectrophotometer
Solenoid 32 V PCA (Motor drive PCA) and its cabling, and repair it.
Severity
Continuable (if the spectrophotometer is not in use this output is not needed)

10.05.42:40
E-cabinet PPS power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The PPS 24V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in that subsystem or its
power cabling.
PPS 24V switch overload
Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the scan-axis motor system
Severity
Continuable
10.05.51:40
E-cabinet SAX power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The scan-axis motor 42 V switch in the e-cabinet PCA is overloaded. Probably there is a short-circuit in that
SAX 42 V switch overload

Corrective actions
2. Shut down the printer (completely, main switch off), look for a short-circuit in the scan-axis motor system
Severity
10.05.52:40
E-cabinet PSU-5-2 power output overload. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
Unused 42 V switch in the e-cabinet PCA is overloaded.
Unused 42 V switch overload
Corrective actions
As this output is not used, no action is needed.
Severity
Continuable
10.06.09:40
One or more emergency stops are pressed.
Corrective actions
1. Ensure that no emergency stops are pressed.

3. Run e-cabinet diagnostics and check the e-cabinet PCA LEDs. See Table 5-22 E-cabinet on page 586.
4. Check the emergency stops cabling for the following problems:
● Disconnected at some point (inside the e-cabinet or at an emergency stop button)
● Cable cut at some point (and maybe short-circuited to ground)
To confirm this problem, check the impedance to ground from the e-cabinet terminals where the
emergency stops are connected, with all the pushbuttons released. Look for the cabling segment
that has been cut and repair it.
NOTE: This condition can also trigger a 10.02.00:41 system error.
Severity
10.08.00:01
E-cabinet fan not working
Description
E-cabinet fan rotation feedback signal not detected. It is likely that the fan is not working or its cabling is
disconnected or damaged. If the fan does not work, the ambient temperature in the e-cabinet will rise.
Depending on the room temperature and on what the printer is doing, this may lead to an e-cabinet temperature
warning and then an e-cabinet temperature error.
a. Fan malfunction
b. Fan not connected or cabling damaged
c. E-cabinet PCA malfunction
Corrective actions
1. Check the fan and its cabling. Ensure that +24 V DC arrive at the end of the fan extension cable.
2. Install a new fan if necessary. See E-cabinet fan (K4T88-67199) on page 873.
3. If the fan rotates normally, check that the feedback wire in the fan extension cable is not damaged (check
for continuity between the PCA end and the fan end). If the cable has no issue, install a new e-cabinet PCA.
See E-cabinet PCA (K4T88-67288) on page 880.
Severity
Continuable

10.09.00:11
Safety circuit powered by default
Description
The e-cabinet PCA detects power output to the safety circuit when there should be no power. The power switch
in the PCA is probably damaged.
a. Rearm button pressed during start-up (button trapped, malfunction)
b. E-cabinet contactor K1 closed when it should not
c. E-cabinet PCA malfunction
Corrective actions
2. Double check that the rearm button is working properly (not trapped when pressed) and restart the printer.
3. Check that the E-cabinet contactor K1 is not activated before the rearm button is pressed.
Severity
11. Pipeline error codes

11.01.01:01
E-box Fiber Optics PCA malfunction.
a. Fiber-optic PCA in e-box doesn't work.
b. Fiber-optic PCA in e-box isn't powered.
Corrective actions
1. Check that PCA is in place.
2. Check PCA input voltage.

Severity
ADVISORY
11.01.01:04
E-box Fiber Optics PCA not responding.
a. Fiber-optic PCA in e-box does not work or it is not connected.
b. Check the cabling of Engine PCA to fiber-optics PCA.
Corrective actions
1. Check that the PCA is in place.
2. Check all the cabling.
3. Check LEDs.
Severity
ADVISORY
11.02.01:09
Fiber optics cable not properly connected to E-box Fiber Optics PCA.
Connection problem
Corrective actions
1. Check if the connector is latched OK.
2. Check if the cable is not damaged.
Severity
ADVISORY

11.03.01:04
Carriage fiber-optics PCA not responding.
a. Fiber-optic PCA in carriage doesn't work or isn’t connected
b. FO damage
c. Carriage PSU output not working or fuse blown.
Corrective actions
1. Check that the PCA is on place.
2. Check all the cabling.
3. Check LEDs.
4. Check fiber-optic cable.
5. Look for other existing errors in the service plot. Sometimes, an error may appear in the service plot but
not in the IPS. This could be the case with PSU related errors (fuses, switch overload, etc.).
Severity
ADVISORY
11.04.0X:09 (X may be in the range 1–4)

(11.04.01:09, 11.04.02:09, 11.04.03:09, 11.04.04:09)
1. 01 Cable to Printhead Interconnect PCA 1 (Optimizer) not properly connected to connector J11 of Carriage
Fiber Optics PCA.
2. 02 Cable to Printhead Interconnect PCA 2 (CK) not properly connected to connector J8 of Carriage Fiber
Optics PCA.
3. 03 Cable to Printhead Interconnect PCA 3 (YM) not properly connected to connector J10 of Carriage Fiber
Optics PCA.
4. 04 Cable to Printhead Interconnect PCA 4 (Lm/Lc) not properly connected to connector J9 of Carriage Fiber
Optics PCA.
a. FO PCA cable to printhead interconnect X is not connected/damaged/broken.
b. FO PCA is damaged or not working.

Corrective actions
1. Run Control link diagnostics test. See Table 5-4 Printhead control link on page 546.
2. Check cabling and LEDs in fiber-optics PCA and printhead interconnect X.
3. Swap printhead interconnect PCA (same color)
4. If the problem accompanies the printhead interconnect PCA, install a new one. See Printhead interconnect
color PCA (1HA06-67002) on page 713 or Printhead interconnect optimizer PCA (1HA06-67003)
on page 717. Otherwise, install a new cable.
5. If the problem remains, install a new fiber-optics PCA. See Fiber-optics PCA (CZ056-67389) on page 739.
Severity
ADVISORY

(11.05.01:01, 11.05.02:01, 11.05.03:01, 11.05.04:01)
Printhead interconnect X malfunction. Restart the printer in diagnostic mode and run printhead control
diagnostics. If problem is confirmed, call your support representative.
Printhead interconnect X is not working/damaged/broken.
Corrective actions
1. Run the control link diagnostics test. See Table 5-4 Printhead control link on page 546.
2. Check cabling and LEDs in the fiber-optics PCA and printhead interconnect X.
3. Swap the printhead interconnect PCA with one of the same color.
on page 717.
Severity
ADVISORY

(11.05.01:04, 11.05.02:04, 11.05.03:04, 11.05.04:04)

Printhead interconnect X not responding. Restart the printer and run printhead control diagnostics. If problem is
confirmed, call your support representative.
Printhead interconnect X is not working/damaged/broken.
Corrective actions
1. Run control link diagnostics test. See Table 5-4 Printhead control link on page 546.
2. Check cabling and LEDs in the fiber-optics PCA and printhead interconnect X. See Board name: Fiber-optics
PCA on page 408.
3. If the issue is affecting the PH Interconnect PCA 2, 3 or 4, swap the affected PCA with another to check if
the issue follows the PCA.
on page 717. SVC Part: PH Interconnect color PCA (1HA06-67002) or PH Interconnect optimizer
(1HA06-67003).
Severity
ADVISORY
16. Curing error codes

The Curing subsystem is composed by 6 modules, each one including 2 chambers. In the system errors
codification, a standard has been used to define the indexation of each module and chamber. Each PCA controls
the module with the same ID.
16.01.00:05
Restart the printer. If the problem persists, call support. Caution! Hot surfaces inside the printer. Do not touch
heating modules.

The curing module cannot reach the target temperature in time, either while warming up or while cooling down.
Possible reasons:
a. The curing module is not properly closed and latched.
b. The curing module has had an internal failure (fan or resistor).
Corrective actions
1. Check that the ambient temperature is within the printer specifications.
2. Check that the curing module is properly closed and sealed.
3. Ensure that the curing module recirculation funnels are not blocked.
4. Check the curing nail and ensure that the distance between it and the diverter is 10 mm.
5. Ensure that the temperature sensor is not touching any metal part. Run the diagnostics explained below to
know which is the module that is not warmed up. Then open it, check the position of the chamber
temperature sensors, and check that they are not damaged.
6. Check that the VR vacuum is disabled during warm-up.
7. Run the Status of curing modules diagnostic (16002) and check all that modules with substrate under
them are able to warm up and cool down. In the diagnostic, choose the option Heaters ON, fans @ 40%.
8. Install a new fan and resistor module (see Curing heater and fan module (1HA07-67038) on page 750).
SVC part: Curing heater and fan module S (1HA07-67038).
NOTE: The curing fan heater resistor has a nominal impedance of 34.2 Ω and a minimum acceptable
impedance of 32.49 Ω.
Severity
ADVISORY
The current printing queue is canceled, and the error will be cleared at the start of the next printing job.
16.01.00:86
Printer AC Input Voltage configuration is out of range. Contact your support representative in order to set proper
installation parameter.
The AC input voltage configuration is not correctly set.
Corrective actions
Reconfigure the AC input voltage according to the installation instructions. Then restart the printer so that the
new configuration can take effect.

Severity
ADVISORY
The curing system is disabled and printing is not allowed, until you have reconfigured the AC input voltage and
restarted the printer.
16.01.00:97
Synchronization error between curing modules. Restart the printer. If problem persists, please contact your
support representative.
Description
The curing modules interchange information with each other. This System Error will appear if the communication
is not reliable and some communication messages are being lost during runtime. Note: This system error
appears only if the communication has been lost during a short amount of time. Otherwise, other
communication errors might appear.
There is interference in the control line between modules.
Corrective actions
1. Reboot the printer.
2. If the problem persists, ensure all cables are not damaged and that there is no interference.
Severity
ADVISORY

(16.01.01:01, 16.01.02:01, 16.01.03:01, 16.01.04:01, 16.01.05:01, 16.01.06:01)
Curing module X error state. Module disabled, substrate going under this module won't be cured. But if module is
required to print, run subsystem diagnostic. If the problem persists, call support.
a. There is a problem in communicating with the curing PCA.
b. The curing module reports a transient internal failure and cannot be used.
c. The curing PCA has failed.

Corrective actions
1. Check curing PCA connections: both control line and power line.
2. Check curing PCA LEDs. See Board name: Curing PCA on page 418.
3. Run e-cabinet and e-box diagnostics, and fix any error detected. See Table 5-22 E-cabinet on page 586,
Table 5-21 E-box on page 585.
4. Check curing PCA communication errors. See Troubleshoot curing PCA communication errors on page 420.
5. Install a new curing PCA. See Curing and Vapor removal PCA (CZ056-67384/1HA07-67015) on page 772.
SVC part: Curing PCA (CZ056-67384/1HA07-67015).
Severity
ADVISORY
The curing module with the error is disabled. It is possible to print only if the curing module is not over the
substrate.

(16.01.01:02, 16.01.02:02, 16.01.03:02, 16.01.04:02, 16.01.05:02, 16.01.06:02)
Curing module X temperature servo start failure. Retry, and if the problem persists call HP support and run
diagnostic.
a. Curing PCA failure
b. Curing PCA fan connection problem
c. Curing PCA configuration problem
Corrective actions
2. Update the printer’s firmware.
3. Check that the Curing PCA fan is correctly connected to the Curing PCA.
4. Install a new Curing PCA. See Curing and Vapor removal PCA (CZ056-67384/1HA07-67015) on page 772.
5. SVC part: Curing PCA (CZ056-67384/1HA07-67015)
Severity
ADVISORY
substrate.


(16.01.01:03, 16.01.02:03, 16.01.03:03, 16.01.04:03, 16.01.05:03, 16.01.06:03)
Curing module X firmware and hardware mismatch. Module is disabled, substrate going under this module won't
be cured. But if module is required to print, reinstall/upgrade printer firmware. If problem persists, call support.
Current firmware version and curing module hardware version mismatch
Corrective actions
1. Update printer firmware.
3. SVC part: PCA Curing (CZ056-67384/1HA07-67015)
Severity
ADVISORY
substrate.
16.01.0X:04 (X may be 1 in the range 1–6)

(16.01.01:04, 16.01.02:04, 16.01.03:04, 16.01.04:04, 16.01.05:04, 16.01.06:04)
Curing module X generic comms error Module disabled, substrate going under this module won't be cured. But if
module is required to print, run subsystem diagnostic. If the problem persists, call support.
a. Printer cannot communicate with module
b. Cabling problem or curing PCA problem
Corrective actions

SVC part: PCA Curing (CZ056-67384/1HA07-67015).
Severity
ADVISORY
substrate.

(16.01.01:09, 16.01.02:09, 16.01.03:09, 16.01.04:09, 16.01.05:09, 16.01.06:09)
Curing module X: no PCA device detected. Module disabled, substrate going under this module won't be cured.
But if module is required to print, run subsystem diagnostic. If problem persists, call support.
Description
The printer cannot detect the curing PCA.
a. Curing PCA communication problem
b. Curing PCA malfunction
c. Module address not well set
Corrective actions
Severity
ADVISORY
substrate.


(16.01.01:10, 16.01.02:10, 16.01.03:10, 16.01.04:10, 16.01.05:10, 16.01.06:10)
Curing module X AC power out of range. Module disabled, substrate going under this module won't be cured. But
if module is required to print, run subsystem diagnostic. If problem persists, call support.
Description
The AC power to the curing module has been cut or is out of range.
a. One or more curing ACBs (Automatic Circuit Breakers) in the e-cabinet are down (a couple of modules will
have the error for each ACB that is down).
b. There has been an AC power cut or the AC input tension is out of range (too low or too high).
c. There has been a disconnection in the AC power line going to the curing module.
d. Resistor degradation.
e. There has been a curing PCA failure.
Corrective actions
1. Check that all curing ACBs (Automatic Circuit Breakers) in the e-cabinet are OK and in working position.
2. Check whether the customer has power cuts and input voltage problems.
3. Check that AC power cables are properly connected and in good shape.
4. Check the curing PCA and install a new one if necessary. See Curing and Vapor removal PCA
(CZ056-67384/1HA07-67015) on page 772. SVC part: Curing PCA (CZ056-67384/1HA07-67015).
5. Check the AC input tension and, if necessary, turn off the printer and reconfigure its AC input configuration.
6. Check the impedance of the resistors for both heaters. The nominal value is 34.2 Ω; if the impedance is less
than 32.49 Ω, replace the curing heater/fan assembly. See Curing heater and fan module (1HA07-67038)
on page 750.
7. Swap pairs of heater/fan assemblies between consecutive modules (using different AC lines).
NOTE: The PCAs are connected two to each AC input phase, as follows:
● #1 and #4 to the same phase
8. Depending on the reported issues, proceed as follows:

● If the failure moves to the other module, following the heater/fan: Swap the fan/heater of the
chambers#2 between both consecutive modules. The failure will then point to the module that
contains the defective fan/heater, which should be replaced.
● If the failure remains in the same module, the problem is not in the heater/fan assemblies. Swap the
curing PCAs between consecutive modules (using different AC lines).
If the failure follows the curing PCA, replace the curing PCA. See Curing and Vapor removal PCA
(CZ056-67384/1HA07-67015) on page 772. If not, the AC input may be out of range: check the AC
input and the electrical configuration of the curing module in the e-cabinet. See Figure 2-13 Curing
Subsystem on page 87.
Severity
ADVISORY

(16.01.01:41, 16.01.02:41, 16.01.03:41, 16.01.04:41, 16.01.05:41, 16.01.06:41)
Curing module X heater overcurrent warning. Contact your support representative to check input voltage
configuration.
a. Wrong configuration of AC input tension
b. AC input tension out of range
c. Resistor degradation
Corrective actions
1. Check the connections of each cable connected to the curing modules.
2. Check the AC input tension and, if necessary, turn off the printer and reconfigure its AC input configuration.
3. Check the impedance of the resistors for both heaters. The nominal value is 34.2 Ω; if the impedance is less
than 32.49 Ω, replace the curing heater/fan assembly.

● If the failure moves to the other module, following the heater/fan: Swap the fan/heater of the
chambers#2 between both consecutive modules. The failure will then point to the module that
curing PCAs between consecutive module 2 modules (using different AC lines).
If the failure follows the curing PCA, replace the curing PCA. See Curing and Vapor removal PCA
(CZ056-67384/1HA07-67015) on page 772. If not, the AC input may be out of range: check the AC
input and the electrical configuration of the curing module in the e-cabinet. See Figure 2-21 TUR
(Pinch Switch & SLIT SOL) and VR Subsystems on page 95.
Severity
ADVISORY

(16.02.01:01, 16.02.02:01, 16.02.03:01, 16.02.04:01, 16.02.05:01, 16.02.06:01)
Curing module X PCA error. Module disabled, substrate going under this module won't be cured. But if module is
required to print, reinstall/upgrade printer firmware. If problem persists, call support.
a. Curing PCA internal error
b. Curing PCA malfunction
Corrective actions
1. Reinstall or update the printer’s firmware.
Severity
ADVISORY
substrate.


(16.02.01:04, 16.02.02:04, 16.02.03:04, 16.02.04:04, 16.02.05:04, 16.02.06:04)
Curing module X comm error between curing PCA and e-box. Module disabled, substrate going under this
module won't be cured. But, if module is required to print, run subsystem diagnostic. If problem persists, call
support.
a. Curing PCA connection problem
b. Curing PCA not properly identified by curing fan cable (CZ056-50120)
c. Curing PCA malfunction
Corrective actions
4. Check curing PCA communication errors. See Troubleshoot curing PCA communication errors on page 420
Severity
ADVISORY
substrate.

(16.02.01:10, 16.02.02:10, 16.02.03:10, 16.02.04:10, 16.02.05:10, 16.02.06:10)
Curing module X PCA DC supply error. Module disabled, substrate going under this module won't be cured. But, if
module is required to print, run subsystem diagnostic. If problem persists, call support.
a. Curing PSU 24 V error
b. 24 V cabling problem

c. Curing PCA problem
d. E-cabinet PCA problem
Corrective actions
1. Check the 24 V DC PSUs. See PSU configuration on page 14.
2. Run the Monitor one curing module diagnostic (16003), and check that the 24 V report value is in range.
See Table 5-18 Curing on page 581.
3. Check 24 V DC cabling and connections.
4. Check the 24 V DC PSU that provides 24 V DC power to the curing PCA.
5. If any part is faulty, install a new one.
Severity
ADVISORY
substrate.

(16.02.01:21, 16.02.02:21, 16.02.03:21, 16.02.04:21, 16.02.05:21, 16.02.06:21)
Curing module X PCA temp too high. Module disabled, substrate going under this module won't be cured. But, if
a. Ambient temperature too high
b. Curing PCA cooling fan not working
c. Vapor is reaching the electronics
Corrective actions
1. Check that the ambient temperature is within printer specifications.
2. Check the curing PCA cooling fan, it should be turning and not blocked by powder.
3. Check that vapor removal is working properly. Ensure that there is no vapor or hot air from the curing
module reaching the electronics.
4. Run the Monitor one curing module diagnostic (16003, see Table 5-18 Curing on page 581), set module to
Heater off and fans 95% and wait 15 minutes for the module to cool down. Monitor the PCA temperature, if

it is far from the ambient temperature then install a new curing PCA (the ambient temperature should be
below 40°C).
5. Install a new curing PCA cooling fan. See Curing PCA cooling fan (K4T88-67304) on page 768. SVC part:
Fan curing PCA (K4T88-67133).
Severity
ADVISORY
substrate.

(16.10.01:20, 16.10.02:20, 16.10.03:20, 16.10.04:20, 16.10.05:20, 16.10.06:20)
Curing module X temperature chamber 1 out of range. Module disabled, substrate going under this module
won't be cured. But, if module is required to print, run subsystem diagnostic. If problem persists, call support.
a. Ambient temperature too high or too low
b. Not enough airflow in module chamber
c. Failure in temperature control
Corrective actions
2. Check that the fans are working, and that the holes in the curing plate are not blocked.
3. Ensure that the temperature sensor is not touching any metal part.
4. Check the curing PCA by running the Monitor one curing module diagnostic (16003, see Table 5-18 Curing
on page 581). Set the module to Heater off and fans 95% and wait 10 minutes for the module to cool
down. Check that the chamber 1 temperature is near ambient temperature and similar to the chamber 2
temperature (if chamber 2 is not reporting an error). Otherwise, check the temperature sensor and cable.
Set the module to Heater on and fans 40%. The temperature in chamber 1 should increase slowly (and at
the same rate as the temperature in chamber 2). If the temperature increases quickly, check the resistor,
the temperature sensor, and the cable.
Interchange the temperature sensors. If the error changes to the other chamber, install a new sensor (see
Curing temperature sensor kit (CZ056-67055) on page 753. Otherwise, interchange the fan and heater
assemblies. If the error changes to the other chamber, install a new heater (see Curing heater and fan
module (1HA07-67038) on page 750). If the error is not related to the sensor or the resistor, install a new

curing PCA (see Curing and Vapor removal PCA (CZ056-67384/1HA07-67015) on page 772. SVC part: PCA
Curing (CZ056-67384/1HA07-67015).
Severity
ADVISORY
The current printing queue is canceled and the error will be cleared at the start of the next printing job.

(16.11.01:01, 16.11.02:01, 16.11.03:01, 16.11.04:01, 16.11.05:01, 16.11.06:01)
Curing module X chamber 1 temperature sensor failure. Module disabled, substrate going under this module
won't be cured. But, if module is required to print, run subsystem diagnostic. If the problem persists, call support.
Temperature sensor problem
Corrective actions
2. Check the temperature sensor cable and connection.
3. Install a new temperature sensor (see Curing temperature sensor kit (CZ056-67055) on page 753). SVC
part: curing temperature sensor kit (K4T88-67055).
4. Install a new curing PCA (see Curing and Vapor removal PCA (CZ056-67384/1HA07-67015) on page 772).
Severity
ADVISORY
substrate.

(16.13.01:01, 16.13.02:01, 16.13.03:01, 16.13.04:01, 16.13.05:01, 16.13.06:01)
Curing module X chamber 1 fan no spinning detected. Module disabled, substrate going under this module won't
be cured. But if module is required to print, run subsystem diagnostic. If the problem persists, call support.

Description
No left chamber fan movement is detected in module X.
The fan is not detected to be spinning. The problem could be the fan itself, the fan power, or the tachometer
signal.
Corrective actions
1. Look at fan and verify it is not spinning. If it is spinning, the problem involves the encoder signal (encoder,
cabling, connections). Check the fan connections and cabling.
2. If the fan rotor is locked, swap two curing heater and fan modules. If the issue remains in the same module
and chamber, recheck the connections and the Curing PCA. If the issue continues with the fan, install a new
one (see Curing heater and fan module (1HA07-67038) on page 750). SVC part: Curing heater and fan
module S (1HA07-67038).
3. Run the Monitor one curing module diagnostic (16003, see Table 5-18 Curing on page 581), set module to
Heaters off and fans 95%, check that fan speed is in the range 8500 to 10000 rpm, and check that fan
current is in the range 2700 to 4000 mA. If any value is out of range, interchange fans in chambers. If the
error follows the fan, then install a new fan. If the error stays in the same chamber, install a new
intermediate cable between the fans and the curing PCA. Remember to configure the fan cable.
Severity
ADVISORY
substrate.

(16.14.01:15, 16.14.02:15, 16.14.03:15, 16.14.04:15, 16.14.05:15, 16.14.06:15)
Curing module X chamber 1 open circuit detected. Module disabled, substrate going under this module won't be
cured. But, if module is required to print, run subsystem diagnostic. If problem persists, call support.
a. Resistor failure
b. Resistor cabling error
c. Curing PCA failure (relay, triac, current sensor)

Corrective actions
1. Check the resistor and cabling and install new parts if necessary. See Curing heater and fan module
(1HA07-67038) on page 750.
2. Install a new curing heater and fan module. SVC part: Curing heater and fan module S (1HA07-67038).
3. Reinstall or update the firmware.
(CZ056-67384/1HA07-67015) on page 772. SVC part: PCA Curing (CZ056-67384/1HA07-67015).
Severity
ADVISORY
substrate.

(16.15.01:01, 16.15.02:01, 16.15.03:01, 16.15.04:01, 16.15.05:01, 16.15.06:01)
Curing module X resistor 1 PCA failure. Module disabled, substrate going under this module won't be cured. But,
Description
The printer has protected itself to prevent damages related to a short-circuit in a curing resistor or the Curing
PCA. If this error is reported with SEVERE severity, the issue involves the Curing PCA. If the severity is ADVISORY it
might only involve the resistor.
▲ Curing PCA failure (relay or triac are short-circuited)
Corrective actions
This error can report two levels of severity, depending on which different actions are required.
SEVERE: The printer cannot be safely operated and is shut down. Install a new curing PCA and restart the printer.
ADVISORY: The curing module with the error is disabled. It is possible to print only if the curing module is not
over the substrate. Follow the corrective action below:
▲ Check the curing PCA and install a new one if necessary. See Curing and Vapor removal PCA

Severity
SEVERE: The printer cannot be safely operated and is shut down.
over the substrate.

(16.20.01:20, 16.20.02:20, 16.20.03:20, 16.20.04:20, 16.20.05:20, 16.20.06:20)
Curing module X temperature chamber 2 out of range. Module disabled, substrate going under this module
b. Not enough airflow in module chamber
Corrective actions
2. Check that the fans are working, and that the holes in the curing plate are not blocked.
4. Check the curing PCA by running the Monitor one curing module diagnostic (16003, see Table 5-18 Curing
Interchange the temperature sensors. If the error changes to the other chamber, install a new sensor (see
Curing temperature sensor kit (CZ056-67055) on page 753). Otherwise, interchange the fan and heater
assemblies. If the error changes to the other chamber, install a new heater (see Curing heater and fan
module (1HA07-67038) on page 750). If the error is not related to the sensor or the resistor, install a new
curing PCA (see Curing and Vapor removal PCA (CZ056-67384/1HA07-67015) on page 772).
Severity
ADVISORY
The current printing queue is canceled and the error will be cleared at the start of the next printing job.


(16.21.01:01, 16.21.02:01, 16.21.03:01, 16.21.04:01, 16.21.05:01, 16.21.06:01)
Curing module X chamber 2 temperature sensor failure. Module disabled, substrate going under this module
Temperature sensor problem
Corrective actions
2. Check the temperature sensor and connection.
3. Install a new temperature sensor (see Curing temperature sensor kit (CZ056-67055) on page 753).
Severity
ADVISORY
substrate.

(16.23.01:01, 16.23.02:01, 16.23.03:01, 16.23.04:01, 16.23.05:01, 16.23.06:01)
Curing module X chamber 2 fan no spinning detected. Module disabled, substrate going under this module won't
be cured. But, if module is required to print, run subsystem diagnostic. If problem persists, call support.
The fan is not detected to be spinning. The problem could be the fan itself, the fan power, or the tachometer
signal.
Corrective actions
1. Check the fan connections and cabling.
2. Check that the fan rotor is not locked. If locked, install a new fan.

3. Run the Monitor one curing module diagnostic (16003, see Table 5-18 Curing on page 581), set the
module to Heaters off and fans 95%, check that the fan speed is in the range 8500 to 10000 rpm, check
that the fan current is in the range 2700 to 4000 mA. If any value is out of range, interchange the fans
between chambers, if the error follows the fan then install a new fan. If the error stays in the same
chamber, install a new intermediate cable between the fans and the curing PCA. Remember to configure
the fan cable.
Severity
ADVISORY
substrate.

(16.24.01:15, 16.24.02:15, 16.24.03:15, 16.24.04:15, 16.24.05:15, 16.24.06:15)
Curing module X chamber 2 open circuit detected. Module disabled, substrate going under this module won't be
a. Resistor failure
b. Resistor cabling error
c. Curing PCA failure (relay, triac, current sensor)
Corrective actions
1. Check the resistor and cabling, and install new parts if necessary. See Curing heater and fan module
(1HA07-67038) on page 750.
2. Reinstall or update the firmware.
Severity
ADVISORY
substrate.


(16.25.01:01, 16.25.02:01, 16.25.03:01, 16.25.04:01, 16.25.05:01, 16.25.06:01)
Curing module X resistor 2 PCA failure. Module disabled, substrate going under this module won't be cured. But,
▲ Curing PCA failure (relay or triac are short-circuited)
Corrective actions
SEVERE: The printer cannot be safely operated and is shut down. Install a new curing PCA and restart the printer.
over the substrate. Follow the corrective action below:
▲ Check the curing PCA and install a new one if necessary. See Curing and Vapor removal PCA
Severity
over the substrate.

(16.33.01:01, 16.33.02:01, 16.33.03:01, 16.33.04:01, 16.33.05:01, 16.33.06:01)
Curing module X PCA fan no spinning detected. Module disabled, substrate going under this module won't be
The curing module electronics cooling fan is not detected to be spinning. The problem could be the fan itself, the
fan power, or the tachometer signal.

Corrective actions
1. Check the fan connections.
2. Install a new fan (see Curing PCA cooling fan (K4T88-67304) on page 768). SVC part: Fan curing PCA
(K4T88-67133).
Severity
ADVISORY
substrate.

(16.33.01:09, 16.33.02:09, 16.33.03:09, 16.33.04:09, 16.33.05:09, 16.33.06:09)
Curing module X fan connector issue. Module disabled, substrate going under this module won't be cured. But, if
The curing intermediate fan cable is not properly configured with the curing module address.
Corrective actions
Check that the intermediate fan cable is properly configured according to the fan cable installation instructions.
Severity
ADVISORY
substrate.

(16.90.01:90, 16.90.02:90, 16.90.03:90, 16.90.04:90, 16.90.05:90, 16.90.06:90)
Curing module X safety monitor disabled. Safety mechanism disabled, printer can’t be operated. Reboot in
diagnostic mode and run safety diagnostics. If problem persists, call support.

The curing PCA internal safety monitor is disabled.
Corrective actions
1. Update the printer firmware.
Severity
ADVISORY
substrate.

(16.91.01:01, 16.91.02:01, 16.91.03:01, 16.91.04:01, 16.91.05:01, 16.91.06:01)
Curing module X safety relay failure detected. Safety mechanism disabled, printer can't be operated. Reboot in
diagnostic mode and run safety diagnostics. If problem persists, call support.
A failure has been detected in a curing PCA internal relay.
Corrective actions
▲ Install a new curing PCA (see Curing and Vapor removal PCA (CZ056-67384/1HA07-67015) on page 772).
Severity
SEVERE
17. Drying error codes

The Drying subsystem is composed of 4 modules, each one including 2 chambers. In the system errors
codification a standard has been used to define the indexation of each module and chamber. Each PCA controls
the module with the same ID.

17.01.00:05
The drying subsystem cannot reach the target temperature in time. Restart the printer. If the problem persists,
call support. Caution! Hot surfaces inside the printer. Do not touch heating modules.
Description
The Drying module cannot reach the target temperature in time, either while warming up or while cooling down.
a. The front door is not properly closed
b. Signal from temperature sensor not correctly read (issue with sensor or cabling)
c. Fan or resistor issue
Corrective actions
1. Check that the ambient temperature is within the printer specifications.
2. Check that the front door is properly closed.
3. Ensure that the temperature sensor is not touching any metal part. Run the diagnostics explained below to
know which is the module that is not warmed up. Then open it, check the position of the chamber
temperature sensors, and check that they are not damaged.
4. Run the Status of Drying module diagnostic (17002) and check all that modules are able to warm up and
cool down. In the diagnostic, choose the option Heaters ON, fans @ 40%.
5. Install a new fan and resistor module. See Drying heater and fan (K4T88-67107) on page 790. SVC part:
Drying heater and fan module S (K4T88-67107).
NOTE: The Drying fan heater resistor has a nominal resistivity value of 32.4 Ω and a minimum acceptable
resistivity value of XXX Ω.

Severity
ADVISORY
17.01.00:86
Printer AC Input Voltage configuration is out of range. Contact your support representative in order to set the
proper installation parameter.
The AC input voltage configuration is not correctly set.
Corrective actions
Reconfigure the AC input voltage according to the installation instructions. Then restart the printer so that the
new configuration can take effect.
Severity
ADVISORY
17.01.00:97
Synchronization error between drying modules. Restart the printer. If problem persists, please contact your
Description
The drying modules interchange information with each other. This System Error will appear if the communication
is not reliable and some communication messages are being lost during runtime. Note: This system error
appears only if the communication has been lost during a short amount of time. Otherwise, other
communication errors might appear.
There is interference in the control line between modules.
Corrective actions
1. Reboot the printer.
2. If the problem persists, ensure all cables are not damaged and that there is no interference.

Severity
ADVISORY

(17.01.01:01, 17.01.02:01, 17.01.03:01, 17.01.04:01)
Drying module X error state. Drying disabled, printer can't be operated. Run subsystem diagnostic. If problem
persists, call support.
a. There is a problem in communicating with the Drying PCA
b. The Drying module reports a transient internal failure and cannot be used
c. The Drying PCA has failed
Corrective actions
1. Check Drying PCA connections: both control line and power line.
2. Check Drying PCA LEDs. See Board name: Drying PCA on page 423 (K4T88-67070).
3. Run e-cabinet and e-box diagnostics, and fix any error detected. See Table 5-22 E-cabinet on page 586
and See Table 5-21 E-box on page 585.
4. Check Drying PCA communication errors. See Troubleshoot drying PCA communication errors on page 426.
5. Install a new Drying PCA (see Drying PCA (K4T88-67070) on page 784). SVC part: Drying PCA
(K4T88-67070).
Severity
ADVISORY

(17.01.01:02, 17.01.02:02, 17.01.03:02, 17.01.04:02)
Drying module X temperature control start failure. Retry, and if the problem persists call HP support and run
diagnostic.
Description
The temperature control has not been able to start, usually because there is some other issue in the printer.

a. Drying PCA failure
b. Drying PCA fan connection problem
c. Drying PCA configuration problem
Corrective actions
3. Check that the Drying PCA fan is correctly connected to the Drying PCA.
4. Install a new Drying PCA. See Drying PCA (K4T88-67070) on page 784. SVC part: Drying PCA
(K4T88-67070).
Severity
ADVISORY

(17.01.01:03, 17.01.02:03, 17.01.03:03, 17.01.04:03)
Drying module X firmware and hardware mismatch. Drying disabled, printer can't be operated. Run subsystem
diagnostic. If problem persists, call support.
Current firmware version and Drying module hardware version mismatch
Corrective actions
(K4T88-67070).
Severity
ADVISORY

(17.01.01:04, 17.01.02:04, 17.01.03:04, 17.01.04:04)

Drying module X PCA communication error. Drying disabled, printer can't be operated. Run subsystem diagnostic.
If problem persists, call support.
a. Printer cannot communicate with module
b. Cabling problem or Drying PCA problem
Corrective actions
1. Check Drying PCA connections: both control line and power line. Verify that the address in the fan connector
of the Drying PCA is correctly configured.
(K4T88-67070).
Severity
ADVISORY

(17.01.01:09, 17.01.02:09, 17.01.03:09, 17.01.04:09)
Drying module X: no PCA detected. Drying disabled, printer can't be operated. Run subsystem diagnostic. If
problem persists, call support.
Description
The printer cannot detect the Drying PCA.
a. Drying PCA communication problem
b. Drying PCA malfunction
c. Module address not well set
Corrective actions

and Table 5-21 E-box on page 585.
(K4T88-67070).
Severity
ADVISORY

(17.01.01:10, 17.01.02:10, 17.01.03:10, 17.01.04:10)
Drying module X AC Input Voltage out of range. Drying disabled, printer can't be operated. Run subsystem
Description
The AC power to the Drying module has been cut or is out of range.
a. One or more Drying ACBs (Automatic Circuit Breakers) in the e-cabinet are down (a couple of modules will
have the error for each ACB that is down)
b. There has been an AC power cut or the AC input tension is out of range (too low or too high)
c. There has been a disconnection in the AC power line going to the Drying module
d. Resistor degradation
e. There has been a Drying PCA failure
Corrective actions
1. Check that all Drying ACBs (Automatic Circuit Breakers) in the e-cabinet are OK and in working position.
2. Check whether the customer has power cuts and input voltage problems.
3. Check that AC power cables are properly connected and in good shape.
4. Check the Drying PCA and install a new one if necessary. See Drying PCA (K4T88-67070) on page 784. SVC
part: Drying PCA (K4T88-67070).
5. Check the AC input tension, and if necessary, turn off the printer and reconfigure its AC input configuration.
6. Check the resistivity value of the resistors for both heaters. The nominal value is 32.4 Ω; if the resistivity
value is less than 30.8 Ω, replace the drying heater/fan assembly.

● If the failure moves to the other module, and continues in the heater/fan: Swap the fan/heater of the
chambers #2 between both consecutive modules. The failure will then point to the module that
Drying PCAs between consecutive modules (using different AC lines). If the failure continues in the
same Drying PCA, replace the Drying PCA. See Drying PCA (K4T88-67070) on page 784. If not, the AC
input may be out of range: check the AC input and the electrical configuration of the drying module in
the e-cabinet.
Severity
ADVISORY

(17.01.01:41, 17.01.02:41, 17.01.03:41, 17.01.04:41)
Drying module X heater overcurrent warning. Contact your support representative to check input voltage
configuration.
a. Wrong configuration of AC input tension
b. AC input tension out of range
c. Resistor degradation
d. Cabling failure
Corrective actions
1. Check the connections of each cable connected to the drying modules.
2. Check the AC input tension, and if necessary, turn off the printer and reconfigure its AC input configuration.
3. Check the resistivity value of the resistors for both heaters. The nominal value is 32.4 Ω; if the resistivity
value is less than XXXX Ω, replace the drying heater/fan assembly.

● If the failure moves to the other module, and continues in the heater/fan: Swap the fan/heater of the
chambers #2 between both consecutive modules. The failure will then point to the module that
Drying PCAs between consecutive module 2 modules (using different AC lines). If the failure continues
in the Drying PCA, replace the Drying PCA. See Drying PCA (K4T88-67070) on page 784. If not, the AC
input may be out of range: check the AC input and the electrical configuration of the drying module in
the e-cabinet.
Severity
ADVISORY

(17.02.01:01, 17.02.02:01, 17.02.03:01, 17.02.04:01)
Drying module X PCA error. Drying disabled, printer can't be operated. Reinstall/Upgrade printer firmware. If
a. Drying PCA internal error
b. Drying PCA malfunction
Corrective actions
1. Reinstall or update the printer’s firmware.
(K4T88-67070).
Severity
ADVISORY


(17.02.01:04, 17.02.02:04, 17.02.03:04, 17.02.04:04)
Drying module X communication error between Drying PCA and e-box. Drying disabled, printer can't be operated.
Run subsystem diagnostic. If problem persists, call support.
a. Drying PCA connection problem
b. Drying PCA not properly identified by Drying fan cable (CZ056-50120)
c. Drying PCA malfunction
Corrective actions
1. Check Drying PCA connections: both control line and power line.
and See Table 5-21 E-box on page 585.
(K4T88-67070).
Severity
ADVISORY

(17.02.01:10, 17.02.02:10, 17.02.03:10, 17.02.04:10)
Drying module X PCA DC supply error. Drying disabled, printer can't be operated. Run subsystem diagnostic. If
a. Drying PSU 24 V error
b. 24 V cabling problem
c. Drying PCA problem
d. E-cabinet PCA problem

Corrective actions
1. Check the 24 V DC PSUs. See PSU configuration on page 14.
2. Run the Monitor one Monitor one Drying module diagnostic (16003), and check that the 24 V report value is
in range. See Table 5-20 Drying on page 583.
3. Check 24 V DC cabling and connections.
4. Check the 24 V DC PSU that provides 24 V DC power to the Drying PCA.
5. If any part is faulty, install a new one.
Severity
ADVISORY

(17.02.01:21, 17.02.02:21, 17.02.03:21, 17.02.04:21)
Drying module X PCA temperature too high. Drying disabled, printer can't be operated. Run subsystem
a. Drying PCA 1 cooling fan filter full
b. Ambient temperature too high
c. Drying PCA 1 cooling fan not working
d. Vapor is reaching the electronics
Corrective actions
2. Check and clean the Drying PCA cooling fan filter, it should not be full of powder.
3. Check the Drying PCA cooling fan, it should be spinning and not full of powder.
4. Check that vapor removal is working properly. Ensure that there is no vapor or hot air from the Drying
module reaching the electronics.
5. Run the Monitor one Drying module diagnostic (17003, see Table 5-20 Drying on page 583), set module to
Heater off and fans 95% and wait 15 minutes for the module to cool down. Monitor the PCA temperature, if
it is far from the ambient temperature then install a new Drying PCA (the ambient temperature should be
below 40°C).
6. Install a new drying fan PCA. See Drying fan PCA (K4T88-67110) on page 787. SVC part: Drying fan PCA
(K4T88-67110).

Severity
ADVISORY

(17.10.01:20, 17.10.02:20, 17.10.03:20, 17.10.04:20)
Drying module X temperature chamber 1 out of range. Drying disabled, printer can't be operated. Run
subsystem diagnostic. If problem persists, call support.
Description
During printing, the printer has detected that the temperature of the left chamber of the module X is outside the
acceptable desired range.
b. Not enough or too much airflow in module chamber
Corrective actions
2. Check all cables and connections.
3. Check that the rear part of the printer is not blocked and thus preventing the cold air to enter the drying.
5. Check the Drying PCA by running the Monitor one Drying module diagnostic (17003, see Table 5-20 Drying
resistivity value of 30.8 Ω.
6. Interchange the temperature sensors. If the error changes to the other chamber, install a new sensor ( see
Curing temperature sensor kit (CZ056-67055) on page 753), SVC part: Temperature sensor
(CZ056-67055). Otherwise, interchange the fan and heater assemblies (see Drying heater and fan
(K4T88-67107) on page 790. SVC part: Drying heater and fan module S K4T88-67107). If the error
changes to the other chamber, install a new heater (see Drying heater and fan (K4T88-67107)
on page 790. SVC part: Drying heater and fan module S K4T88-67107). If the error is not related to the

sensor or the resistor, install a new Drying PCA (see Drying PCA (K4T88-67070) on page 784). SVC part:
Drying PCA (K4T88-67070).
Severity
ADVISORY

(17.11.01:01, 17.11.02:01, 17.11.03:01, 17.11.04:01)
Drying module X chamber 1 temperature sensor failure. Drying disabled, printer can't be operated. Run
a. Temperature sensor problem
b. The temperature signal is not correctly read due to a failing Drying PCA
Corrective actions
2. Check the temperature sensor cable and connection.
3. Install a new temperature sensor (see Curing temperature sensor kit (CZ056-67055) on page 753).
(K4T88-67070).
Severity
ADVISORY

(17.13.01:01, 17.13.02:01, 17.13.03:01, 17.13.04:01)
Drying module X chamber 1 fan no spinning detected. Drying disabled, printer can't be operated. Run subsystem
diagnostic. If the problem persists, call support.
Description
No movement is detected on the left chamber fan in the module X.

a. Fan failure
b. Fan power cabling failure
c. Tachometer signal
Corrective actions
1. Look at the fan and verify it is not spinning. If it is spinning, the problem involves the encoder signal
(encoder, cabling, connections). Check the fan connections and cabling.
2. If the fan rotor is locked, swap two drying heater and fan modules. If the issue remains in the same module
and chamber, recheck the connections and the Drying PCA. If the issue continues with the fan, install a new
one. See Drying heater and fan (K4T88-67107) on page 790. SVC part: Drying heater and fan module S
(K4T88-67107).
error continues with the fan, then install a new fan. If the error stays in the same chamber, install a new
intermediate cable between the fans and the Drying PCA. Remember to configure the fan cable.
(K4T88-67070).
Severity
ADVISORY

(17.14.01:15, 17.14.02:15, 17.14.03:15, 17.14.04:15)
Drying module X resistor 1 open circuit detected. Drying disabled, printer can't be operated. Run subsystem
a. Internal bimetal of resistor open (may be a transient failure)
b. Resistor failure
c. Resistor cabling error
d. Fan not spinning at correct speed
e. Drying PCA failure (relay, triac, current sensor)

Corrective actions
1. Restart the printer and allow system to cool down. If the error does not disappear or reappears frequently,
continue with the troubleshooting.
2. Check the resistor and cabling and install new parts if necessary. See Drying heater and fan (K4T88-67107)
on page 790. SVC part: Drying heater and fan module S (K4T88-67107).
Severity
ADVISORY

(17.15.01:01, 17.15.02:01, 17.15.03:01, 17.15.04:01)
Drying module X resistor 1 PCA failure. Drying disabled, printer can't be operated. Run subsystem diagnostic. If
the problem persists, call support.
Description
The printer has protected itself to prevent damages related to a short-circuit in the Drying PCA. If this error is
reported with SEVERE severity, the issue involves the Drying PCA.
▲ Drying PCA failure (relay or triac are short-circuited)
Corrective actions
This error can report two levels of severity, depending on which different actions are required:
SEVERE: The printer cannot be safely operated and is shut down. Install a new Drying PCA and restart the printer.
ADVISORY: Drying disabled, printer can't be operated. Follow the corrective actions below:
error continues with the fan, then install a new fan. If the error stays in the same chamber, install a new

ADVISORY: Drying disabled, printer can't be operated.
Severity
ADVISORY/SEVERE

(17.20.01:20, 17.20.02:20, 17.20.03:20, 17.20.04:20)
Drying module X temperature chamber 2 out of range. Drying disabled, printer can't be operated. Run
Description
During printing, the printer has detected that the temperature of the right chamber of the module X is outside
the acceptable desired range.
b. Not enough or too much airflow in module chamber
Corrective actions
2. Check all cables and connections.
3. Check that the rear part of the printer is not blocked and thus preventing the cold air to enter the drying.
5. Check the Drying PCA by running the Monitor one Drying module diagnostic (17003, see Table 5-20 Drying
6. Interchange the temperature sensors. If the error changes to the other chamber, install a new sensor (see
Curing temperature sensor kit (CZ056-67055) on page 753, SVC part: Temperature sensor
CZ056-67055). Otherwise, interchange the fan and heater assemblies (see Drying heater and fan
(K4T88-67107) on page 790. SVC part: Drying heater and fan module S K4T88-67107). If the error

changes to the other chamber, install a new heater (see Drying heater and fan (K4T88-67107)
on page 790. SVC part: Drying heater and fan module S K4T88-67107). If the error is not related to the
sensor or the resistor, install a new Drying PCA. See Drying PCA (K4T88-67070) on page 784. SVC part:
Drying PCA (K4T88-67070).
Severity
ADVISORY

(17.23.01:01, 17.23.02:01, 17.23.03:01, 17.23.04:01)
Internal Print Server message Drying module X chamber 2 fan no spinning detected. Drying disabled, printer
can't be operated. Run subsystem diagnostic. If the problem persists, call support.
Description
No movement is detected on the right chamber fan in the module X.
a. Fan failure
b. Fan power cabling failure
c. Tachometer signal
Corrective actions
1. Look at fan and verify it is not spinning. If it is spinning, the problem involves the encoder signal (encoder,
cabling, connections). Check the fan connections and cabling.
2. If the fan rotor is locked, swap two Drying heater and fan modules. If the issue remains in the same module
and chamber, recheck the connections and the Drying PCA. If the issue follows the fan, install a new fan
(see Drying heater and fan (K4T88-67107) on page 790. SVC part: Drying heater and fan module S
K4T88-67107).
error follows the fan, then install a new fan. If the error stays in the same chamber, install a new
(K4T88-67070).
Severity
ADVISORY


(17.24.01:15, 17.24.02:15, 17.24.03:15, 17.24.04:15)
Drying module X resistor 2 open circuit detected. Drying disabled, printer can't be operated. Run subsystem
a. Internal bimetal of resistor open (may be a transient failure)
b. Resistor failure
c. Resistor cabling error
d. Fan not spinning at correct speedl
e. Drying PCA failure (relay, triac, current sensor)
Corrective actions
1. Restart the printer and allow the system to cool down. If the error does not disappear or reappears
frequently, continue with the troubleshooting.
2. Check the resistor and cabling and install new parts if necessary. See Drying heater and fan (K4T88-67107)
on page 790. SVC part: Drying heater and fan module S (K4T88-67107).
Severity
ADVISORY

(17.25.01:01, 17.25.02:01, 17.25.03:01, 17.25.04:01)
Drying module X resistor 2 PCA failure. Drying disabled, printer can't be operated. Run subsystem diagnostic. If

Description
The printer has protected itself to prevent damages related to a short-circuit in the drying PCA. If this error is
reported with SEVERE severity, the issue involves the Drying PCA.
▲ Drying PCA failure (relay or triac are short-circuited)
Corrective actions
SEVERE: The printer cannot be safely operated and is shut down. Install a new Drying PCA and restart the printer.
ADVISORY: Drying disabled, printer can't be operated. Follow the corrective action below:
▲ Check the Drying PCA and install a new one if necessary. See Drying PCA (K4T88-67070) on page 784. SVC
ADVISORY: Drying disabled, printer can't be operated.
Severity
ADVISORY/SEVERE
17.33.0X:01 (X may be 1 or 3)
(17.33.01:01, 17.33.03:01).
Drying module X PCA fan no spinning detected. Drying disabled, printer can't be operated. Run subsystem
Description
The Drying module electronics cooling fan is not detected to be spinning.
a. Drying PCA cooling fan failure
b. Drying PCA cooling fan power failure (cabling or PCA issue)
c. Tachometer signal (cabling or PCA issue)

Corrective actions
1. Check the fan connectionst.
2. Install a new Drying PCA cooling fan. See Drying fan PCA (K4T88-67110) on page 787. SVC part: Fan Drying
PCA (K4T88-67110).
3. Install a new Drying PCA (see Drying PCA (K4T88-67070) on page 784. SVC part: PCA Drying
(K4T88-67070).
Severity
ADVISORY

(17.90.01:90, 17.90.02:90, 17.90.03:90, 16.90.04:90)
Drying module X safety monitor disabled. Safety mechanism disabled, printer can't be operated. Reboot in
diagnostic mode and run safety diagnostics. If the problem persists, call support.
Description
The Drying PCA internal safety monitor is disabled.
a. Printer firmware issue
b. Failure in Drying PCA
Corrective actions
(K4T88-67070).
Severity
ADVISORY

(17.91.01:01, 17.91.02:01, 17.91.03:01, 17.91.04:01)

Drying module X safety relay failure detected. Safety mechanism disabled, printer can't be operated. Reboot in
diagnostic mode and run safety diagnostics. If the problem persists, call support.
Description
A failure has been detected in a Drying PCA internal relay.
Internal failure in Drying PCA
Corrective actions
▲ Install a new Drying PCA (see Drying PCA (K4T88-67070) on page 784). SVC part: Drying PCA
(K4T88-67070).
Severity
SEVERE
22. Ink delivery system error codes

22.00.00:73
Ink system set is not purged. Run subsystem diagnostic. If problem persists, call your support representative.
Description
The ink system is set as not purged and requires the purging procedure, or the purging procedure has not been
completed. Both the ISM and the TRS are normally set as purged; the error is displayed when either of them is
not set as purged.
The ISM is set as purged:
● During printer installation, when Purge and setup menu ►IDS Purge (22515) has been completed
The TRS is set as purged:
● During printer installation, when Purge and setup ►IDS Purge (22515) has been completed
The ISM and TRS are not set as purged:
● When the diagnostic utility under Purge and setup ►IDS Purge (22515) has not been completed correctly.
● When the diagnostics Set ISM as not purged (22603) or TRS as not purged (22604) under Reshipment
preparation have been executed.

a. A purge has not been performed.
b. A purge has been performed but not completed.
c. A purge has been completed manually but the diagnostics Set printer as purged (22516) has not been
executed.
d. The diagnostics Set ISM as not purged (22603) or TRS as not purged (22604) under Reshipment
preparation have been executed.
Corrective actions
1. If a purge has not been performed, complete a full purge of the ink system according to the installation
guide (see the chapter “Purge the ink system).
2. If a purge has been performed but not completed, complete the full purging process according to the
installation guide.
3. If a purge has been completed manually, and the tubes from the ISM to the printheads are full of ink, use
diagnostic Set printer as purged (22516), under Purge and setup menu ►Misc. utilities. The printer cannot
detect automatically whether the ink system is really full of ink.
Do not set the ink system as purged if you are not fully convinced that a correct and complete purge of the
system as been performed.
Severity
SEVERE
22.01.00:01
IDS Air PCA internal failure. Run subsystem diagnostic. If problem persists, call your support representative.
Description
An internal failure in IDS Air PCA has been detected by the printer.
a. Intermittent issue.
b. IDS Air PCA malfunction.
c. IDS PSU output not working or fuse blown.
Corrective actions
1. Restart the printer to verify that the problem is not intermittent.
2. Run diagnostic 22001 ISS Electronics to identify the problem.

3. Check the IDS Air PCA’s LEDs, D and E should be flashing which indicates that the communication with the
printer is fine. If they are not flashing, check LEDs A, B and C to determine which is the issue (if LED A is off,
IDS Air PCA is not powered. If LEDs B or C are off, there could be an internal failure).
4. Install a new IDS Air PCA (SVC Part: K4T88-67037).
5. Look for other existing errors in the service plot. Sometimes, an error may appear in the service plot but
not in the IPS. This could be the case with PSU related errors (fuses, switch overload, etc.).
Severity
SEVERE
22.01.00:04
IDS Air PCA communication failure. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
There has been a communication error with IDS Air PCA. The problem could be either in the communication
between IDS Ink PCA and IDS Air PCA or in the communication between ebox Interconnect and IDS Ink PCA.
a. Cable between IDS Ink PCA and IDS Air PCA not properly connected.
b. Cable between ebox interconnect PCA and IDS Ink PCA not properly connected.
c. IDS Ink PCA not properly powered (PSU 2 not supplying correct voltage, cabling, etc.).
d. IDS Air PCA not properly powered (IDS Ink PCA not supplying correct voltage to IDS Air PCA).
e. Intermittent communication issue.
f. IDS Ink PCA malfunction.
g. IDS Air PCA malfunction.
Corrective actions
1. Run diagnostic 22001 ISS Electronics to diagnose if the problem is affecting only IDS Air PCA or both IDS Ink
PCA and IDS Air PCA.
2. Check that IDS Air PCA is properly powered (the red led A should be blinking, see Board name: IDS air PCA
on page 412) and communicating (the red led D and the orange led E should be blinking, see Board name:
IDS air PCA on page 412). If it is not, check the cable between IDS Ink PCA and IDS Air PCA (SVC Part:
K4T88-50183).
3. Check that IDS Ink PCA is properly powered, LED A under connector J8 in IDS Ink PCA should be glowing and
communicating (the red led D and the orange led E should be blinking, see Board name: IDS air PCA
on page 412. If it is not, check if PSU 2 is supplying the correct voltage - 24V +/- 3V - and verify that the

power cables between the PSU and IDS Ink PCA (SVC Part: K4T88-50017) are properly connected and not
damaged. Check that there is a intermediate connection on the IDS Interconnect Panel.
4. Check the communication cable between the ebox Interconnect PCA and IDS Ink PCA (SVC Part:
K4T88-50148).
6. Install a new IDS Ink PCA (SVC Part: K4T88-67036).
Severity
SEVERE
22.01.00:16
IDS Air PCA short-circuit detected (in one of the cables connected to J6, J7, J14 or J15 IDS Air PCA connectors).
Run subsystem diagnostic. If problem persists, please contact your support representative.
Description
There is a short-circuit either in one of the LED Arrays (or in the LED Array cables connected to J6 and J7 of the
IDS Air PCA).
▲ One of the cables going from the IDS Air PCA to the LED Arrays has short-circuited.
Corrective actions
1. Start the printer in diagnostic mode (from PrintCare click on Printer tools ►Power options ►Restart in
diagnostic mode). Disconnect J6 and J7 connectors in the IDS Air PCA. Verify that now the blue led F in the
IDS Air PCA (see Board name: IDS air PCA on page 412) is not powered (this LED is powered when a short-
circuit is detected). Then follow the next steps:
— Connect the cable corresponding to the J6 connector. If the blue led F in the IDS Air PCA is powered,
replace the cable for a new one (SVC Part: K4T88-50061).
— Disconnect the cable corresponding to the J6 connector and connect the cable corresponding to the J7
connector. If the blue led F in the IDS Air PCA is powered, replace the cable for a new one (SVC Part:
K4T88-50147).
2. If the previous troubleshooting did not resolve the issue, install a new IDS Air PCA (SVC Part:
K4T88-67037).
Severity
ADVISORY

22.01.01:76
Backup NVM failure: read/write failed or readback error
Description
There is a short-circuit in one of the black cables providing power to the electrovalves or one of the electrovalves
is short-circuited.
a. Connection issue between e-cabinet or e-box and the IDS Ink PCA
b. Defective IDS Ink PCA (backup NVM/EEROM)
Corrective actions
1. Check the IDS Ink PCA LEDs.
2. Check the e-box interconnect LEDs at the J_481 connector. See Board name: E-box interconnect PCA
on page 395.
3. Check connections at the IDS Ink PCA, e-box interconnect (J_481), engine adaptor PCA 2, and engine PCA 2.
See Figure 2-17 E-box on page 91.
4. Install a new ISS PCA. See IDS Ink PCA (K4T88-67036) on page 1029.
5. Install new ISS communication cables.
6. Install a new engine PCA 2. See Engine PCA (K4T88-67067) on page 805.
Severity
SEVERE

(22.02.01:06, 22.02.02:06, 22.02.03:06, 22.02.04:06, 22.02.05:06, 22.02.06:06, 22.02.07:06)
Intermediate tank broken bag detected in slot X. Replace the intermediate tank (see the Print Care wizard:
"Replace an intermediate tank”). If problem persists, call your support representative.
Description
X refers to the color and matches the label on the intermediate tank so that you can identify the intermediate
tank reporting a broken bag.

1. K (black)
2. C (cyan)
3. M (magenta)
4. Y (Yellow)
5. Lc (Light cyan)
6. Lm (Light magenta)
7. OPT (Optimizer)
The intermediate tanks consist of an internal bag containing ink inside the plastic container of the tank. If there is
ink leakage from the bag, or the bag breaks, the ink can pass to the air pressurization system causing
depressurization in the pressure line. Cases of bag breakage are detected by the leakage sensor, located inside
the PIP. Once the broken bag condition is triggered, the printer no longer functions until the issue is fixed.
a. A genuine broken bag. There is ink in the air lines coming from the intermediate tank
b. Wet or dirty EE contacts
c. Ink on the IDS Air PCA or intermediate tank connector
Corrective actions
1. Check that the "broken bag" message is real.
2. If there is indeed a broken bag, then replace the following components corresponding to the affected color:
a. Replace the ink pressure sensor
b. Replace the intermediate tank
c. Replace the air circuit components that were contaminated with the ink
3. Delete the "broken bag" error using the IT broken bag recovery (22016) diagnostic (see Table 5-12 Ink
delivery system on page 571).
4. Enter the calibration values of the new PIP into the printer by using the PrintCare diagnostic: 22019—
Calibrate pressure sensor (see Table 5-12 Ink delivery system on page 571).
Severity
SEVERE
22.02.0X:07 (X may be in the range 1-7)

(22.02.01:07, 22.02.02:07, 22.02.03:07, 22.02.04:07, 22.02.05:07, 22.02.06:07, 22.02.07:07)

Intermediate tank end of life X. Proceed with the intermediate tank maintenance procedure (see the Print Care
wizard: “Replace an intermediate tank”). If problem persists, call your support representative.
Description
X refers to the color and position, and matches the label on the intermediate tank so that you can identify the
component that reached the end of its life.
1. K (black)
2. C (cyan)
3. M (magenta)
4. Y (Yellow)
5. Lc (Light cyan)
7. OPT (Optimizer)
The intermediate tank has reached the end of its life and should be replaced with a new one to prevent any
broken bag.
Corrective actions
Install a new intermediate tank. Guidance is available from Print Care (it can be done by the customer), from the
user guide, or see ISM intermediate tank (CZ056-67073) on page 1055.
NOTE: During the replacement process, the replaced tank will have to be refilled, either by using the PrintCare
Wizard or by executing the PrintCare diagnostic Intermediate tanks replacement (22018).
Severity
ADVISORY
22.02.0X:74 (X in the range 1-7)

(22.02.01:74, 22.02.02:74, 22.02.03:74, 22.02.04:74, 22.02.05:74, 22.02.06:74, 22.02.07:74)
Intermediate tank X empty. Run subsystem diagnostic to replace the intermediate tank. If the problem persists,
call your support representative.

Description
The intermediate tank is detected as empty. This situation should not normally happen as the printer should
perform an automatic refill when the level of an intermediate tank decreases. If the system error appears, there
are probably other issues in the IDS that caused this to happen.
1. Intermediate tank K
2. Intermediate tank C
3. Intermediate tank M
4. Intermediate tank Y
5. Intermediate tank Lc
6. Intermediate tank Lm
7. Intermediate tank OPT
a. The ink pump is failing and is not able to introduce enough ink in the intermediate tanks.
b. There is a non-detected ink leakage in the system.
c. Internal SW problem caused refill to not finish properly.
Corrective actions
1. Check if the different system elements are working properly and that there is no ink leakage.
2. Replace the affected intermediate tank by a new one and run diagnostic 22018 Intermediate Tanks
replacement to finish the replacement. This diagnostic will refill the new intermediate tank and clear the
error in the printer.
NOTE: The intermediate tank that showed the system error should not be reused as it might cause a
future broken bag issue.
Severity
SEVERE

(22.05.01:02, 22.05.02:02, 22.05.03:02, 22.05.04:02, 22.05.05:02, 22.05.06:02, 22.05.07:02)
PIP X presence check failure. Check connection. Run subsystem diagnostic. Restart the printer and repeat the
operation. If problem persists, call your support representative.

Description
One of the PIPs (Ink pressure sensors) is undetected.
1. PIP K
2. PIP C
3. PIP M
4. PIP Y
5. PIP Lc
6. PIP Lm
7. PIP OPT
a. The affected PIP is not properly connected or the cable is damaged.
b. The affected PIP is damaged.
Corrective actions
1. Check the connection and cable of the affected PIP. Restart the printer to verify if the problem is solved.
2. Change the affected PIP (SVC Part: K4T88-67018) and restart the printer to verify the problem is solved.
3. Change the cable between the IDS Ink PCA and the PIPs (SVC Part: K4T88-50176). Restart the printer to
verify the problem is solved.
Severity
SEVERE

(22.05.01:27, 22.05.02:27, 22.05.03:27, 22.05.04:27, 22.05.05:27, 22.05.06:27, 22.05.07:27)
PIP sensor X pressure out of range. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
The ink pressure signal measured by the PIPs (Ink Pressure Sensors) is expected to be within a working range to
ensure that correct decisions are taken based on its measurements. If the read values are out of the working
range, this system error is triggered.

1. PIP K
2. PIP C
3. PIP M
4. PIP Y
5. PIP Lc
6. PIP Lm
7. PIP OPT
a. Ink pressure sensor not calibrated
b. Ink pressure sensor broken
c. Ink cartridge not in the right position or with a heavy object on it
Corrective actions
1. Check that the ink cartridge is in the right position with nothing on it.
2. Run the Calibrate pressure sensor diagnostic (22019) (see Table 5-12 Ink delivery system on page 571),
checking the calibration values marked on each ink pressure sensor PCA label and comparing the values
returned from the diagnostic. If the values are different, set the label values.
3. Install a new Ink Pressure Sensor (PIP) and calibrate it with diagnostic Calibrate Pressure sensor (22019).
Severity
SEVERE
22.05.0X:70 (X in the range 1-7)

(22.05.01:70, 22.05.02:70, 22.05.03:70, 22.05.04:70, 22.05.05:70, 22.05.06:70, 22.05.07:70)
Refill of Intermediate Tank X not finished. Reboot the printer. If problem persists, call your support
representative.
Description
During the refill of the Intermediate Tank X the PIP measures are detected to be not reliable. To avoid printer
damage the refill has stopped (the printer is using the ink left in the ìntermediate tanks). If a job was being
printed the print might continue. If the on-going plot is very long, it is recommended to stop it before the
intermediate tanks are low on ink.

1. Intermediate tank K
2. Intermediate tank C
3. Intermediate tank M
4. Intermediate tank Y
5. Intermediate tank Lc
6. Intermediate tank Lm
7. Intermediate tank OPT
If a very long plot is being printed after this system error appears, the printer might stop printing after a while
showing an "Ink system needs attention" message. This means that the intermediate tanks are below a
minimum level of ink to safely operate. If the printer is powered off during some time (a few hours) the
intermediate tanks can recover the minimum level of ink and the printer will automatically recover itself.
a. There is air in the ink tubes zone between the ink cartridges and the intermediate tanks.
b. One of the ink pumps is not working properly.
Corrective actions
1. Restart the printer and try to print again. If the error reappears the issue is confirmed (if it does not
reappear, the first time it appeared the cause could be a small bubble of air in the ink tubes, which can be
safely absorbed by the intermediate tanks at the next refill).
2. Check there is no air in the ink tubes in the zone between the ink cartridges and the intermediate tanks. If
there is air, take it out and retry.
3. If no air has been detected and the printer repeatedly reports the system error, install a new Ink Pump (SVC
Part: K4T88-67026).
Severity
ADVISORY

(22.05.01:83, 22.05.02:83, 22.05.03:83, 22.05.04:83, 22.05.05:83, 22.05.06:83, 22.05.07:83)
PIP sensor X not calibrated. Run subsystem diagnostic. If problem persists, call your support representative.
Description
Ink pressure sensors in the ink pressure sensors board must be calibrated with the appropriate values in order to
measure the ink pressure accurately for each color. Incorrect calibration of these sensors could cause

unexpected system errors or incorrect functioning of the ISM system, such as incorrect detection of remaining
ink in the cartridges. The calibration values, once introduced, are stored in the non-volatile memory of the ISM
system. This system error is raised if calibration values are not present.
1. PIP K
2. PIP C
3. PIP M
4. PIP Y
5. PIP Lc
6. PIP Lm
7. PIP OPT
The ink pressure sensor is not calibrated.
Corrective actions
1. Check that the ink cartridge is in the right position, with nothing on it.
2. Run the Calibrate pressure sensor diagnostic (22019) (see Table 5-12 Ink delivery system on page 571).
3. For the color reporting the failure, read the corresponding calibration values marked on the ink pressure
sensor, and enter these values in the test Calibrate pressure sensor.
Severity
SEVERE
22.06.00:09
IDS Ink PCA to Ink Leakage sensor cable issue (in IDS Ink PCA J15 connector). Check connection. Run subsystem
diagnostic. If problem persists, please contact your support representative.
Description
The printer has detected that the cable going from IDS Ink PCA to the Ink leakage sensor is not properly
connected to the J15 connector of the IDS Ink PCA.
▲ Cable going from IDS Ink PCA to the Ink leakage sensor not properly connected to J15 connector on the IDS
Ink PCA.

Corrective actions
1. Check that the cable is properly connected and restart the printer to clear the error.
2. Change the affected cable (SVC Part: K4T88-50180).
Severity
ADVISORY
22.06.01:06
General ISM ink leakage. Check if there is actually a leakage in the bottom tray of the ISM system. Restart the
printer and repeat the operation. If problem persists, call your support representative.
Description
The ISM ink leak condition has been triggered. The detectors are two terminal pins located in the bottom tray of
the ISM system. The system error is triggered when the pins are short-circuited by an ink leak or any other
water-based fluid reaching the ink tray. Note that the sensor is connected to the IDS Ink PCA connector J15.
a. A genuine ink leakage
b. A false ink leakage
c. False ink leakage detection
Corrective actions
1. Check the bottom tray and the leak sensor sump to identify the color of the leak. If there is ink present, find
the source of the ink leak and fix it.
a. Check the faulty ink line, paying attention to the ink pressure sensor, ink four-way valve,
electrovalves, tubes, and fitting.
b. Replace the leaking part with a new one.
c. Clean the system.
2. If there is water or condensation in the ink tray, clean the accumulated water, dry the tray and the sensor
contacts if required, and remove any possible root cause of the accumulation of water.
In some cases, condensation above the sensor, or above the ink tray (up to the vapor removal blower
pump), could drip on the sensor. Remember to check for this.

3. If you find no ink or water in the ink tray, check the connection from the ink leakage sensor to the IDS Ink
PCA. See Figure 2-18 IDS (Ink Delivery System) on page 92 and Board name: IDS Ink PCA.See Figure 2-18
IDS (Ink Delivery System) on page 92
In some cases, condensation above the sensor, or above the ink tray (up to the vapor removal blower
pump), could drip on the sensor. Remember to check for this.
4. After fixing the problem, run the Ink system leakage diagnostic (22017) (see Table 5-12 Ink delivery
system on page 571), to check that it is fixed and clear the error.
Severity
SEVERE
22.07.00:01
IDS Ink PCA internal failure. Run subsystem diagnostic. If problem persists, call your support representative.
Description
An internal failure in IDS Ink PCA has been detected by the printer.
a. Intermittent issue
b. IDS Ink PCA malfunction
Corrective actions
1. Restart the printer to verify that the problem is not intermittent.
2. Run diagnostic 22001 ISS Electronics to identify the problem.
Severity
SEVERE
22.07.00:04
IDS Ink PCA communication failure. Run subsystem diagnostic. If problem persists, call your support
representative.

Description
There has been a communication error with IDS Ink PCA.
a. Cable between ebox interconnect PCA and IDS Ink PCA not properly connected.
b. IDS Ink PCA not properly powered (PSU 2 not supplying correct voltage, cabling, etc.).
c. Intermittent communication issue.
d. IDS Ink PCA malfunction.
Corrective actions
1. Run diagnostic 22001 ISS electronics to diagnose if the problem is coming from the power line or the
control line.
2. Check that IDS Ink PCA is properly powered and the LED A under connector J8 in IDS Ink PCA should be
glowing and communicating (the red led D and the orange led E should be blinking, see Board name: IDS air
PCA on page 412). If it is not, check if PSU 2 is supplying the correct voltage - 24V +/- 3V - and verify that
the power cables between the PSU and IDS Ink PCA (SVC Part: K4T88-50017) are properly connected and
not damaged.
3. Check the communication cable between ebox Interconnect PCA and IDS Ink PCA (SVC Part: K4T88-50148).
Severity
SEVERE

(22.08.01:02, 22.08.02:02, 22.08.03:02, 22.08.04:02, 22.08.05:02, 22.08.06:02, 22.08.07:02)
LED Array X presence check failure. Check connection. Run subsystem diagnostic. If problem persists, please
contact your support representative.
Description
There is no electrical presence for LED Array X.
1. K (black)
2. C (cyan)
3. M (magenta)
4. Y (Yellow)

5. Lc (Light cyan)
7. OPT (Optimizer)
a. LED Array X not correctly connected or malfunctioning.
b. Cable between IDS Air PCA and LED Arrays is damaged (if the error appears for all the LED Arrays, this is the
most probable cause).
Corrective actions
1. Check that the affected LED Array is correctly connected to the IDS Air PCA and that the cable (SVC Part:
K4T88-50061 -X: 1- or K4T88-50147 -X: 2-) is not damaged.
2. Swap the affected LED Array to check if the issue follows the LED Array or stays the same color. If the
failure follows the LED Array, install a new LED Array (SVC Part: K4T88-67059). If the issue remains in the
same supply, install a new cable between the IDS Air PCA and the LED Arrays.
Severity
ADVISORY

(22.09.01:02, 22.09.02:02, 22.09.03:02, 22.09.04:02, 22.09.05:02, 22.09.06:02, 22.09.07:02)
Ink Pump X presence check failure. Check connection. Run subsystem diagnostic. If problem persists, please
Description
One of the Ink Pumps is not detected.
1. Ink Pump K
2. Ink Pump C
3. Ink Pump M
4. Ink Pump Y
5. Ink Pump Lc

6. Ink Pump Lm
7. Ink Pump OPT
a. The affected Ink Pump is not properly connected or the cable is damaged.
b. The affected Ink Pump is not working properly.
Corrective actions
1. Check the connection and the cable of the affected Ink Pump. Restart the printer to verify if the problem is
solved.
2. Change the affected Ink Pump (SVC Part: K4T88-60338) and restart the printer to verify the problem is
solved.
3. Change the cable between the IDS Ink PCA and the Ink Pumps (SVC Part: K4T88-50177). Restart the printer
to verify the problem is solved.
Severity
SEVERE

(22.09.01:05, 22.09.02:05, 22.09.03:05, 22.09.04:05, 22.09.05:05, 22.09.06:05, 22.09.07:05)
Intermediate tank X refill timeout. Check ink pump and ink tubes. Run subsystem diagnostic. If problem persists,
please contact your support representative.
Description
The refill of the intermediate tank X is taking more time than expected. The printer stops the refill for safety
reasons.
1. Ink Pump K
2. Ink Pump C
3. Ink Pump M
4. Ink Pump Y
5. Ink Pump Lc
6. Ink Pump Lm
7. Ink Pump OPT

a. Some element in the ink circuit is not working as expected (ink pump, PIP sensor, etc.).
b. There is air between the ink cartridge X and the PIP sensor X.
Corrective actions
1. Check the ink circuit ensuring there is no visible ink leakage or air inside the tubes.
2. Check that the ink cartridge for the affected supply has enough ink to complete the refill.
3. Check the ink pump for the affected supply.
4. Check the PIP sensor for the affected supply.
Severity
SEVERE

(22.10.01:02, 22.10.02:02)
Air pump X presence check failure. Check connection. Run subsystem diagnostic. If problem persists, call your
Description
There is no electrical presence of the Air Pump X.
a. Pump not correctly connected or malfunctioning.
b. Cable between IDS Air PCA and Air Pumps is damaged.
Corrective actions
1. Check that the affected Air Pump is correctly connected to the IDS Air PCA and that the cable (SVC Part:
K4T88-50021) is not damaged.
2. Swap the two Air Pumps to check if the issue follows the pump or stays in the same pump. If the failure
follows the pump, install a new Air Pump (SVC Part: K4T88-67025). If it stays in the same pump, recheck its
connection to the IDS Air PCA.
Severity
ADVISORY


(22.10.01:16, 22.10.02:16)
Air pump X short-circuit detected. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
There is a short-circuit in the Air Pump X.
a. Cable going from IDS Air PCA to Air Pump is short-circuited.
b. Air Pump is short-circuited.
Corrective actions
1. Check that the cable going from IDS Air PCA to the affected Air Pump (SVC Part: K4T88-50021 or
K4T88-67025) is not damaged.
follows the pump, install a new Air Pump (SVC Part: K4T88-67025). If it stays in the same pump, recheck its
connection to the IDS Air PCA.
Severity
ADVISORY
22.10.01:30
Air pressure out of range. Run subsystem diagnostic. If problem persists, call your support representative.
Description
Air pressure sensor valves have been detected as out of the expected measurement range. The expected
pressure is between −0.2 and 6.6 psi. For the system error to be triggered, the condition must be repeated for 1
minute, affecting the IDS Air PCA.
▲ Pressure sensor malfunction.
Corrective actions
1. Run the Air pressure system (22002), see Table 5-12 Ink delivery system on page 571. The system is
pressurized for at least 60 seconds, time to check whether there is any visible problem with the ISM.
2. Install a new IDS Air PCA. (SVC Part: K4T88-67037).

Severity
SEVERE
22.10.01:32
Air Pressure System (APS) unable to pressurize. Restart the printer and run the subsystem diagnostic. If problem
persists, call your support representative.
Description
The air system is unable to pressurize to the expected working pressure, which, depending on the actual
working cycle, could be 4.5–5.0 psi (normal working pressure).
a. Air tube disconnected from the air system or damaged
b. Air pump failure (pump or IDS Air PCA failure)
c. Air relief valve failure
d. Intermediate tank leak
e. Air pressure bottle leak
f. Air sensor failure, leading to IDS Air PCA failure
g. Bad Installation of one Intermediate Tank
h. Intermediate tank supports failure
Corrective actions
1. Review all air tube connections and ensure that there is no disconnection.
2. Run the Air pressure system diagnostic (22002), testing air pressure system; the system is pressurized.
See Table 5-12 Ink delivery system on page 571. You can disconnect the tube from the air pressure sensor
to ensure that pressure is reaching the air pressure sensor. Check that the activated pumps are working
listening to each of them.
3. If the pumps do not work, check pump connections and verify pin integrity.
follows the pump, install a new Air Pump (SVC Part: K4T88-67025). If it stays in the same pump, install a
new cable between the IDS Air PCA and the Air Pumps (SVC Part: K4T88-50021).
5. Run the Air pressure system diagnostic (22002), testing APS. The system is pressurized. See Table 5-12 Ink
delivery system on page 571. Check for any failed tube. Leave the pumps on test with the diagnostic
procedure, the pump will operate until 4.5-5 psi is reached.
6. Check that the relief valve is closed and air is not escaping from it when pressurizing. See IDS Air pump and
relief valve (K4T88-67025) on page 1017.

7. Try to adjust tubes and check connections, clean if required.
8. Extract and install again all the Intermediate Tanks, to verify they are well installed. Run Air pressure
system diagnostic (22002) to check if the problem is solved.
9. Install a new APS relief valve (SVC Part: K4T88-67025).
11. Install a new set of Intermediate Tanks and run Air pressure system diagnostic (22002) to check if the
problem is solved.
12. If necessary, install a new ink circuit module. See IDS Ink circuit (K4T88-67024) on page 1035.
Severity
SEVERE
22.11.00:09
APS relief valve presence check error. Check connection. Run subsystem diagnostic. If problem persists, call your
Description
There is no electrical presence for the APS relief valve.
a. APS relief valve not correctly connected or malfunctioning.
b. Cable between IDS Air PCA and APS relief valve is damaged.
Corrective actions
1. Check that the APS relief valve is correctly connected to the IDS Air PCA (in the intermediate connector) and
that the cable (SVC Part: K4T88-50021) is not damaged.
2. Install a new APS relief valve (SVC Part: K4T88-67025).
Severity
SEVERE

22.11.00:16
APS relief valve short-circuit detected. Run subsystem diagnostic. If problem persists, please contact your
Description
There is a short-circuit in the relief valve or in the cable going from the IDS Air PCA to the relief valve.
a. One of the cables going from IDS Air PCA to the APS relief valve has short-circuited.
b. The relief valve has a short-circuit.
Corrective actions
1. Check if the cable between the IDS Air PCA and the Relief valve (SVC Part: K4T88-50021) is damaged.
2. Install a new relief valve (SVC Part: K4T88-67025).
Severity
SEVERE
22.11.01:01
Air Pressure System (APS) unable to depressurize. Restart the printer and run subsystem diagnostic. If problem
Description
The air system is unable to depressurize in a certain time limit. The system is considered to be depressurized at
0.3 psi, and there is a timeout of 120 seconds to depressurize. The standard operating range is 4.5-5 psi
(working pressure).
a. Relief valve does not open.
b. Relief valve cable disconnected.
c. Relief tubes blocked.
d. Pressure sensor does not detect depressurizing.

Corrective actions
1. Check that the relief valve cable is correctly connected to the valve and to the IDS Air PCA.
2. Run the Air pressure system diagnostic (22002). This diagnostic will confirm the issue and will try to point
to the correct failing part: Air pump (SVC Part: K4T88-67025) , relief valve (SVC Part: K4T88-67025), IDS Air
PCA (SVC Part: K4T88-67037). If the diagnostic detects any affected part, replace it with a new one.
3. Install new air pump, relief valve, and tubes (SVC Part: K4T88-50021). See IDS Air pump and relief valve
(K4T88-67025) on page 1017.
4. If the relief system seems to be working correctly, install a new IDS Air PCA (see IDS Air PCA, SVC Part:
K4T88-67037).
Severity
SEVERE
22.13.00:09
IDS Ink PCA to PIPs cable issue (in IDS Ink PCA J14 connector). Check connection. Run subsystem diagnostic. If
problem persists, please contact your support representative.
Description
The printer has detected that the cable going from IDS Ink PCA to PIPs (Ink pressure sensors) is not properly
connected to the J14 connector of the IDS Ink PCA.
▲ Cable going from IDS Ink PCA to PIPs (Ink pressure sensors) not properly connected to J14 connector on the
IDS Ink PCA.
Corrective actions
Severity
SEVERE
22.15.00:09
IDS Ink PCA to Acumens cable issue (in IDS Ink PCA "Ink supply port" connector). Check connection. Run
subsystem diagnostic. If problem persists, please contact your support representative.

Description
There are 2 cables that connect the Acumens to the IDS Ink PCA: a cable with the presence sensor information
for each accumen (connected to the J13 connector in the IDS Ink PCA, "Presence Sensor"), and another for
acumen communication (connected to the J12 connector in the IDS Ink PCA, "Ink supply port"). The printer has
detected that one of these cables (the one with the acumen communication) is not properly connected to the
J12 connector of the IDS Ink PCA ("Ink supply port").
▲ Cable going from IDS Ink PCA to Acumens not properly connected to J12 connector on the IDS Ink PCA ("Ink
supply port").
Corrective actions
Severity
ADVISORY
22.15.00:16
IDS Ink PCA to Acumens cable short-circuit detected. Run subsystem diagnostic. If problem persists, please
Description
There is a short-circuit in one of the cables going from IDS Ink PCA to Acumens.
a. Cable going from IDS Ink PCA to Acumens has short-circuited.
b. Ink cartridge connector electrical leads short-circuit (the leads could be bent and touching if incorrect
insertion has been made).
Corrective actions
1. Check that the cable going from IDS Ink PCA to Acumens (SVC Part: K4T88-50178) is not damaged.
2. Check that the ink cartridge connector is not damaged.
3. Install a new Supply.
Severity
ADVISORY

22.16.00:09
IDS Ink PCA to Acumens cable issue (in IDS Ink PCA “Presence Sensor” connector). Check connection. Run
subsystem diagnostic. If problem persists, please contact your support representative.
Description
There are 2 cables that connect the Acumens to the IDS Ink PCA: a cable with the presence sensor information
for each acumen (connected to the J13 connector in IDS Ink PCA, "Presence Sensor") and another with for the
acumen communication (connected to the J12 connector in IDS Ink PCA, "Ink supply port"). The printer has
detected that one of these cables (the one with the presence sensors information) is not properly connected to
the J13 connector of the IDS Ink PCA ("Presence Sensor").
▲ Cable going from IDS Ink PCA to Acumens not properly connected to J12 connector on the IDS Ink PCA
("Presence sensor").
Corrective actions
Severity
SEVERE
22.17.00:16
IDS Ink PCA to Ink Pumps cable short-circuit detected (in one of the red cables). Run subsystem diagnostic. If
problem persists, please contact your support representative.
Description
One of the red cables providing power to the ink pumps has a short-circuit.
▲ Cable going from IDS Ink PCA to Ink Pumps has short-circuited.
Corrective actions
1. Run diagnostic 22001 ISS Electronics to identify the defective cable.
2. Replace the defective cable (SVC Part: K4T88-50177) and restart the system to clear the error.

Severity
SEVERE
22.17.00:41
IDS Ink PCA to Ink Pumps cable short-circuit detected (in one pump or one of the black cables). Run subsystem
diagnostic. If problem persists, please contact your support representative.
Description
There is a short-circuit either in one of the black cables providing power to the ink pumps or in one of the ink
pumps.
a. Cable going from IDS Ink PCA to Ink Pumps is short-circuited.
b. One of the ink pumps has short-circuited.
Corrective actions
1. Run diagnostic 22001 ISS Electronics to identify the defective cable or pump.
2. Replace the defective cable (SVC Part: K4T88-50177) and restart the system to clear the error.
3. If problem persists, the cause can be the pump itself. Replace the defective pump (SVC Part: K4T88-60338)
and restart the system to clear the error.
Severity
SEVERE
22.18.00:02
IDS Air PCA to Air pumps cable issue (in IDS Air PCA J10 connector). Check connection. Run subsystem diagnostic.
If problem persists, call your support representative.
Description
The printer has detected that the cable going from IDS Air PCA to the Air Pumps cable is not properly connected
to the J10 connector of the IDS Air PCA.
▲ Cable going from IDS Air PCA to the Air Pumps not properly connected to J10 connector on the IDS Air PCA.

Corrective actions
Severity
SEVERE

(22.19.01:02, 22.19.02:02)
IDS Air PCA to LED Array cable issue (in IDS Air PCA X connector). Check connection. Run subsystem diagnostic. If
problem persists, call your support representative.
Description
The printer has detected that the cable going from IDS Air PCA to the LED array cable is not properly connected
to the connector X of the IDS Air PCA.
1. J6 (connector for the LED Arrays K, C, M, Y).
2. J7 (connector for the LED Arrays Lc, Lm, OPT).
▲ Cable going from IDS Air PCA to the affected LED arrays not properly connected to connector (J6 or J7
depending on X) on the IDS Air PCA.
Corrective actions
2. Change the affected cable (SVC Part: K4T88-50061 -X: 1- or K4T88-50147 -X: 2-).
Severity
ADVISORY

(22.21.01:02, 22.21.02:02)

IDS Air PCA to Broken bag sensors cable X issue. Check connection. Run subsystem diagnostic. If problem
persists, please contact your support representative.
Description
The printer has detected that one the cables going from IDS Air PCA to broken bag sensors is not properly
connected to the IDS Air PCA.
1. Cable connected to J15 connector in the IDS Air PCA (connected to the broken bag sensors 0, 1, 2 and 3).
SVC Part: K4T88-50237.
2. Cable connected to J14 connector in the IDS Air PCA (connected to the broken bag sensors 4, 5 and 6). SVC
Part: K4T88-50238.
▲ Cable going from IDS Air PCA to broken bag sensors not properly connected to J14 or J15 connectors of the
IDS Air PCA (J14 or J15 depending on X, see system error description above).
Corrective actions
2. Change the affected cable (SVC Part: K4T88-50237 or K4T88-50238).
Severity
ADVISORY

(22.21.01:09, 22.21.02:09, 22.21.03:09, 22.21.04:09, 22.21.05:09, 22.21.06:09, 22.21.07:09)
IDS Air PCA to broken bag sensors cable X issue (in intermediate connector to broken bag sensor). Check
connection. Run subsystem diagnostic. If problem persists, please contact your support representative
Description
The printer has detected that one of the intermediate connectors in the cable going from the IDS Air PCA to the
broken bag sensors is not properly connected.
1. Broken Bag sensor K (labelled as "Broken Bag 0")
2. Broken Bag sensor C (labelled as "Broken Bag 1")
3. Broken Bag sensor M (labelled as "Broken Bag 2")

4. Broken Bag sensor Y (labelled as "Broken Bag 3")
5. Broken Bag sensor Lc (labelled as "Broken Bag 4")
6. Broken Bag sensor Lm (labelled as "Broken Bag 5")
7. Broken Bag sensor OPT (labelled as "Broken Bag 6")
a. Intermediate connector in one of the cables going from the IDS Air PCA to the broken bag sensors is not
properly connected.
b. Cable going from the IDS Air PCA to the broken bag sensors is not properly connected to the J14 or J15
connectors of the IDS Air PCA (if the error appears for all the broken bag sensors, this is the most probable
cause).
Corrective actions
1. Check that the intermediate connector is properly connected and restart the printer to clear the error.
2. If the error appears for all the broken bag sensors (7 different system errors), check that the connectors in
J14 and J15 are properly connected and restart the printer to clear the error.
3. Change the affected cable (SVC Part: K4T88-50237 or K4T88-50238).
Severity
ADVISORY
22.22.0X:02 (X may be 1, 3, 5, 7)
(22.22.01:02, 22.22.03:02, 22.22.05:02, 22.22.07:02)
Electrovalves X presence check error. Check connection. Run subsystem diagnostic to identify the failing
electrovalve. If problem persists, please contact your support representative.
Description
There is no electrical presence for one or some of the electrovalves.
1. Electrovalve 1 (K) or 2 (C)
3. Electrovalve 3 (M) or 4 (Y)
5. Electrovalve 5 (Lc) or 6 (Lm)
7. Electrovalve 7 (OPT)

a. One of the affected electrovalves is not properly connected or it is malfunctioning.
b. Cable between IDS Ink PCA and the affected electrovalves is damaged (SVC Part: K4T88-50089 and/or
K4T88-50090).
Corrective actions
1. Check that the affected electrovalves are correctly connected to the IDS Ink PCA and that the cable (SVC
Part: K4T88-50089 and/or K4T88-50090) is not damaged.
2. Install a new electrovalve (SVC Part: K4T88-67042).
Severity
SEVERE
22.23.00:16
IDS Ink PCA to Electrovalves cables short-circuit detected (in one of the black cables). Run subsystem diagnostic.
If problem persists, please contact your support representative.
Description
There is a short-circuit in one of the black cables providing power to the electrovalves or one of the electrovalves
is short-circuited.
a. One of the black cables going from IDS Ink PCA to the electrovalves has short-circuited.
b. One of the electrovalves has short-circuited.
Corrective actions
1. Run diagnostic 22001 ISS Electronics to diagnose which of the electrovalves is reporting the short-circuit.
2. Check the cable going from IDS Ink PCA to the affected electrovalve (SVC Part: K4T88-50089 for
electrovalves K, C, M and Y or K4T88-50090 for electrovalves Lc, Lm and OPT) and verify it is not damaged.
3. Install a new electrovalve (SVC Part: K4T88-67042).
4. Install a new IDS ink PCA (SVC Part: K4T88-67036).
Severity
SEVERE

30. Vapor removal error codes

30.01.00:01
Vapor-removal blower is not spinning, the vapor-removal system is not working properly. To continue ensuring
operator comfort and reliable printer operation, run subsystem diagnostics. If problem persists beyond a few
minutes, discontinue printing and call your support representative. Continuous printing in this condition may
cause a higher level of condensation, marks on prints, and risk of condensation on electrical circuits.
a. Vapor removal blower not powered up (no AC power to the blower)
b. Control cable between vapor removal PCA and blower faulty or disconnected
c. Faulty vapor removal blower
d. Faulty vapor removal PCA
Corrective actions
1. Check that the Vapor removal and Vacuum ACB (automatic circuit breaker) labeled as "PUMPS" is on (lever
should be up). If it is not, turn it on and reboot the printer.
2. Check the blower connections. Ensure that cables are correctly connected and not damaged.
3. Run the Blower test diagnostic (30002). See Table 5-28 Vapor removal on page 598.
4. Install a new vapor removal blower. See Vapor removal pump (K4T88-67096) on page 1324.
5. Install a new vapor removal PCA. See Vapor removal PCA (K4T88-67069) on page 1304. SVC Part: Vapor
Removal PCA (K4T88-67069).
Severity
ADVISORY
30.01.00:02
Vapor-removal blower is not spinning, the vapor-removal system is not working properly. To continue ensuring
operator comfort and reliable printer operation, run subsystem diagnostics. If problem persists beyond a few
minutes, discontinue printing and call your support representative. Continuous printing in this condition may
cause a higher level of condensation, marks on prints, and risk of condensation on electrical circuits.
b. Blower fan cable damaged or not correctly connected

c. Faulty vapor removal blower fan
Corrective actions
2. Run the Vapor removal blower check diagnostic (30002). See Table 5-28 Vapor removal on page 598.
3. Install a new vapor removal blower. See Vapor removal pump (K4T88-67096) on page 1324. SVC Part:
Vapor Removal Pump (K4T88-67096).
Severity
ADVISORY
30.01.00:63
Vapor-removal blower is not spinning at the expected speed, the vapor-removal system is not working properly.
To continue ensuring operator comfort and reliable printer operation, run subsystem diagnostics. If problem
persists beyond a few minutes, discontinue printing and call your support representative. Continuous printing in
this condition may cause a higher level of condensations, marks on prints, and risk of condensation on electrical
circuits.
b. Blower fan cable damaged or not correctly connected
c. Faulty vapor removal blower fan
Corrective actions
2. Run the Vapor removal blower check diagnostic (30002). See Table 5-28 Vapor removal on page 598.
3. Install a new vapor removal blower. See Vapor removal pump (K4T88-67096) on page 1324. SVC Part:
Vapor Removal Pump (K4T88-67096).
Severity
ADVISORY

30.02.00:01
Vapor removal PCA error. Run subsystem diagnostics. If problem persists call support.
Vapors and condensates may not be properly extracted. If vapors and condensates generate operator
discomfort or affect printer operation, discontinue printing and call support. Continuous printing in this condition
may imply higher level of condensation, marks on plots and risk of condensation on electrical circuits.
a. Internal PCA firmware error
b. Faulty vapor removal PCA (internal 12 V DC out of range)
Corrective actions
1. Run the Vapor removal electronics check diagnostic (30001). See Table 5-28 Vapor removal on page 598.
Severity
ADVISORY
30.02.00:02
Vapor removal module speed servo start failure. Retry the operation and run subsystem diagnostic. If problem
Description
The temperature control has not been able to start, usually because there is some other issue in the printer.
a. Vapor-removal PCA failure.
b. Vapor-removal PCA configuration problem.

Corrective actions
3. Install a new vapor removal PCA. See Vapor removal PCA (K4T88-67069) on page 1304.
Severity
ADVISORY
30.02.00:03
Vapor removal PCA firmware version does not match hardware version. Run subsystem diagnostics. If problem
persists call support.
a. Automatic firmware upgrade failed for vapor removal PCA.
b. Incorrect firmware revision programmed in the vapor removal PCA.
Corrective actions
Severity
ADVISORY
30.02.00:04
No feedback from the vapor removal PCA. Run subsystem diagnostics. If problem persists call support.

a. Incorrect instance ID in the vapor removal PCA: wrong wire address
b. Vapor removal PCA not powered up
c. Error or misconnection in data cables or connectors from the e-box to the vapor removal subsystem
d. Faulty or missing vapor removal PCA
e. Faulty e-box interconnect PCA, engine adaptor PCA, engine PCA, or interconnecting cables
Corrective actions
1. Use the vapor removal PCA LEDs to make sure the vapor removal PCA is powered up and running. The uC
beat LED should blink 7 times. See Vapor removal PCA (K4T88-67069) on page 1304.
2. Check that the fan control cable (K4T88-50159) has the correct address set. If not, install a new cable. See
Cables on page 1469.
3. Check that the data cables from the e-box to the vapor removal subsystem are correctly connected.
Run the Vapor removal electronics check diagnostic (30001). See Table 5-28 Vapor removal on page 598.
4. Check connections in the e-box and ensure that all cables are correctly connected and not damaged. See
Figure 2-7 E-cabinet on page 81. If necessary, replace a damaged cable with a new one.
The e-box communication chain includes the E-box interconnect PCA (CZ056-67189) on page 801, the
Engine PCA (K4T88-67067) on page 805, the Engine adaptor PCA (CZ056-67188) on page 802, and the
Formatter PCA (CZ056-67186) on page 809. See also the E-box cable kit (K4T88-67231) on page 818.
TIP: The CAN B bus cable, inside the e-box, should be checked first as it is most likely to be faulty. See
Cables on page 1469.
6. Interchange the engine adaptor PCAs 2 and 3. If the problem moves, change PCA 3. Otherwise, it could be
the cables or another PCA. Follow the same procedure until the problem is identified. Replace the damaged
part with a new part.
Severity
ADVISORY
30.02.00:05
Intermittent communication errors with vapor removal PCA. Run subsystem diagnostics. If problem persists call
support.

a. Vapor removal PCA not powered up
b. Error or misconnection in data cables or connectors from the e-box to the vapor removal subsystem
c. Faulty vapor removal PCA
d. Faulty e-box interconnect PCA, engine adaptor PCA, engine PCA, or interconnecting cables
Corrective actions
1. Check that the data cables from the e-box to the vapor removal subsystem are correctly connected.
2. Check connections in the e-box and ensure that all cables are correctly connected and not damaged. See
Figure 2-7 E-cabinet on page 81. If necessary, replace a damaged cable with a new one.
The e-box communication chain includes the E-box interconnect PCA (CZ056-67189) on page 801, the
Engine PCA (K4T88-67067) on page 805, the Engine adaptor PCA (CZ056-67188) on page 802, and the
Formatter PCA (CZ056-67186) on page 809. See also the E-box cable kit (K4T88-67231) on page 818.
4. Interchange the engine adaptor PCAs 2 and 3. If the problem moves, change PCA 3. Otherwise, it could be
the cables or another PCA. Follow the same procedure until the problem is identified. Replace the damaged
part with a new part.
Severity
ADVISORY
30.02.00:10
Vapor removal PCA DC 24V supply out of range. Run subsystem diagnostics. If problem persists call support.

a. 24 V PSU damaged
b. 24 V power cable error
Corrective actions
1. Run the Power supplies diagnostic (10004) (see Table 5-22 E-cabinet on page 586) or manually check that
the PSU 2 output is 24 V. If necessary, install a new 24 V PSU. See E-cabinet PSU 24V-600W COSEL
(K4T88-67205) on page 828.
2. Check that the 24 V power cables are correctly connected and not damaged. Replace any damaged cable
with a new one. See Vapor removal interconnect kit (K4T88-67249) on page 1318.
Severity
ADVISORY
30.03.0X:01 (X may be 1 or 2)
(30.03.01:01, 30.03.02:01)
Vapor removal cooling fans Fan Array #X not spinning detected. Run subsystem diagnostics. If problem persists
call support.
a. Faulty heat exchanger fans
b. Heat exchanger fans not connected to vapor removal PCA
Corrective actions
1. Ensure that the fan cables (K4T88-50159) are correctly connected at both ends and not damaged.
2. Run the Heat exchanger fan array check diagnostic (30003). See Table 5-28 Vapor removal on page 598.
3. Install new fans. See Vapor removal fan (CZ056-67379) on page 1285.
5. Run the Heat exchanger fan array check diagnostic (30003) again to check that the problem has gone. See
Table 5-28 Vapor removal on page 598.

Severity
ADVISORY
30.03.0X:42 (X may be 1 or 2)
(30.03.01:42, 30.03.02:42)
Vapor removal cooling fans in Fan Array #X current too low. Please run subsystem diagnostics. If problem
persists call support.
a. Faulty heat exchanger fan in fan array X
b. One or more fans in fan array X is not connected
c. Error in cable
d. Faulty vapor removal PCA.
Corrective actions
1. Ensure that the fan cables are correctly connected at both ends and not damaged.
2. Run the Heat exchanger fan array check diagnostic (30003). See Table 5-28 Vapor removal on page 598.
3. Install new fans. See Vapor removal fan (CZ056-67379) on page 1285. SVC Part: Vapor Removal fan
(K4T88-67103).
5. Run the Heat exchanger fan array check diagnostic (30003) again to check that the problem has gone. See
Table 5-28 Vapor removal on page 598.
Severity
ADVISORY
41. Substrate path error codes

41.00.00:62
The roll may be over. So, thread a new roll, inflate the spindles and perform a substrate load. Otherwise, check
spindles are inflated and perform a Substrate Load.

a. The end of the roll has been reached.
b. The spindle is not inflated or the core is slipping.
c. The end of the roll is not taped or otherwise attached to the core: there is slippage starting before reaching
the end of the roll. The end of the roll must be attached to the core.
d. An elastic substrate is loaded.
e. The substrate is broken.
Corrective actions
If you have reached the end of the roll, thread a new roll, inflate the spindles, and load the substrate. Otherwise,
check that the spindles are inflated and load the substrate.
If you want to check the slippage between the substrate/core and spindle, place a mark on the edge of the
substrate going to the core, and mark the spindle too, before starting to load the substrate. If the line drawn
looks ‘broken’ after the system error, there has been slippage between substrate and core, or core and spindle.
Severity
ADVISORY
41.00.00:66
Too much skew. Potential misalignment of image. Reload the substrate. Check for substrate telescoping, edge
damage, or skew.
Description
When printing side B during double-sided printing, potential misalignment of the image due to skew.
a. Skew
b. Telescoping
c. Edge damage
Corrective actions
Reload the substrate making sure it is correctly centered.
Severity
ADVISORY

41.00.00:67
Left edge cannot be found. Reload the substrate and ensure that it is not dirty or printed. Check for substrate
telescoping, edge damage, skew or sensor dirtiness.
Description
When printing side B during double-sided printing, the left edge cannot be found.
a. Edge damage
b. Substrate edge holder dirtiness
c. Line sensor dirtiness
d. PPS too high for Line sensor to detect the substrate.
Corrective actions
1. Reload the substrate
2. Clean the substrate edge holders
3. Clean the Line sensor
4. Run Line sensor calibration in Print Care using a glossy substrate
5. Lower PPS height as close as possible to the substrate
Severity
ADVISORY
41.00.00:85
Wrong substrate settings file. At least one setting is missing. Update Media preset (*.oms files) package and if
problem persists call service.
Substrate properties missing
Corrective actions
If the problem is due to a wrong setting in an installed Media preset (*.oms files) package, ensure that it is not
corrupted and try to reinstall it.
If the problem persists, the problem might be related to the firmware. Check whether you have the latest
firmware, and update it if necessary.

Severity
ADVISORY
41.00.01:62
Possible end of roll detected. If so, thread a new roll and perform a Substrate Load. Otherwise, check spindles
are inflated, check roll is not detached from core, and perform a Substrate Load.
a. The end of roll has been reached.
b. The spindle is not inflated or the core is slipping.
c. Too much substrate is unwound on the input or output side.
d. The end of the roll is not taped or otherwise attached to the core, so that slippage starts before reaching
the end of the roll. The end of the roll must be attached to the core.
Corrective actions
You may have reached the end of the roll, or it may be detached from the core. If it has come to the end, thread a
new roll, inflate the spindles, and load the substrate. Otherwise, check that the spindles are inflated and load the
substrate.
If you want to check the slippage between the substrate/core and spindle, place a mark on the edge of the
substrate going to the core, and mark the spindle too, before starting to load the substrate. If the line drawn
looks ‘broken’ after the system error, there has been slippage between substrate and core, or core and spindle.
Severity
ADVISORY
41.01.00:51
Substrate loading table latch unexpectedly open. Close substrate loading table latches at both ends. If problem
persists run substrate path sensors check diagnostic.
a. Latch open
b. Connection problem of the sensor (left and right) to the motor drive PCA located at the back of the roll-to-
floor (middle of the printer)
c. Sensor failure (two sensors)

Corrective actions
1. Ensure that substrate loading table latches are closed on both sides.
2. Check the connections of the two sensors, mainly the connections on the sensors and on the motor drive
PCA (in the middle of the printer).
3. Run the Substrate path sensors diagnostic (41001), mainly to check the loading table latches: when
opening or closing the loading table, the sensor status should change between open and closed. See Table
5-5 Substrate path mechanics on page 551.
If the test fails, check whether the clamp set screw is touching the switch.
4. Install new sensors. See Pinch switch assembly (K4T88-67089) on page 1216.
Severity
ADVISORY
41.01.00:61
Input spindle not moving. Reload substrate and run substrate path motors diagnostic if problem persists.
a. Connection problem
b. Substrate jam
c. Spindle end cap worn out or blocked
d. Substrate input transmission problem
e. Substrate input motor problem
Corrective actions
1. Reload the substrate to clear the error.
2. Run the Motor test and Motor calibration diagnostics (41002 and 41004) and follow the instructions
provided. See Table 5-5 Substrate path mechanics on page 551.
3. Enter diagnostic mode, and follow the motor diagnostic flowchart to decide whether to install a new motor
or a new transmission. See Table 5-5 Substrate path mechanics on page 551.
4. Check the connections.
Severity
ADVISORY

41.02.00:08
Main roller substrate jam. Try to remove the jam and reload substrate, run substrate path motors diagnostic if
problem persists.
Substrate blocking the substrate path
Corrective actions
1. Remove all substrate from the substrate path.
2. Reload the substrate.
3. Run the Main roller motor test diagnostic (41003). See Table 5-5 Substrate path mechanics on page 551.
4. If the motor is faulty, and after being restarted by firmware it remains faulty, then the motor’s internal
electronics may be damaged. Install a new motor. See MA motor (CZ056-67269) on page 1182.
5. If the roller has abnormally high friction, install a new helical gear, clean the worm, and grease the whole
transmission.
6. Unmount the MA motor and motor mount, and check that the drive roller can move freely. Remount the
motor mount and motor, and check that, when turning the decoupling/axis of the motor, the drive roll
rotates easily.
Severity
ADVISORY
41.02.00:61
Problem moving main roller. Check that there is no jam, reload substrate and run substrate path mechanics
diagnostics if problem persists.
a. At the end of the roll, one end of the substrate is taped or glued to the input core.
b. Substrate jam
c. Media advance motor connection problem
d. Media advance encoder connection problem
e. Transmission worn out
f. Drive roller encoder (disc encoder and reader) problem
g. Main roller motor problem

h. OMAS control PCA connection or PCA problem
i. Vacuum control PCA connection or PCA problem
Corrective actions
Follow the next steps and, after each step, run diagnostics 41001, 41002 and 41003 to verify if the issue is
fixed.
If the issue is resolved (verified by running the previous diagnostics) after the manipulation/change of any
mechanical part (steps 5, 6, 7, 8 or 9) you should also calibrate the media advance: first reboot the printer and
load substrate, then run diagnostics 41006 and 41007.
NOTE: Before loading substrate and calibrating it is important to reboot the printer. If the printer is not
rebooted, the calibration values will not be correct.
1. If the roll has come to an end, there is no need to do anything, this is normal printer behavior. The printer
cannot turn the drive roller because the end of the roll is taped or glued to the input core. Reload the
substrate to clear the error.
2. Check that 42V power is correctly reaching the media advance motor:
● Check that there is power output (42V) in the output of the E-cabinet PCA. The fuses LEDs on the
external side of the E-cabinet should be off for all connected outputs. If any LED is on and red, install
a new fuse on the corresponding output. See Board name: E-cabinet PCA on page 371.
● Check that the power cable is connected between the MA output of the E-cabinet PCA and the MA
motor, and reconnect it if needed. You can also use a tester to verify the pin to pin continuity of the
cables to ensure they are not damaged. If they are damaged replace the cables. See MA motor power
cable (K4T88-67240) on page 1187.
3. Check that the data cable and the encoder cable are correctly connected to the Media advance motor:
● Check that the data cable is correctly connected between the J_301 output of the E-box Interconnect
PCA and the MA motor. You can also use a tester to verify the pin to pin continuity of the cables to
ensure they are not damaged. If they are damaged replace the cables. See MA motor data cable
(K4T88-67239) on page 1187.
● Check that the encoder cable is correctly connected between the J1 output of the Vacuum control PCA
and the MA motor. You can also use a tester to verify the pin to pin continuity of the cables to ensure
they are not damaged. If they are damaged replace the cables. See MA motor encoder cable
(CZ056-67094) on page 1187.
4. Check that the Vacuum control PCA and the OMAS control PCA are correctly working:
● Vacuum control PCA should be correctly powered and communicating. DS1, DS2 and DS3 LEDs
should be ON. If they are not, review the connections and replace the Vacuum control PCA if needed.
See Board name: Vacuum control PCA on page 432.
● OMAS control PCA should be correctly powered and communicating. DS1, DS2, DS3 and DS4 LEDs
should be ON. If they are not, review the connections and replace the Vacuum control PCA if needed.
See Board name: OMAS control PCA on page 433.
NOTE: The following steps should be executed with the printer powered off. Remember to reboot the
printer and run diagnostics 41001, 41002 and 41003 after each step to verify if the issue is fixed. In case
all diagnostics pass, you should also calibrate the media advance: first reboot the printer and load
substrate, then run diagnostics 41006 and 41007.

NOTE: Remember, before loading substrate and calibrating it is important to reboot the printer. If the
printer is not rebooted, the calibration values will not be correct.
5. Check if there is some grease between the worm gear and the drive roller gear. Grease it if necessary.
6. Check if there is any degradation on the drive roller gear. If there is, replace it. See Substrate drive roller
transmission assembly (CZ056-67228) on page 1187.
7. Check if there is clearance between the media drive mounting structure and the printer’s side plate. In case
there is not, tight correctly the motor mounting to the structure.
8. Dismount the MA motor and motor mount, and check that the drive roller can move freely. Remount the
motor mount and motor, and check that, when turning the decoupling/axis of the motor, the drive roll
rotates easily.
9. Check if there is any damage on the encoder disc. If it is dirty with grease or others, clean it. If it is not
correctly installed, reinstall it properly. If it is damaged, replace the encoder disc. See Drive roller encoder
disc and PCA (CZ056-67374) on page 1185.
10. Check if there is any damage on the encoder reader. If there is, replace the encoder reader. See Drive roller
encoder disc and PCA (CZ056-67374) on page 1185.
Severity
ADVISORY
41.02.00:83
Main roller encoder is not calibrated. Run main roller encoder calibration, if problem persists call service.
Calibration values missing
Corrective actions
1. Run the Encoder calibration diagnostic (41005) to recalibrate the main roller encoder. See Table 5-5
Substrate path mechanics on page 551.
2. Install a new analog encoder assembly (both the code wheel and the encoder PCA) and recalibrate it. See
Drive roller encoder disc and PCA (CZ056-67374) on page 1185.
Severity
ADVISORY

41.02.00:84
Main roller encoder zero position could not be found. Run main roller encoder calibration, if problem persists call
service.
a. Encoder disk broken, dirty, or scratched
b. Connections or encoder PCA problem
Corrective actions
1. Run the Encoder calibration diagnostic (41005) to check that the encoder does not read the zero. See Table
5-5 Substrate path mechanics on page 551.
Severity
ADVISORY
41.02.00:85
Main roller encoder cannot be read. Run main roller encoder calibration, if problem persists call service.
Connections or encoder PCA problem
Corrective actions
1. Check the connection of the encoder reader/disc. See Figure 2-10 E-stops and Interlocks on page 84.
2. Run the Encoder calibration diagnostic (41005) to recalibrate the main roller encoder. See Table 5-5
Severity
ADVISORY

41.04.00:61
Output spindle not moving. Reload substrate and run substrate path motors diagnostic if problem persists.
b. Substrate jam
d. Substrate output transmission problem
e. Substrate output motor
f. EE driver failure
Corrective actions
Severity
ADVISORY
41. Substrate path (Roll-to-free-fall only) error codes (accessory)

NOTE: These system errors only apply if the Roll-to-free-fall Kit is installed in the printer.
41.05.00:51
Tension roller pinch bar unexpectedly raised.
a. Pinch bar raised.
b. Sensor failure.

Corrective actions
1. Ensure that the pinch bar is lowered (by using the tension roller lever).
2. Run the Sensor check diagnostic (41012) to check that the sensor works correctly. See Table 5-6 Roll-to-
free-fall Kit on page 557.
3. Install a new sensor if necessary. See Pinch switch assembly (K4T88-67089) on page 1216.
Severity
ADVISORY
41.05.00:61
Tension roller not moving. Reload substrate and run substrate path motors diagnostic if problem persists.
Description
Roll-to-free-fall Tension Roller not moving
b. Substrate jam
d. Substrate tension roller transmission problem
e. Roll-to-free-fall motor (MF Motor) problem
Corrective actions
2. Check the timing belt tension. See the Roll-to-free-fall kit Installation guide.
4. Run the Motor check and Motor calibration diagnostics (41013 and 41014) and follow the instructions
provided. See Table 5-6 Roll-to-free-fall Kit on page 557.
or a new transmission. See Table 5-6 Roll-to-free-fall Kit on page 557.
Severity
ADVISORY

41.05.01:51
Tension roller latch unexpectedly open..
a. Tension roller latch opened.
b. Sensor failure.
Corrective actions
1. Close tension roller latches at both ends. Ensure that the tension roller latches are closed on both sides.
2. Run the Sensor check diagnostic (41012) to check that the sensor on the capping station side works
correctly. See Table 5-6 Roll-to-free-fall Kit on page 557.
Severity
ADVISORY
41.10.01:08
Possible take-up reel jam, optical sensor never detects media. Check that TUR inwards/outwards winding
selection is correct and that the media is not covering the sensor, if so run Media path sensors diagnostic. If you
are printing with very big rolls that cover the sensor, ignore this warning. If problem persists call support.
a. The Substrate collector sensor (take-up reel) detection path is blocked.
b. The sensor has failed or is not properly connected.
c. The roll at the substrate collector sensor is greater than 250/300 mm in diameter.
Corrective actions
1. Check that the substrate collector sensor works correctly and that there is no object blocking its line of
sight.
2. Run the Sensor check diagnostic (41012). See Pinch switch assembly (K4T88-67089). See Table 5-6 Roll-
to-free-fall Kit on page 557. Check the Substrate collector sensor manually by covering and uncovering the
sensor; it should show closed when covered and open when uncovered.
Severity
ADVISORY

43. Substrate vacuum system error codes

43.01.00:01
Vacuum blower does not seem to be working. Check connections and run the substrate path vacuum system
diagnostics.
a. Vacuum pump malfunction
b. Vacuum pump AC power issue
c. Vacuum pressure sensor (in Vacuum Control PCA) issue. Air tube disconnected or damaged
Corrective actions
1. Check that the Vapor removal and Vacuum ACB (automatic circuit breaker) labeled as "PUMPS" is on (lever
should be up). If it is not, turn it on and reboot the printer.
2. Run the Vacuum system diagnostic (43001). See Table 5-9 Substrate path vacuum on page 563.
3. Check whether the vacuum pump is powered and turning.
4. Check whether the air pressure sensor tube is properly connected to the Vacuum Control PCA and to the
vacuum chamber and working.
5. Replace any failed part with a new one. See OMAS and vacuum PCA (CZ056-67321) on page 1260 and
OMAS and vacuum PCA (CZ056-67321) on page 1260.
If you have replaced the vacuum pump, run the Vacuum sensor defaults and Reset vacuum pump usage
diagnostics (43002 and 43003). See Table 5-9 Substrate path vacuum on page 563.
Severity
ADVISORY
43.03.00:04
No feedback from the vacuum pressure sensor.
a. Pressure sensor wrongly connected
b. Failure on electrical connection to vacuum PCA

Corrective actions
1. Check electrical and air tube connections.
2. Install a new vacuum control PCA. See OMAS and vacuum PCA (CZ056-67321) on page 1260.
Severity
ADVISORY
43.03.00:30
Vacuum level is out of expected range. Check connections and run substrate path vacuum system diagnostics.
a. Air path open
b. Pressure sensor inlet disconnected
c. Power problem
d. Pump problem
Corrective actions
2. Check connections.
3. Check EE and air connections.
Severity
SILENT
43.03.00:83
Vacuum sensor calibration fail. Check that substrate behavior in the print zone is OK. Run diagnostic when the
job finishes.
a. Calibration process failure
b. Cabling

c. Sensor malfunction
d. Vacuum pump failure
Corrective actions
2. Check cabling and wiring.
4. Install a new vacuum control PCA. See OMAS and vacuum PCA (CZ056-67321) on page 1260.
5. Install a new vacuum pump. See Vacuum pump and pipe (K4T88-67141) on page 1262.
Run the Vacuum sensor defaults and Reset vacuum pump usage diagnostics (43002 and 43003). See
Table 5-9 Substrate path vacuum on page 563.
Severity
ADVISORY
46. Printhead primer error codes

(46.05.01:06, 46.05.02:06, 46.05.03:06, 46.05.04:06)
Primer X (1 = OPT, 2 = CK, 3 = YM, 4 = Lm/Lc) leakage detected. Reset primer latch and/or check o-rings. Run
subsystem diagnostic. If problem persists, call your support representative.
Description
The primer pumps air into the printhead regulator to create excessive pressure inside and force ink to flow
through clogged nozzles. Proper priming occurs when the system is properly sealed, then the priming pump can
create the proper pressure wave.
After priming, the current consumption signal of the primer is analyzed to determine if the priming was
successful. This system error appears after priming, when the primer current consumption has been close to
open/free prime (which means air leakage). Under these conditions it is highly probable that priming has been
unsuccessful.
a. The printhead latch is badly closed, so the system is not properly sealed.

b. The plastic tabs in the primer latch (marked 1 in the picture) are damaged, so the system is not properly
sealed.
c. The o-rings in the primer latch (marked 2 in the picture) are damaged, so the system is not properly sealed.
d. The air tubes are disconnected or broken, so the system is not properly sealed.
e. Pump or solenoid valve malfunction.
Corrective actions
After each step is completed, run diagnostic 46002 Primer check in HP PrintCare ►Diagnostics ►Printhead
Primers to verify that the problem is solved. If the issue still appears, continue with the troubleshooting.
1. Relatch the printhead, ensuring proper engagement of the primer ports.

Place the latch as explained in the video http://www8.hp.com/h20621/video-gallery/us/en/customer-care/

latex-printers/2305410423001/replacing-a-printhead-on-the-hp-latex-3000-printer/video/. Make sure
you press on the primer with two fingers to ensure the primer ports are well inserted.

2. Check latches, plastic tabs and o-rings for damage.
If any part is broken; replace primer and latch assemblies using parts included in the standard uptime kit
(SVC Part: Pen Pocket Assembly K4T88-60026). Follow the procedure explained in HP PrintCare ►Replace
the primer:
3. Grease the o-rings and tabs.
4. Check primer assembly (tubes and fittings), look for leaks.
5. Install a new primer and latch assemblies using parts included in the standard uptime kit (SVC Part: Pen
Pocket Assembly K4T88-60026).

Severity
ADVISORY
46.03.00:40
Carriage Interconnect PCA current out of range. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
Before a priming operation is executed (during primer self-calibration) the system will check the current
consumption of the Carriage Interconnect PCA. If this current is out of expected range, this system error will
appear.
NOTE: This system error does not prevent priming, however after the system error appears, since the current
signal has been detected to be unreliable, the system will not analyze the current consumption during priming to
determine if it has been successful
a. Cabling problem between Carriage interconnect PCA and Carriage power management PCA (the current
signal coming from Carriage interconnect PCA is read in Carriage power management PCA).
b. E-cabinet PCA does not supply power to Carriage interconnect PCA.
c. Carriage interconnect PCA failure.
Corrective actions
1. Check the cabling and connections between Carriage interconnect PCA and Carriage power management
PCA.
2. Check the visual indicators (LEDs) on Carriage power management PCA. LEDs A, B and C (marked as 3, 7
and 2 in the carriage cover) should be ON (see Board name: Carriage power management PCA
on page 405). If LEDs A and B are ON but C is OFF, there is probably a short-circuit in the Carriage
Interconnect PCA. If LED A is ON but LEDs B and C are off, there is probably an issue with the Carriage power
management PCA.
3. Check the visual Indicators on Carriage interconnect (See Board name: Carriage Interconnect PCA
on page 404).
4. Install a new Carriage Interconnect PCA (SVC part: CZ056-67373).
Severity
ADVISORY

46.03.01:04
Carriage Interconnect PCA communication failure.
Description
There has been a problem communicating with the Carriage interconnect PCA.
a. Cabling problem in the Carriage interconnect PCA: cabling with PH interconnect 3 (YM) and 4 (LmLc) (data
cables) or with Carriage power management PCA.
b. E-cabinet PCA does not supply power to the Carriage interconnect PCA.
c. Carriage interconnect PCA failure.
Corrective actions
1. Check the cabling and connections between the Carriage interconnect PCA and the PH interconnect PCAs,
as well as the cabling between the Carriage interconnect PCA and the Carriage power management PCA.
2. Check the visual indicators (LEDs) on the Carriage power management PCA. LEDs A, B and C (marked as 3,
7 and 2 in the carriage cover) should be on (see Board name: Carriage power management PCA
on page 405). If LEDs A and B are on but C is off, there is probably a short-circuit in the Carriage
interconnect PCA. If LED A is on but LEDs B and C are off, there is probably an issue with the Carriage power
management PCA.
3. Check the visual Indicators on the Carriage interconnect (See Board name: Carriage Interconnect PCA
on page 404).
4. Install a new Carriage Interconnect PCA (SVC part: CZ056-67373).
Severity
ADVISORY
46.04.0X:40 (X may be 1 or 3)
(46.04.01:40, 46.04.03:40)
Primer solenoid valve (X = 1: 1 (OPT) and/or 2 (CK), X = 3: 3 (YM) and/or 2 (Lm/Lc)) current out of range. Check
solenoid valves and their connectors. Run subsystem diagnostic. If problem persists, call your support
representative.
Description
consumption of the solenoid valves. If this current is out of expected range, this system error will appear. The

system can read two current signals: one for the solenoid valves 1 (OPT) and 2 (CK) and another for the solenoid
valves 3 (YM) and 4 (Lm/Lc), thus, when this error appears the printer cannot distinguish which valve is failing.
a. Cabling problem between Carriage interconnect PCA and the affected solenoid valves.
b. Solenoid valve malfunction.
Corrective actions
1. Check the cabling and connections between Carriage interconnect PCA and affected solenoid valves.
2. Run the diagnostic 46002 Primer check. Verify if the current of the affected valves is out of expected range
and visually check if any of the 2 affected valves is actually not priming.
3. If a failing valve is identified, replace primer and latch assemblies using parts included in the standard
uptime kit (SVC Part: Pen Pocket Assembly (K4T88-60026)). Follow the procedure explained in HP
PrintCare ►Replace the Primer.
4. Run the diagnostic 46002 Primer check to verify that all values are inside range again.
Severity
ADVISORY

(46.05.01:40, 46.05.02:40, 46.05.03:40, 46.05.04:40)
Primer pump X (X = 1 OPT, X = 2 CK, X=3 YM, X =4 Lm/Lc) current out of range. Check pump and its connector.
Run subsystem diagnostic. If problem persists, call your support representative.
Description
consumption of the primer pumps. If this current is out of expected range, this system error will appear.
a. Cabling problem between Carriage interconnect PCA and the affected primer pump.
b. Primer pump malfunction.

Corrective actions
1. Check the cabling and connections between Carriage interconnect PCA and the affected primer pump.
2. Run the diagnostic 46002 Primer check. Verify if the current of the affected pump is out of expected range
and visually check if the pump is actually priming.
3. Replace primer and latch assemblies using parts included in the standard uptime kit (SVC Part: Pen Pocket
Assembly (K4T88-60026)). Follow the procedure explained in HP PrintCare ►Replace the Primer.
4. Run the diagnostic 46002 Primer check to verify that all values are inside range again.
Severity
ADVISORY
47. Printhead cleaning error codes

47.00.00:50
Wiper engage height error. Run subsystem diagnostics. If the problem persists, call your support representative.
Description
The rubber blade moves up and down, lifting the cleaner roll to ensure that the printheads make proper contact
with the cloth during cleaning. The up/down motion has two main positions. The engage position is the upper
position calibrated for correct printhead cleaning, and the disengage position is the lowest resting position of the
rubber blade.
a. The printer is detecting an error in the engage system.
b. The cleaning roll is not properly set.
c. Engage is not working properly.
d. The height is wrong.
Corrective actions
1. Check engage and cleaning roll. See Web wipe central cage top cover (K4T88-67114) on page 1114.
2. Run the Printhead cleaning Z calibration check diagnostic (47005), and if necessary run the Set printhead
cleaning Z calibration diagnostic (47006). See Table 5-16 Printhead cleaning on page 580.
3. Run the Visual movement check diagnostic (47002), Manual movement check (47003), and Motor direction
test (47004) diagnostics. See Table 5-16 Printhead cleaning on page 580.
Severity
ADVISORY

47.00.00:80
Wiper Engage X calibration missing. Default value applied to allow continue working. Call HP support to get more
information.
Description
The rubber blade position along the scan axis is calibrated versus the printhead, so it can be engaged and
disengaged properly and synchronized. If calibration values are missing, nominal values are applied as a backup.
Calibration has been lost.
Corrective actions
None, as the default calibration works well.
Severity
SILENT
47.00.00:82
Wiper Engage Z calibration missing. Default value applied to allow printing to continue. Call your support
representative for more information.
Description
The printhead cleaning blade height calibration values are missing from the NVM. The calibrations must be
performed before the mechanism will function correctly. Height calibration is required to ensure proper cleaning
force.
Calibration has been lost.
Corrective actions
1. Run the Printhead cleaning Z calibration check diagnostic (47005), and if necessary run the Set printhead
cleaning Z calibration diagnostic (47006). See Table 5-16 Printhead cleaning on page 580.

Severity
ADVISORY
47.01.01:01
Wiper engage motor servo shutdown. Check that your cleaning roll is not blocked. Run subsystem diagnostics. If
Description
The printhead cleaning engage motor has failed to perform the engage movement as expected. The engage
motor is controlled in a closed loop by the main interconnect board. The motor receives the PWM signal from the
main interconnect board. The internal motor encoder reads the encoder movement signals and sends the
signals to the linear-to-differential encoder PCA, then to the main interconnect board with an intermediate
connection at the rear of the printhead cleaning module.
a. Rubber blade up/down path obstructed
b. Rubber blade up/down system mechanically blocked
c. Rubber blade up/down motor encoder failure
d. Rubber blade up/down motor failure (cable disconnected or motor failed)
e. Main interconnect board failure
Corrective actions
1. Make sure there are no mechanical parts stuck or preventing the rubber blade going up. If necessary, see
Web wipe central cage top cover (K4T88-67114) on page 1114.
2. Move the system and check for any possible obvious damage.
4. Check the whole encoder path from the motor to the encoder PCA down to the module connection and
then to the main interconnect. Ensure all connections are correct and install new cables if required.
5. Check the cable connected to each of the four motor drive PCAs at connector J4 (coming from encoder
reader of each motor). Between each motor drive PCA there is a specific cable connected to J4 as it contains
the specific address of the printer, detected by the motor drive PCA when the printer is powered up. See
Motor encoder cable (x4) (CZ056-50116) in Cables on page 1469.
6. Replace any faulty parts with new ones.
Severity
ADVISORY

47.01.01:02
Wiper Engage motor initialization error. Run subsystem diagnostics. If the problem persists, call support.
a. System initialization fails.
b. The printhead cleaning roll is not correctly installed.
c. Engage is jammed.
Corrective actions
Severity
ADVISORY
47.01.02:01
Wiper advance motor servo shutdown. Check that your cleaning roll is not blocked. Run subsystem diagnostics. If
Description
The printhead cleaning advance motor has failed to perform the wiper advance movement as expected. The
advance motor is controlled in a closed loop by the main interconnect board, from which it receives the PWM
signal. The internal motor encoder reads the encoder movement signals and sends the signals to the linear-to-
differential encoder PCA, then to the main interconnect board with an intermediate connection at the rear of the
printhead cleaning module.
a. Printhead cleaner pinch module is not correctly closed.
b. Printhead cleaner path blocked. The roller cannot move the roll.
c. Advance motor roller connections failure, motor power failure, or encoder cables disconnected.

d. Advance roller mechanical failure.
e. Main interconnect board failure.
f. Printhead cleaning roll system mechanical failure.
Corrective actions
1. Make sure the pinch mechanism is closed. Push in the black holder to ensure correct latching of the
system. Repeat closing operation and restart the system.
2. Check the wiper path for obstructions. If there is an obstruction, re-do the wiper path and ensure that there
is no damage to the wiper or printhead cleaning roll parts.
3. Check the cable connections of the encoder and motor system.
NOTE: Check the electrical diagram to ensure that all cables in the motor power and encoder path are
correctly connected.
4. Check behind the printhead cleaning roll and ensure that there is no obvious damage to the transmission
system, such as a broken gear or motor out of position.
6. Install a new advance motor assembly. See MA motor (CZ056-67269) on page 1182. You may interchange
transmission boxes to find whether the problem stays in the same transmission box or axis.
7. Install a new motor drive PCA. See Printhead cleaning system motor drive PCA (CZ056-67190)
on page 1131. You may interchange motor drive PCAs to confirm that the failure follows the PCA.
8. Replace the failing parts of the printhead cleaning roll with new parts.
Severity
ADVISORY
47.01.02:02
Wiper advance motor initialization error. Run subsystem diagnostics. If the problem persists, call your support
representative.
a. There has been a system initialization failure.
b. The printhead cleaning roll is not correctly installed.
c. The printhead cleaning advance motor is jammed.

Corrective actions
Severity
ADVISORY
47.01.04:01
Wiper Input Motor Servo Shutdown. Run subsystem diagnostics. If problem persists call support.
Description
The printhead cleaning input motor has failed to advance the roll as expected. The input motor is controlled in a
closed loop by the main interconnect board, from which it receives the PWM signal. The internal motor encoder
reads the encoder movement signals and sends the signals to the linear-to-differential encoder PCA, then to the
main interconnect board with an intermediate connection at the rear of the printhead cleaning module.
c. Input motor roller connections failure, motor power failure, or encoder cables disconnected.
d. Input motor failure.
e. Motor drive PCA failure.
Corrective actions
2. Check the wiper path for obstructions. If there is an obstruction, re-do the wiper path and ensure there is
no damage to the wiper or printhead cleaning roll parts.

7. Install a new input motor assembly. See MI motor on page 1237. You may interchange transmission boxes
to find whether the problem stays in the same transmission box or axis.
on page 1131.
Severity
ADVISORY
47.01.04:02
Wiper input motor initialization error. Run subsystem diagnostics. If the problem persists, call your support.
a. System initialization failure.
b. Printhead cleaning roll is not correctly installed.
c. Input motor is jammed.
Corrective actions
Severity
ADVISORY

47.01.05:01
Wiper output motor servo shutdown. Run subsystem diagnostics. If the problem persists, call support.
Description
The printhead cleaning advance motor has failed to advance the roll as expected. The advance motor is
controlled in a closed loop by the main interconnect board, from which it receives the PWM signal. The internal
motor encoder reads the encoder movement signals and sends the signals to the linear-to-differential encoder
PCA, then to the main interconnect board with an intermediate connection at the rear of the printhead cleaning
module.
c. Output motor roller connections failure, motor power failure, or encoder cables disconnected.
d. Output motor failure.
e. Motor drive PCA failure.
Corrective actions
7. Install a new advance motor. See MA motor (CZ056-67269) on page 1182. You may interchange
transmission boxes to find whether the problem stays in the same transmission box or axis.
on page 1131.

Severity
ADVISORY
47.01.05:02
Wiper output motor initialization error. Run subsystem diagnostics. If the problem persists, call your support
representative.
a. System initialization failure.
b. Printhead cleaning roll is not correctly installed.
c. Output motor is jammed.
Corrective actions
Severity
ADVISORY
47.01.06:52
String motors wiper advance motor cleaning roll pinch unlocked.
Description
If the pinch system of the printhead cleaning roll assembly is not properly closed, the cleaning operation could
fail and the cleaning roll assembly could be damaged when the carriage beam is raised.
NOTE: This error could still occur even if the pinch system is properly closed, if there is slippage between the
core of the printhead cleaning roller and its motor. But this should not happen in the future, as the core has been
modified to grip the motor better. The newer core has a hexagonal cross-section, while the original core was
round.

a. Failure when initializing the printer
b. Failure when replacing the printhead cleaning roller
Corrective actions
Ensure that the pinch system of the printhead cleaning roll assembly is properly closed.
Severity
ADVISORY
47.04.00:01
End of web wipe.
Description
End of printhead cleaning roll. Check that your cleaning roll is not blocked. If it is empty, replace it with a new
one.
a. Real end of roll
b. The cleaning roll has slipped over its axis and the printer detects that it is not moving correctly
Corrective actions
If there is still some printhead cleaning roll on the input core:
2. Check that the core of the input cleaning roller can still rotate when sliding out from the input axis.
Severity
SILENT

47.05.11:04
Motor drive PCA 111, printhead cleaning roll Z (engage), communication problem.
Description
The e-box cannot communicate with the engage motor drive PCA, communication failure.
a. Engage motor drive PCA wiring/cabling problem
b. Engage motor drive PCA malfunction
Corrective actions
1. Check the connections of the motor drive PCAs:
a. Check that the data bus is well terminated at the motor drive PCA by having the term jumper in place.
b. Check the power supply to the motor drive PCA, by checking the following LEDs:
● Motor drive PCA: see Board name: Motor drive PCA on page 435.
● E-box interconnect PCA, connector U151 (micci2): see Board name: E-box interconnect PCA
on page 395.
● E-cabinet PCA, WW connector: see Board name: E-cabinet PCA on page 371.
c. Check the cable connected to each of the four motor drive PCAs at connector J4 (coming from
encoder reader of each motor). Between each motor drive PCA there is a specific cable connected to
J4 as it contains the specific address of the printer, detected by the motor drive PCA when the printer
is powered up. See Motor encoder cable (x4) (CZ056-50116) in Cables on page 1469.
2. Run the Visual movement check diagnostic (47002). See Table 5-16 Printhead cleaning on page 580.
3. Install a new motor drive PCA if necessary. See Printhead cleaning system motor drive PCA (CZ056-67190)
on page 1131.
Severity
SEVERE
47.05.12:04
Motor drive PCA 112, printhead cleaning roll MA (Media Advance), communication problem.
Description
The e-box cannot communicate with the advance motor drive PCA, communication failure.

a. Advance motor drive PCA wiring/cabling problem
b. Advance motor drive PCA malfunction
Corrective actions
on page 395.
on page 1131.
Severity
SEVERE
47.05.14:04
Motor drive PCA 114, printhead cleaning roll MI (Media Input), communication problem.
Description
The e-box cannot communicate with the input motor drive PCA, communication failure.
a. Input motor drive PCA wiring/cabling problem
b. Input motor drive PCA malfunction
Corrective actions

on page 395.
on page 1131.
Severity
SEVERE
47.05.15:04
Motor drive PCA 115, printhead cleaning roll MO (Media Output), communication problem
Description
The e-box cannot communicate with the output motor drive PCA, communication failure.
a. Output motor drive PCA wiring/cabling problem
b. Output motor drive PCA malfunction
Corrective actions

on page 395.
on page 1131.
Severity
SEVERE
48. PPS error codes

(48.01.01:59, 48.01.02:59)
PPS Servo X (1 = SVS side, 2 = IDS side) shutdown. Check that the scan beam is not blocked. PPS not usable,
printer cannot be operated. Run subsystem diagnostic. If problem persists, call your support representative.
Description
The meaning of X is:
1 = Right motor (SVS side)
2 = Left motor (IDS side)
An error in the closed-loop control (servo control) of the PPS system has occurred meaning that the PPS system
is not moving as expected in closed-loop control. The servo-controlled movements consist of applying a specific
PWM to a motor (a certain amount of energy) and receiving the encoder feedback about the actual movement of
the motor after applying that specific PWM.
If after applying a specific PWM the encoder does not register the expected number of encoder counts
(movement), the system produces this error. The error also appears if the PWM values are out of a certain range
of values for the movement (i.e. too high PWM to obtain a movement).

a. PWM is too high due to a mechanical failure. Mechanical system jammed, mechanical system broken, loose
or not well greased.
b. Encoder signals indicating the movement not registered: Encoder sensor disconnected, encoder sensor
broken or failed, encoder strip dirty, broken or deflected, encoder sensor cabling failure.
c. Motor failure, motor cable failure or disconnected.
d. PWM generator (motor drive PCA) failure.
e. PPS Safety PCA failure.
f. PPS system fuse failure. Contact between mechanical system fuse and the motor module.
Corrective actions
1. Check whether any object is trapped between the scan axis and PPS support. Also check all motor and
encoder connections and the encoder strips.
2. Try to move the carriage beam to SUBSTRATE LOADING position (from the Internal Print Server).
4. Verify that the encoder strip is in good shape, clean and well placed, so that the encoder sensor can detect
the counts.
5. Check that power (24V line) is supplied to the motor drive PCA (LED on the eCabinet PCA for the PPS
output, see Board name: E-cabinet PCA on page 371).
6. Check that power (data line) is supplied to the motor drive PCA (LED on the e-box interconnect PCA, see
Board name: E-box interconnect PCA on page 395).
7. Add grease to the PPS system: columns and motor.
8. Run the diagnostic 48002 Scan-beam motor and encoder check. Follow the instructions on the test to
better diagnose the issue. Possible corrective actions proposed by the diagnostic could be: changing the
PPS motor (SVC part: K4T88-67060), the encoder (SVC part: K4T88-67062 ), the PPS safety PCA (SVC part:
K4T88-67063) or the motor drive PCA (SVC part: CZ056-67190).
Severity
ADVISORY

(48.03.01:05, 48.03.02:05)
PPS encoder X (X=1 SVS Side, X=2 IDS Side) engage timeout. Run subsystem diagnostic. If problem persists, call
your support representative.

Description
When the PPS motors are in a lower position than the PRINTING position they are not engaged to the scan beam.
If the motors are in the lower position (for example, due to a replacement – the motors as a service part come in
this position), the system has to make an engage movement between the lower position of the motor and the
PRINTING position.
If the motor cannot complete engagement within a certain time limit, the printer stops the movement to prevent
damage and the system error appears.
a. Motor not moving: Motor failure, motor cable failure or disconnection.
b. Encoder signals indicating the movement not registered: Encoder sensor disconnected, encoder sensor
broken or failed, encoder strip dirty, broken, or deflected, encoder sensor cable failure.
Corrective actions
1. Restart the printer and try to start again the process for loading media.
2. Check all motor and encoder connections and the encoder strips.
3. Verify if the motor is actually engaged to the scan beam.
4. Run the diagnostic 48004 Scan-beam motor open-loop movement following these steps:
a. Move down both motors as much as possible.
b. Move up both motors until the lifter engages again with the top structure and you are able to see the
encoder counts increasing.
5. If, when using diagnostic 48004, the motor is not able to move up and down, the problem will be in the
motor chain (motor, motor cabling, motor drive PCA). If the motor is able to move up and down but after
engaging the encoder counts do not increase, the problem is in the encoder chain (encoder sensor, encoder
strip, encoder cabling, motor drive PCA).
6. Change the failing part: PPS motor (SVC part: K4T88-67060), the encoder (SVC part: K4T88-67062 ) or
motor drive PCA (SVC part: CZ056-67190).
Severity
ADVISORY

(48.03.01:47, 48.03.02:47)
PPS encoder X (X=1 SVS Side, X=page2 IDS Side) homing flag not found. Check that nothing is preventing normal
movement of the scan beam and move it to SUBSTRATE LOADING position (from the Internal Print Server) to
recover subsystem. Run subsystem diagnostic. If problem persists, call your support representative.

Description
The PPS reaches PRINTING position when a flag is detected by the encoder and the system detects higher PWM
consumption at the same time. This system error appears if the printer detects the rise of PWM, but does not
detect the flag.
a. PWM is too high due to a mechanical failure. Mechanical system jammed, mechanical system broken, loose
or not well greased.
b. Flag sensor signal not registered: Flag sensor disconnected, flag sensor broken or failed, mechanical flag
deformed or broken, flag sensor cable failure.
c. Encoder signals indicating the movement not registered: Encoder sensor disconnected, encoder sensor
broken or failed, encoder strip dirty, broken or deflected, encoder sensor cable failure.
d. Motor failure, motor cable failure or disconnected.
e. PWM generator (motor drive PCA) failure.
f. PPS Safety PCA failure.
g. PPS system fuse failure. Contact between mechanical system fuse and motor module.
Corrective actions
4. Verify that the mechanical flag is inside the path of the flag sensor, so that it can be correctly detected.
5. Verify that the encoder strip is in good shape, clean and well placed so that the encoder sensor can detect
the counts.
6. Check that power (24V line) is supplied to the motor drive PCA (LED on the eCabinet PCA for the PPS
output, see Board name: E-cabinet PCA on page 371).
7. Check that power (data line) is supplied to the motor drive PCA (LED on the e-box interconnect PCA, see
Board name: E-box interconnect PCA on page 395).
8. Add grease to the PPS system: columns and motor.
9. Run the diagnostic 48002 Scan-beam motor and encoder check. Follow the instructions on the test to
better diagnose the issue. Possible corrective actions proposed by the diagnostic could be: Changing the
PPS motor (SVC part: K4T88-67060), the encoder (SVC part: K4T88-67062 ), changing the PPS safety PCA
(SVC part: K4T88-67063), or changing the motor drive PCA (SVC part: CZ056-67190).
Severity
ADVISORY

48.03.00:38
PPS misalignment during movement. Check that nothing is preventing normal movement of the scan beam and
move it to SUBSTRATE LOADING position (from the Internal Print Server) to recover subsystem. If problem
Description
The relative movement of one of the PPS modules with respect to the other is incorrect, which means danger of
complete system misalignment. This system error protects the system to prevent any possible damage.
When misalignment is detected the printer tries to automatically align the scan beam and this system error (with
SILENT severity) will be logged in the printer .log file but not shown in the IPS. If, during the retry movement,
misalignment is detected again, another SILENT error will be logged. Finally, if the retry movement fails and the
printer is not able to align the scan beam automatically, the system error will be raised in the IPS with ADVISORY
severity. In this case the movement will stop until a user action is taken.
a. An obstruction has damaged the power transmission and broken the mechanical power chain.
b. Motor wearing or high friction in movement.
c. Encoder signals indicating movement not registered: Encoder sensor disconnected, encoder sensor broken
or failed, encoder strip dirty, broken or deflected, encoder sensor cabling failure.
d. Motor failure, motor cable failure or disconnection.
Corrective actions
4. Run the diagnostic 48002 Scan-beam motor and encoder check (from PrintCare). If the PWM for one of the
motors during the movements is outside the acceptable range or there is a big difference between the 2
motors; verify that the system is well greased and check the motor, encoder connections, and the encoder
strip.
5. If the previous steps did not help to recover the system and the scan beam is still misaligned, run
diagnostic 48004 Scan-beam motor open-loop movement: Individually move the motors in order to align
the scan-beam. Once it is aligned try to move the carriage beam to SUBSTRATE LOADING position (from the
Internal Print Server).
6. Check the PPS safety PCA and connections (K4T88-67063).
7. Check that all cables are correctly connected to e-cabinet contactors (K4T88-67211).
8. Install a new encoder (SVC part: K4T88-67062).
9. Install a new PPS motor (SVC part: K4T88-67060).

Severity
SILENT/ADVISORY
48.03.00:65
PPS misalignment when a printing position is reached. Move the scan beam to SUBSTRATE LOADING position
(from the Internal Print Server) to recover subsystem and repeat the previous operation. Run subsystem
diagnostic. If problem persists, call your support representative.
Description
When the PPS reaches a printing position (usually a custom printing position) the misalignment of the scan beam
should be very small in order to have a good print quality and to protect the printheads. This system error
appears when misalignment of the scan beam is higher than 0.5 mm.
a. High friction in the movement.
b. Motor wearing or failing motor.
Corrective actions
3. Clean and grease the mobile parts of the PPS subsystem (columns).
4. Install a new PPS motor (SVC part: K4T88-67060).
Severity
ADVISORY

(48.05.21:04, 48.05.22:04)
Driver motor PCA X communication issue. Run diagnostics to recover the PPS subsystem. If the problem persists,
call your service representative.
Description
The meaning of X is:

1 = Right PPS motor (SVS side)
2 = Left PPS motor (IDS side)
There is a communication problem between the PCA of motor X, the motor itself, or the rest of the electronics.
Usually a result of disconnected or damaged cables, but it can also be the result of a defective PCA or motor.
a. Power cable not providing power to Driver motor PCA.
b. Driver Motor PCA address not well set or missing. Address is set in encoder connector (J4).
c. Data cable/connector problem (cable connected to J1 in Driver motor PCA).
d. E-box problem.
e. Driver motor PCA problem.
Corrective actions
1. Check power cable going from Ecabinet PCA to Motor Drive PCA (24V).
2. Check the encoder cable and connector (J4 in Motor Drive PCA). Address should be correctly configured (see
image below).
3. Check data cable connected to J1 in Motor Drive PCA. For X = 2, check also the connection between e-box
interconnect PCA and Motor Drive PCA 1.
4. Run the subsystem diagnostics for PPS (see Table 5-11 Scan-beam on page 565) and E-box (see Table
5-21 E-box on page 585). Replace the faulty part with a new one.
5. Install a new Driver Motor PCA (SVC Part: CZ056-67190).
Severity
SEVERE

49. Carriage aerosol removal error codes

49.01.0X:01 (X may be 1 or 2)
(49.01.01:01, 49.01.02:01)
(X=1) left, (X=2) right bar aerosol removal fan fault detected. Run subsystem diagnostic to check them. If the
Description
A fault has been detected in the aerosol removal fans, the aerosol produced while printing may not be properly
extracted and may affect print quality. The aerosol can make other parts of the printer dirty, such as encoders or
sensors, and create spontaneous failures. You should fix the problem as soon as possible.
The carriage has two fan arrays with 2 fans to each array. The fans have a fault signal which is activated when
the fan is powered but not rotating. Fans or arrays not connected will not display this error.
a. One of the fan rotors is locked.
b. There is a failure in the fan electronics.
c. There is a failure in the Carriage power management PCA.
Corrective actions
1. Check whether the fans are rotating when they are activated, then run diagnostic 49001 Aerosol Extraction
Status to verify it. In this diagnostic you can set each fan array to a certain PWM and also see the fault
signal. See Table 5-13 Carriage aerosol on page 575.
2. Check the visual indicators (LEDs) on Carriage power management PCA. LEDs A, B and D (marked as 3, 7
and 10 & 11 in the carriage cover) should be ON (see Board name: Carriage power management PCA
on page 405).
3. For troubleshooting purposes, you could swap the two aerosol fans. If the fault follows the fan, install new
aerosol fans (SVC Part: K4T88-67001). If the fault stays in the same place, install a new Carriage power
management PCA (SVC Part: K4T88-67017) and a new cable between the Carriage power management
PCA and the aerosol fans (SVC Part: Carriage cables K4T88-67007).
Severity
ADVISORY
49.04.00:09
Carriage power management PCA cable to PH Interconnect PCA 2 (CK) connector issue. Check connection. Run

Description
During boot up and before each priming operation the system checks that there is connectivity between Carriage
power management PCA and PH Interconnect PCA 2 (CK). This System Error is raised when the check fails.
a. The cable between Carriage power management PCA and PH Interconnect PCA 2 (CK) is disconnected.
b. The cable between Carriage power management PCA and PH Interconnect PCA 2 (CK) is damaged.
Corrective actions
1. Verify that the cable between Carriage power management and PH Interconnect PCA 2 (CK) is properly
connected.
2. Run the diagnostic 46002 Primer check. If the connectivity problem between the Carriage power
management PCA and PH Interconnect PCA 2 (CK) is detected, PrintCare will inform about it.
3. Install a new cable between the Carriage power management PCA and PH Interconnect PCA 2 (CK). (SVC
Part: Carriage Cables K4T88-67007).
Severity
ADVISORY
49.05.00:09
Carriage power management PCA cable to PH Interconnect PCA 1 (OPT) connector issue. Check connection. Run
Description
During boot up and before each priming operation the system checks that there is connectivity between Carriage
power management PCA and PH Interconnect PCA 1 (OPT). This System Error is raised when the check fails.
a. The cable between Carriage power management PCA and PH Interconnect PCA 1 (OPT) is disconnected.
b. The cable between Carriage power management PCA and PH Interconnect PCA 1 (OPT) is damaged.
Corrective actions
1. Verify that the cable between Carriage power management and PH Interconnect PCA 1 (OPT) is properly
connected.
2. Run the diagnostic 46002 Primer check. If the connectivity problem between the Carriage power
management PCA and PH Interconnect PCA 1 (OPT) is detected, PrintCare will inform about it.
3. Install a new cable between the Carriage power management PCA and PH Interconnect PCA 1 (OPT). (SVC
Part: Carriage Cables K4T88-67007).

Severity
ADVISORY
49.06.00:01
Carriage power management PCA cooling fan fault detected. Check fan and its connection. Run subsystem
diagnostic. If problem persists, call your support representative.
Description
The cooling fan in the Carriage power management PCA is not spinning. This could be a fan problem or a
connection problem.
a. Cabling or connection problem between the fan and the Carriage power management PCA.
b. Faulty fan.
c. Problem in the aerosol fans (short-circuit) causing the cooling fan to fail too.
Corrective actions
1. Verify that the cable between Carriage power management PCA and the cooling fan is properly connected.
2. Check visual indicators in Carriage power management PCA: LEDs A, B and D (marked as 3, 7 and 10 & 11
in the carriage cover) should be ON. If LED D is OFF, there may be a short-circuit on the cooling fan or the
aerosol Fans. If LED B is also OFF, Carriage power management PCA may be damaged. See Board name:
Carriage power management PCA on page 405.
3. Install a new Cooling Fan and cable assembly (SVC Part: Carriage Fan K4T88-67015).
4. If changing the cooling fan does not solve the issue and the aerosol fans are not working either, install new
aerosol fans (SVC Part: K4T88-67001) and a new cable between the Carriage power management PCA and
the aerosol fans (SVC Part: Carriage cables K4T88-67007).
Severity
ADVISORY
49.07.00:16
Carriage power management PCA short-circuit detected. The short-circuit could be either in the aerosol removal
fans or in the Carriage power management PCA cooling fan. Run subsystem diagnostic. If problem persists, call
your support representative.

a. Short-circuit in the aerosol removal fans or in the cable connecting them to the Carriage power
management PCA.
b. Short-circuit in the Carriage power management PCA cooling fan or in the cable connecting it to the
Carriage power management PCA.
Corrective actions
1. Check visual indicators in the Carriage power management PCA: If LEDs A (marked as 3 in the carriage
cover) and B (marked as 7 in the carriage cover) are on but LED D (marked as 10 & 11 in the carriage
cover)is off, the short-circuit could be confirmed (continue with step 2). If all three LEDs A, B and D are on,
the error could have been a false positive (restart the printer). If only LED A is on (B and D are off) there
could be a problem with Carriage power management PCA.
2. Remove the enclosure of the PCA and restart the printer. If the problem disappears, there could be some
cable damaged or touching the enclosure, causing the short-circuit. In that case, check all the connections
and change the damaged part.
3. Disconnect the Carriage power management PCA cooling fan. If the error disappears (and only error
49.06.00:01 appears), the short-circuit might be in the cooling fan or its cabling. In that case, install a new
Cooling fan and cable assembly (SVC Part: Carriage fan K4T88-67015). If the error is still present after
disconnecting the cooling fan, continue with step 4.
4. Disconnect the aerosol fans. If the error disappears, the short-circuit might be in the aerosol fans or its
cabling. In that case, install new aerosol fans (SVC Part: K4T88-67001) and a new cable between the
Carriage power management PCA and the aerosol fans (SVC Part: Carriage cables K4T88-67007).
5. Install a new Carriage power management PCA (SVC Part: SVC Part: K4T88-67017).
Severity
ADVISORY
50. OMAS error codes

50.00.01:00
The substrate-advance sensor is not tracking the substrate advance.
Description
This error is triggered when the OMAS is disconnected as the result of a failed calibration or repeated navigation
failures while printing. The error is logged in a file.

a. Substrate not navigable
b. OMAS window dirty
c. OMAS failure
Corrective actions
1. Check whether the substrate type is transparent or lacks sufficient features to be read by the OMAS. If this
is the case, turn off the OMAS for that substrate type.
2. Clean the OMAS window. See the user guide.
3. Install a new OMAS platen assembly. See OMAS platen assembly (K4T88-67137) on page 1200.
Severity
SILENT
50.00.01:68
The substrate-advance sensor cannot find the registration line.
Description
When printing side B during double-sided printing, the sensor cannot find the registration line. This error is
reported if the line cannot be found before starting to print side B, or while printing when two consecutive lines
cannot be found.
a. Registration line wrongly positioned before printing side B
b. Substrate bubble
c. Dirty sensor
d. Faulty sensor
Corrective actions
1. Before printing Side B, the registration line must be aligned with the beginning of the platen to ensure its
detection. Use the pen mark done on the Side B before unloading Side A for the alignment.

2. Check that the substrate is properly loaded, and flat over the sensor.
4. Run the OMAS cleanliness diagnostic (50003) and clean the sensor if necessary (see Table 5-8 Substrate-
advance sensor (OMAS) on page 559).
5. Run the Show sensor status diagnostic (50005) and check the code and its meaning. See Table 5-8
Substrate-advance sensor (OMAS) on page 559.
Severity
ADVISORY
50.00.01:89
The substrate-advance sensor cannot find the registration line.
Description
When printing side B during double-sided printing, the sensor cannot find the registration line. This error is
reported if the line cannot be found when loading side B, or while printing when two consecutive lines cannot be
found.

a. Substrate bubble
b. Dirty sensor
c. Faulty sensor
Corrective actions
1. Check that the substrate is navigable, properly loaded, and flat over the sensor.

3. Run the OMAS cleanliness diagnostic (50003, see Table 5-8 Substrate-advance sensor (OMAS)
on page 559) and clean the sensor if necessary.
Severity
ADVISORY
50.01.01:00
The substrate-advance sensor cannot see fiducials.
a. Substrate bubble
b. Dirty sensor
c. Faulty sensor
Corrective actions
1. Check that the substrate is navigable, properly loaded, and flat over the sensor.
2. Run the OMAS cleanliness diagnostic (50003, see Table 5-8 Substrate-advance sensor (OMAS)
on page 559) and clean the sensor if necessary.
Severity
SILENT
50.01.01:01
OMAS disabled. But the printer can continue printing. Run diagnostics and/or call support if you notice any print-
quality issue.
Description
Critical error detected on the OMAS controller board: OMAS opti-electronics error (cable or mini-PCA at sensor).
This failure occurs only during the OMAS controller self-test, when the printer starts.

a. Sporadic failure
b. Failure in OMAS controller
Corrective actions
1. Restart the printer. This may be sufficient in some cases.
2. If the error is persistent, you can continue printing by turning off the OMAS.
3. Check the OMAS controller board to make sure that everything is correctly connected and undamaged.
4. Install a new OMAS (see OMAS platen assembly (K4T88-67137) on page 1200. SVC Part: K4T88-67137) and
vacuum control box (see OMAS and vacuum PCA (CZ056-67321) on page 1260. SVC Part: CZ056-67321).
Severity
ADVISORY
50.01.01:77
OMAS is disabled but printer can continue printing. Run diagnostics and/or call support if you notice any print-
quality issue.
a. OMAS is dirty.
b. OMAS is not properly connected.
c. OMAS is faulty.
d. OMAS PCA is faulty.
Corrective actions
1. Check and clean the OMAS window.
3. Install a new OMAS (see OMAS platen assembly (K4T88-67137) on page 1200) and vacuum control box (see
OMAS and vacuum PCA (CZ056-67321) on page 1260).
Severity
ADVISORY

50.03.01:01
Substrate-advance close loop lost. Run diagnostic and/or call support if problem persists.
Description
The OMAS is disabled, and the printer tries to continue printing. The OMAS will be re-enabled at the next start-up.
a. Sporadic failure
b. Internal firmware error in OMAS controller
c. OMAS controller failure
Corrective actions
1. Restart the printer. This may be sufficient in some cases.
2. If the error is persistent, it is possible to continue printing by turning off the OMAS. However, we
recommend solving the system error to obtain the full range of printer features.
Severity
ADVISORY
50.03.01:03
OMAS is disabled but printer can continue printing. Check that your firmware is up to date.
Description
OMAS firmware mismatch. The system automatically updates the internal firmware when a mismatch occurs,
therefore this error is displayed only if the internal system has been corrupted and an update is not possible.
Vacuum control box
Corrective actions
Install a new OMAS (see OMAS platen assembly (K4T88-67137) on page 1200) and vacuum control box (see

Severity
ADVISORY
50.07.01:04
Substrate-advance close loop lost. Run diagnostic and/or call support if problem persists.
Description
Failure in communication with the OMAS controller board via CAN bus. See the block diagrams:
● Figure 2-7 E-cabinet on page 81 to follow the OAMS/CAN bus from Engine PCA 2 > Engine adaptor 3> E-
box interconnect PCA > OMAS/Vacuum control PCA.
● Figure 2-10 E-stops and Interlocks on page 84 for the link between the e-box PCA and the OMAS controller.
a. OMAS controller power failure
b. CAN cable line failure
– From e-box to OMAS controller (cable disconnected or failed)
– From engine adaptor PCA (third from the top, to which the thin cable is connected)
c. Vacuum controller PCA CAN line failure
d. OMAS controller failure
Corrective actions
1. Perform the power diagnostics procedure to supply 24 V power. Check power LEDs:
● On the vacuum controller. If the LEDs are off, check that power reaches the power connector (GND, 5
V and 24 V). See Board name: Vacuum control PCA on page 432 and Board name: OMAS control PCA
on page 433.
● On the e-box interconnect, connector J_381. See Board name: E-box interconnect PCA on page 395.
If the power LEDs are off, trace where the power is not coming from.
2. Check data and power cable connections on the e-box interconnect board and within the e-box, and check
voltages. See the following diagrams:
● Figure 2-7 E-cabinet on page 81 to follow the OAMS/CAN bus from Engine PCA 2 > Engine adaptor 3 >
E-box interconnect PCA > OMAS/Vacuum control PCA.
● Figure 2-10 E-stops and Interlocks on page 84 for the link between the e-box PCA and the OMAS
controller.
3. For a data connection, any LAN cable with the necessary length can be used to perform troubleshooting.
Install a new cable and restart the printer.

4. Disassemble the OMAS and vacuum PCA box and ensure all connections are correct.
Severity
SEVERE
52. Drop detector error codes

52.00.00:01
Drop detector all-sensors problem. Run subsystem diagnostic. Call support if diagnostic fails or print quality is
affected.
a. Cable to drop detector sensors disconnected (in aerial connector) or failed.
b. E-box interconnect PCA failed.
Corrective actions
1. Check that all Drop detector sensors are correctly connected to their Drop Mux PCA.
2. Check the e-box interconnect PCA cable connections at both ends (Drop MUX PCAs and Ebox Interconnect
PCA). Make sure that the cable is well connected and check cable integrity.
3. Ensure that 12 V and 5 V power is reaching the board (Power LEDs on). Check the LEDs on the drop MUX
PCAs (on the drop-detector shuttle). If the LEDs are off, power is not reaching the PCAs. See Board name:
Drop-detector PCA on page 431 for more information.
4. Install a new e-box interconnect PCA. See E-box interconnect PCA (CZ056-67189) on page 801.
5. After the checks, restart the printer and run the Check DD electronics diagnostic (52001). See Table 5-15
Drop detector on page 578.
Severity
ADVISORY

(52.01.01:01, 52.01.02:01, 52.01.03:01, 52.01.04:01)

Drop-detector sensor X issue detected, sensor disabled. Run subsystem diagnostic. Call support if diagnostic
fails, or print quality is affected.
Description
The drop detectors’ basic operation consists of receiving power to feed an LED transmitter and a receiver
situated at both sides of the drop-detector window. In standby with no drops or interference in the drop detector
window, the transmitter is permanently powered and the receiver receives a signal of medium range (total range
from 0 to 255, medium range signal around 127). The system error is displayed when the drop detector is 0 in
standby (12 V supplied to the drop detectors, but there is no drop detection activity).
a. Drop detector disconnected
b. Drop detector failed
c. Drop Mux PCA or cable failed
d. E-box interconnect board failed
Corrective actions
1. Check that the power LEDs on the drop MUX PCA corresponding to the faulty sensor are on. If they are off:
a. Make sure that the drop detector is correctly connected to the e-box interconnect PCA. Run the Check
DD electronics diagnostic (52001) to check whether the drop detector is disconnected or faulty. See
Table 5-15 Drop detector on page 578.
b. Swap the problematical drop-detector connection with another drop detector to check whether the
problem is with the drop detector. If the problem moves to the swapped sensor, the problem must be
the cable. If the problem stays with the same sensor, it must be the PCA. Install the appropriate new
part. See Cables on page 1469 and Drop-detector Mux PCA (CZ056-67388) on page 1171.
2. Check the internal connections in the e-box. Each drop detector is connected to a different engine adaptor
PCA through the e-box interconnect PCA. Check that the faulty sensor is properly connected to the
appropriate engine adaptor PCA. Restart the printer.
3. Swap two engine adaptor PCAs and restart the printer. If the problem moves to the swapped connection,
the problem is in the engine adaptor PCA: install a new one. See Engine adaptor PCA (CZ056-67188)
on page 802. If the problem remains in the same place the problem is in the e-box interconnect PCA:
install a new one. See E-box interconnect PCA (CZ056-67189) on page 801.
Severity
ADVISORY

52.03.00:01
Drop-detector encoder synchronization issue. Please run subsystem diagnostics. If problem persists, call your
Description
When performing drop detection, the printer performs synchronization with the linear encoder and the tail
encoder located in the drop detector station motor in order to establish its position with respect to the drop-
detector windows before performing the actual drop-detection action. This error indicates that this
synchronization cannot be achieved as the readings from the two encoders do not match according to the
movements performed.
Causes in order of importance in order of importance
a. Drop-detector linear-encoder sensor dirty, disconnected, or failed; or encoder strip dirty or damaged
b. The drop detection tray cannot move smoothly due to excessive friction or a mechanical problem
c. Failure in the drop detector station motor, motor drive PCA, DD MUX PCAs, or connecting cables
Corrective actions
1. Check the linear encoder strip in the drop detector station. Make sure that the encoder strip is clean and not
visibly damaged. Check that it is correctly installed in the sensor, and correctly placed in its holders at each
end. If it is damaged, install a new encoder strip. See ODD encoder strip (K4T88-67219) on page 1172.
2. Run the drop-detector calibration diagnostic (52003) to check the linear encoder sensor connection. See
Table 5-15 Drop detector on page 578.
● If the reported values are zero, the encoder cannot be read: install a new sensor. See Line sensor
(K4T88-67004) on page 695.
● If the values are correct, the problem is in the drop-detector daisy-chain cable (K4T88-50151); install
a new cable. See Cables on page 1469.
3. Run the Force drop detection diagnostic (52005), then run it again. See Table 5-15 Drop detector
on page 578.
Severity
ADVISORY
52.04.00:02
Drop-detector movement test fault. Run subsystem diagnostic. Call your support representative if the diagnostic
fails, or print quality is affected.

a. Motor encoder problem
b. Motor problem
c. Motor connection problem
Corrective actions
Check that the motor drive PCA is receiving power: check that the 32 V LEDs are on.
● If they are off, check the connections and ensure that cables from the PCA to the e-cabinet (K4T88-50227,
K4T88-50142) are correctly connected.
● If they are on, check the connections between the PCA and the motor (K4T88-50142). If necessary, install a
new motor. See Drop-detector transmission engine (K4T88-67079) on page 1156.
Severity
ADVISORY
52.04.00:08
Drop-detector station jam. Reboot and run subsystem diagnostic. Call your support representative if the
diagnostic fails, or print quality is affected.
a. Shuttle blocked.
b. Friction too high.
c. Linear encoder, encoder strip or linear encoder cabling.
d. Cable between E-box interconnect PCA and MUX PCA damaged or disconnected.
Corrective actions
1. Ensure that there is no obstacle blocking the path of the drop-detector shuttle.
2. Clean and oil the worm and rod sliders if necessary.
3. Check the encoder strip to verify it is clean and not broken.
4. Run diagnostic 52002, Check drop-detector mechanics, and verify that the readings of the linear encoder
are the same for the 4 drop MUX PCAs, and that the DD station is able to move. If any of the PCAs displays a
different value than the others, check the connection from the encoder to that PCA. Check also the
connection between the E-Box interconnect PCA and the affected Drop MUX PCA. If the problem persists,
change the affected Drop MUX PCA.
5. Install a new transmission. See Drop-detector transmission engine (K4T88-67079) on page 1156.

Severity
ADVISORY
52.05.12:04
Drop-Detector motor drive PCA communication issue. Run subsystem diagnostic. If the problem persists, call
support.
a. Power cable not providing power to Driver motor PCA
b. Driver Motor PCA address not well set or missing. Address is set in bump switch connector (J4)
c. Data cable/connector problem (cable connected to J1 in Driver motor PCA)
d. E-box problem
e. Driver motor PCA problem
Corrective actions
1. Check power cable going from E-cabinet PCA to Motor Drive PCA (32V).
2. Check the encoder cable and connector (J4 in Motor Drive PCA). Address should be correctly configured.
Check data cable connected to J1 in Motor Drive PCA.
3. Run the subsystem diagnostics for DD (see Table 5-15 Drop detector on page 578) and E-box (see Table
5-21 E-box on page 585). Replace the faulty part with a new one.
Severity
ADVISORY
52.06.00:01
Drop-Detector homing sensor malfunction. Run subsystem diagnostic. If problem persists, call your support
representative.
a. Bump switch phisically damaged
b. Bump switch cable damaged

c. Jam in the drop-detector station path
d. Motor Drive PCA failure
Corrective actions
1. Check that the drop-detector station is actually in the homing position, activating the bump switch. If it is
not at the homing position, run diagnostic 52004 Move drop-detector station to service position (see Table
5-15 Drop detector on page 578) to verify that there is no problem moving the station along all its path.
2. Check that the bump switch and the cable are not physically damaged and that the cable is correctly
connected to Motor Drive PCA. Install any failing part: Bump switch assy (SVC Part: CZ056-60301) or cable
(SVC Part: K4T88-50142).
3. If the previous troubleshooting did not solve the issue, install a new Motor Drive PCA (SVC Part:
CZ056-67190).
Severity
ADVISORY

(52.07.01:01, 52.07.02:01, 52.07.03:01, 52.07.04:01)
Drop MUX PCA X malfunction. Run drop-detector mechanics diagnostic to verify that encoder readings for this
PCA are correct. If problem persists, call your support representative.
Description
1. CK
2. YM
3. LmLc
4. OPT
Each Drop MUX PCA receives a reading of the DD linear encoder. It uses it when performing a drop-detection of
its corresponding color. This System Error is raised when, during certain DD station movements, the reading of
the encoder received at the PCA X is different from the readings received at the rest of the PCAs. This could
cause problems in the movement and in the drop detection operation.
a. Cable from DD encoder to Drop MUX PCA X (P1 connector) damaged or disconnected.
b. Drop MUX PCA X issue
c. Cable from E-box interconnect PCA to DD MUX PCA X

Corrective actions
1. Run diagnostic 52002 Check drop detector mechanics to verify if the reading is the same for all the DD MUX
PCAs. If it is the same, the system error might be a transitory failure. If some of the readings are different
from each other, continue with the troubleshooting.
2. Check that the cable going from the Drop MUX PCA X P1 connector to the encoder is correctly connected
and not damaged.
3. Check the E-box interconnect PCA cable connections at both ends (Drop MUX PCAs and E-box Interconnect
PCA). Make sure that the cable is well connected (disconnect and reconnect it) and check cable integrity.
4. Ensure that 12 V and 5 V power is reaching the DD MUX PCA (Power LEDs on). Check the LEDs on the drop
MUX PCAs (on the drop-detector shuttle). If the LEDs are off, power is not reaching the PCAs. See Board
name: Drop-detector PCA on page 431 for more information.
5. Install a new E-box interconnect PCA. See E-box interconnect PCA (CZ056-67189) on page 801.
6. After the checks, restart the printer and run the Check DD mechanics diagnostic (52002). See Table 5-15
Drop detector on page 578.
Severity
SILENT
55. Carriage line sensor error codes

55.00.00:02
Problem reading line sensor NVM.
Description
The line sensor is responsible for detecting the edges and skew of the substrate during automatic loading. A
failure in communication with this sensor means that the printer cannot automatically detect where the edges
and skew of the substrate, so the substrate must be loaded manually and the relevant parameters must be
entered manually.
a. Line sensor disconnected
b. Line sensor failed
c. Carriage interconnect failed
Corrective actions
1. Check line sensor connections in the sensor interconnect.
2. Perform the line sensor check. See Table 5-14 Carriage sensors on page 576.

3. Install a new line sensor. See Line sensor (K4T88-67004) on page 695.
4. Install a new printhead interconnect PCA. See Printhead interconnect color PCA (1HA06-67002)
on page 713.
Severity
ADVISORY
55.01.00:83
Restart the printer. If the problem persists, call your support representative. Caution! Hot surfaces inside the
printer. Do not touch heating modules.
Description
The value obtained by the line sensor calibration cannot be found. The calibration value is used to adjust the line
sensor reading, as different sensors can have small differences due to manufacturing that need to be adjusted
separately for each one of them. Thus, the calibration detects how these differences modify the readings and
obtains a numerical value to fix those offsets.
a. Calibration value is missing.
b. Unable to do the calibration.
Corrective actions
1. Repeat calibration (see Table 5-14 Carriage sensors on page 576).
3. Install a new line sensor (see Line sensor (K4T88-67004) on page 695).
Severity
ADVISORY
55.02.00:83
Calibration LS2K missing. Automatic substrate load and alignment disabled. Only manual options available.
Contact your support representative.

Description
The value obtained by the line sensor calibration cannot be found. The calibration value is used to adjust the line
sensor reading, as different sensors can have small differences due to manufacturing that need to be adjusted
separately for each one of them. Thus, the calibration detects how these differences modify the readings and
obtains a numerical value to fix those offsets.
a. Calibration value is missing.
b. Unable to do the calibration.
Corrective actions
Repeat the calibration (see Table 5-14 Carriage sensors on page 576).
Severity
ADVISORY
58. Carriage SOL error codes

58.00.00:01
CLC Calibration wasn't completed successfully. Run subsystem diagnostic Color sensor check (58001). If the
a. SOL shutter is jammed.
b. Sensor is dirty.
Corrective actions
1. Run the Color sensor check diagnostic (58001). See Table 5-14 Carriage sensors on page 576.
2. Raise the carriage beam and ensure that the SOL shutter is properly closed. Run the test Color sensor
open_close door test (58002). See Table 5-14 Carriage sensors on page 576
3. Check whether the internal calibration tail or the sensor is dirty.
4. Install a new color sensor (see Online spectrophotometer (SOL) (K4T88-67005) on page 732).
Severity
ADVISORY

58.00.00:02
CLC measures not increasing value. Check that you have set the right substrate. Run subsystem diagnostics. If
the problem persists, call your support representative.
Job pattern is not printed correctly.
Corrective actions
1. Check the job pattern.
2. Check printhead nozzle health.
Severity
ADVISORY
58.00.00:75
Error saving data on hard disk, out of memory. Calibration wasn't completed successfully. Run subsystem
diagnostics. If the problem persists, call your support representative.
a. Temporary problem
b. Permanent damage to the hard disk drive
Corrective actions
1. Restart the printer and rerun the CLC.
2. Check the hard disk drive and install a new one if necessary (see E-box hard disk drive (K4T88-67268)
on page 797).
Severity
ADVISORY

58.00.00:85
CLC white substrate measure out of range. Check that you have set the right substrate. Run subsystem
If substrate and printed job are OK, the most probable cause is a sensor failure.
Corrective actions
2. Raise the carriage beam and ensure that the SOL shutter is properly closed. Run the test Color sensor
open_close door test (58002). See Table 5-14 Carriage sensors on page 576
3. Check whether the internal calibration tail or the sensor is dirty.
4. Install a new color sensor and shutter mechanism (see Online spectrophotometer (SOL) (K4T88-67005)
on page 732).
Severity
ADVISORY
58.01.00:04
SOL Solenoid Carriage interconnect PCA communication issue. Run subsystem diagnostic. If problem persists,
call your support representative.
a. Power cable not providing power to the Carriage interconnect PCA.
b. Carriage interconnect PCA address not well set or missing. Address is set in encoder connector (J4).
c. Data cable/connector problem (cable connected to J1 in Carriage interconnect PCA).
d. E-box problem.
e. Carriage interconnect PCA problem.
Corrective actions
1. Check power cable going from E-cabinet PCA to Carriage interconnect PCA (24V).
2. Check the encoder cable and connector (J4 in Carriage interconnect PCA). Address should be correctly
configured.
3. Check data cable connected to J1 in Carriage interconnect PCA.

4. Check the Carriage interconnect PCA visual indicators (LEDs). 24V IN LED should be powered and SDA & SCL
LEDs should be blinking. If they are not, recheck the power and data cables arriving to the Carriage
interconnect PCA.
5. Run the subsystem diagnostics for Color Sensor (see Table 5-15 Drop detector on page 578) and E-box
(see Table 5-21 E-box on page 585). Replace the faulty part with a new one.
Severity
ADVISORY
58.02.00:02
SOL shutter door open/close check fail. SOL sensor unusable due to shutter door issue. Run subsystem
diagnostics, if problem persists call support.
a. SOL door failed
b. SOL Solenoid mechanism (in the IDS Side of the printer) damaged or not working properly. SOL Solenoid
Motor Drive PCA failed.
Corrective actions
1. Run the test Color sensor open_close door test (58002). See Table 5-14 Carriage sensors on page 576.
Run the Color sensor check diagnostic (58001) and check at the IDS side of the printer that the shutter is
opening and closing properly. If the door is opening and closing but the printer does not detect it, clean the
spectrophotometer. If the problem persists, install a new one (see Online spectrophotometer (SOL)
(K4T88-67005) on page 732).
2. If the door is actually not opening/closing, check that the shutter mechanism in the IDS side of the printer is
moving when trying to open the door and that it is not broken. If it is not working properly, change it. If this
does not solve the issue, install a new Motor Drive PCA, SVC Part: CZ056-67190).
3. If the shutter mechanism is working properly but the door does not open/close, inspect the
spectrophotometer looking for damage in the door. If it is damaged, install a new one (see Online
spectrophotometer (SOL) (K4T88-67005) on page 732).
Severity
ADVISORY
58.03.00:04
Color sensor communication error. If the problem persists, call your support representative.

Description
When the printer is starting, it communicates with the SOL, first powering up the SOL through the printhead
interconnect PCA 3 (YM)> carriage interconnect board, then communicating through the printhead interconnect
PCA 3 (YM)> carriage interconnect board. See Figure 2-12 Carriage Subsystem on page 86.
a. Cabling problem
b. Color sensor problem
Corrective actions
1. Check that the various cables are not damaged, and install new cables if necessary. Especially check the
cable connecting the color sensor to the carriage interconnect PCA (J36 on carriage interconnect PCA), and
the cables from carriage interconnect PCA to PH colour PCA 3 (YM) (J1 and J28 on carriage interconnect
PCA). See Figure 2-12 Carriage Subsystem on page 86.
3. Check the color sensor, and install a new one if necessary (see Online spectrophotometer (SOL)
(K4T88-67005) on page 732. SVC Part: K4T88-67005).
Severity
ADVISORY
58.03.00:84
SOL calibration failure. Calibration wasn't completed successfully. Run subsystem diagnostics. If the problem
a. The color sensor is faulty.
b. The shutter mechanism is failing.
c. The cables are damaged.
Corrective actions
1. Check cables and connections. See Figure 2-14 Printzone + Day and Night LEDs and Beacon Subsystems
on page 88.
3. Check the SOL mechanism and run the Color sensor open_close door test (58002). See Table 5-14 Carriage
sensors on page 576. Check whether the sensor is dirty.

4. Check that the cable from Carriage Interconnect PCA to PH Colour PCA 3 is not damaged.
5. Install a new color sensor and shutter mechanism if necessary (see Online spectrophotometer (SOL)
(K4T88-67005) on page 732).
Severity
ADVISORY
58.03.00:85
SOL measure error (out of range measure). Calibration wasn't completed successfully. Run subsystem
a. Calibration has failed.
b. The printheads have a lot of blocked nozzles and the pattern is not printed properly.
c. The sensor is dirty or faulty.
d. The shutter mechanism is failing.
Corrective actions
2. Check printhead health.
3. Repeat the calibration.
4. Check the SOL mechanism and run the Color sensor open_close door test (58002). See Table 5-14 Carriage
sensors on page 576. Check whether the internal calibration tail or the sensor is dirty.
5. Switch off the printer, disconnect the line sensor from Printhead interconnect #3 and restart the printer. If
the issue no longer appears, replace the line sensor (see Line sensor (K4T88-67004) on page 695).
6. Install a new color sensor if necessary (see Online spectrophotometer (SOL) (K4T88-67005) on page 732).
Severity
ADVISORY

59. Firmware error codes

59.4:10
No communication with Engine PCA. Restart the printer. If the problem persists, call support. Caution! Hot
surfaces inside the printer. Do not touch heating modules.
Engine PCA HW error.
Corrective actions
1. Switch off the printer and power-enable switch, wait two minutes, and then switch it back on again. If the
problem persists, repeat this process but wait at least 1 hour until switching the printer back on.
2. Replace the Engine PCA. See Engine PCA (K4T88-67067) on page 805.
Severity
Severe (non-continuable)
59.5:19
Call Support.
When present Engine PCA type doesn’t correspond with the expected one (i.e.: a Latex 3000 Engine PCA present
on a Latex 3500).
Wrong Engine PCA Type.
Corrective actions
Switch the power off at the rear of the printer, wait two minutes, then switch it back on again.
Service engineer
▲ Replace the Engine PCA. See Engine PCA (K4T88-67067) on page 805.
Severity

59.7:14
Call Support.
a. Generic cryptographic error
b. Possible FW upgrade
Corrective actions
Call agent
1. Switch off the printer and power-enable switch, wait two minutes, then switch it back on again.
2. Recommend a FW upgrade.
Service engineer
▲ Replace the Engine PCA (see Engine PCA (K4T88-67067) on page 805).
Severity
61. Internal firmware error codes

61.09.00:04
Unexpected end of file. Job canceled.
Check that you have the recommended IPS configuration and the right connection between IPS and printer
engine. Check that your file is OK. If the problem persists, call your support representative.
Description
The current job has been canceled due to an unexpected end of file. Whenever job data arriving to the printer
ends unexpectedly, this system error will be raised.
Usually this is because a lack of system performance: the Internal Print Server is not providing data to the engine
fast enough.
a. The built-in computer is switched off or non-functional, or the LAN cable between the computer and printer
has been removed during printing.
b. HP support is conducting a remote session and performing tests; in this case, the system error can be
ignored.

c. The Internal Print Server is not providing data to the engine fast enough.
d. There are other possible cases, in all of which there should be another system error in the logs (such as
86:04), so you should check whether any other system error occurs at the same time as this one.
Corrective actions
1. Check that the Internal Print Server is printing from its local hard disk drive; it should be avoided printing
from network folders, external hard disks, and external memory sticks.
2. Check that the built-in computer has the recommended configuration, there is no other third-party
software installed, the computer is not infected with any virus or malware, there is no second antivirus
program installed, and there is no other software (custom or third party) running in parallel with the
Internal Print Server and consuming critical resources: CPU, memory, and network bandwidth.
3. Check that the network configuration between computer and printer is the recommended configuration.
Check that you are not trying to print a nested job with many overlapping images, which could overload the
system.
4. Check the computer’s performance configuration as in the installation process.
a. Control Panel ►System and Security ►System ►Advanced system settings (left column)
►Advanced ►Performance ►Visual Effects ►Select custom , and unselect everything except for:
● Enable Desktop composition
● Smooth edges of screen fonts
● Use visual styles on windows and buttons
b. Check that the power plan is set to high performance: Control Panel ►System and Security ►Power
Options . Under Change plan settings, set Put the computer to sleep to Never.
c. Optimize the performance of the hard disk drive:
● Computer ►(right-click) ►Manage ►Device Manager ►Disk drives►(right-click disk)

►Properties ►Policies ►Enable write caching on the disk .

● Computer►(right-click) ►Manage ►Disk Management ►(right-click disk) ►Properties

►General, and uncheck Allow files on this drive to have contents indexed in addition to file
properties. Click OK and apply changes to drive and subfolders.
d. Disable disk backups: Computer ►(right-click) ►Properties ►System Protection ►Select drive &
Configure ►Turn off system protection.
e. Check the performance of the hard disk drive. Run the Windows Experience Index: Control Panel
►System and Security ►System. Check the Windows Experience Index, the rating for the primary
hard disk should reach 5.9.
If the hard disk drive is slower than this, you are recommended to replace it (or replace the whole
computer).

f. Ensure that the hard disk drive is not turned off automatically: Control Panel ►System and Security
►Power Options is set to high performance. Also, under Change plan settings ►Change advanced
power settings , ensure that Turn off hard disk after ►Plugged in is set to Never.
TIP: Some Windows Updates seem to change this setting automatically to 20 minutes.
g. Check that the screen saver is set to None: Control Panel ►Appearance and Personalization
►Personalization.
h. Check that there is no hardware problem in the computer and printer network interfaces. Check that
the network cable between them is correctly connected. If necessary, install a new cable. See E-box
LAN cable to IPS (K4T88-67232) on page 818.
5. Check the printer too. Run printhead control link and drying diagnostics:
● Run the E-box fiber optics PCA (11001), Optical link (11002), Carriage fiber optics PCA (11003), and
Printhead interconnect connectivity (11004) diagnostics. See Table 5-4 Printhead control link
on page 546.
6. Check that IPS is not printing a nesting job with multiple overlapping images; avoid printing nesting jobs
with a large number of simultaneously overlapped images.

7. Check that there are no hardware problems in the network interfaces at the IPS computer and the engine,
check that the network cable is properly attached between them.
8. Replace the LAN cable between the IPS PC and the E-box.
Severity
ADVISORY
IPS PC Blue-Screen Errors related to AntiVirus Software

Blue Screen errors (BSOD) on MS Windows based computers can be caused due to many different causes.
Diagnose the cause of a BSOD is based on the messages the screen shows.
In case of the IPS PC, based on Windows 7 - 64Bit, occurrences of a particular BSOD have been found. These are
related to Symantec Endpoint Protection suite. The following notes indicate how to recover from the BSOD and
prevent from further occurrences.
BSOD with SRTSPL64.SYS
Description
Several cases of BSOD in the Latex 3000 IPS PC have been reported. In all these cases, the same text was
displayed, pointing to a specific library: SRTSPL64.SYS
This failure is related to the Antivirus software, Symantec. These are the recommended actions to solve the
problem.
To prevent from new occurrences, a 3-step process must be followed:
1. Temporarily Disable SYMANTEC

● Sporadic error
2. Run the SYMANTEC LIVE Update
● Upon a normal reboot after the Symantec service has been disabled
3. Re-Enable SYMANTEC and boot IPS PC in Normal Mode
Temporarily disable SYMANTEC
1. Press function key F8 on the IPS PC keyboard during windows boot.
2. Once the boot menu is shown, on Advanced Boot Options , select Safe Mode
3. Once IPS PC has completely started, click on Start and type msconfig in Search programs and files box to
launch the System Configuration tool.
4. Once System Configuration opens, go to the Services tab.
5. Uncheck the following service:
● Symantec Endpoint Protection, as shown in the picture.
6. Click on Ok and select Restart to restart windows normally. The system should restart and no BSOD should
occur at this time.
Updating Symantec Software
1. Open Symantec Endpoint Protection, either from the Task Bar Icons (as shown in the picture) or through
the Start menu.

2. Click on LiveUpdate. It will self connect to Symantec server and update the software, applying the required
patches.
The process may take several minutes to complete. Its progress can be monitored in the LiveUpdate
window.
Re-enable Symantec service and boot normally
1. Click on Start and type msconfig in the Search programs and files box to launch the System Configuration
tool.

2. On the General tab, change start up selection to Normal startup (Selective startup should be selected when
entering into the general tab.
This will, on the next start-up, activate the Symantec Service that was previously disabled in Step 1.
3. Click on OK and restart the PC normally.
79. Miscellaneous error codes

79:03
heating modules.
Description
A critical error has occurred in the communication between the formatter board and one of the engine PCI
boards.
a. Sporadic error
b. PCI board connection failure
c. Faulty engine board
d. Faulty formatter board
Corrective actions
1. Turn off the printer, wait 10 seconds, then restart the printer.
2. Disconnect both PCI boards from the formatter and clean the PCI ports by blowing into them. Clean the PCI
contacts in the engine boards and reconnect.
3. Run the following diagnostics:

● Engine adaptor PCA comm. (01007). See Table 5-21 E-box on page 585.
● E-box fiber optics PCA (11001), Optical link (11002), Carriage fiber optics PCA (11003), Printhead
interconnect connectivity (11004). See Table 5-4 Printhead control link on page 546.
4. Install a new engine board. See Engine PCA (K4T88-67067) on page 805.
5. Install a new formatter board (see Formatter PCA (CZ056-67186) on page 809).
Severity
SEVERE
79:04, 79.1:04, 79.2:04, or 79.05.00:01
heating modules.
a. An internal firmware error has occurred in the printer. If the error persists, retrieve the printer’s error logs
and escalate the problem to HP.
b. The 79.X:04 error is advisory, and does not require an immediate reboot. It reports that the firmware is
functional and that the printer can still be used, but recommends restarting the printer when possible in
order to ensure that this system error will not be displayed again.
c. A 79:04 system error is usually a consequence of an immediate printer shutdown following another
system error.
Corrective actions
1. Switch the printer off and on.
2. Check that the printer has the latest firmware version. If not, update the firmware to the latest version.
3. Run the Engine PCAs (01005), Engine adaptor PCA comm (01007). See Table 5-21 E-box on page 585.
4. Install a new e-box hard disk drive. See E-box hard disk drive (K4T88-67268) on page 797.
Severity
79:04 or 79.05.00:01 SEVERE
79.1:04 or 79.2:04: ADVISORY

86. Scan axis error codes

86.00.00:02
Scan-axis length test failure. Check scan-axis path, clean encoder, run diagnostic.
Description
The scan-axis length is not as expected while performing the Scan-axis analysis diagnostic (86002). The scan-
axis length measured by the printhead carriage does not correspond to the expected length.
a. A high friction point, or something blocking the carriage path
b. Damage to the scan-axis encoder strip
c. Dirt on the scan-axis encoder sensor
Corrective actions
1. Repeat the test and check that the carriage reaches both ends of the scan axis. If not, check for possible
obstructions in the carriage path (with the printer turned off). If there are no obstructions, the problem
could be high friction or damage to the encoder.
2. Run the Friction analysis diagnostic (86003). See Table 5-26 Carriage rail cleanliness on page 594.
If the test finds high friction, clean the carriage rails, then run the Scan-axis analysis diagnostic (86002)
again. See Table 5-10 Scan axis on page 564.
3. Install a new encoder strip. See Impelling encoder strip (K4T88-67044) on page 916.
Severity
ADVISORY
86.01.00:01
Carriage movement failure. Make sure maintenance routines are up to date and then select Reinitialize carriage
from the Tools menu. Perform the carriage-rail cleaning process; if the problem persists, call your support
representative.
Description
The carriage has stopped unexpectedly while moving or has been unable to start moving. Usually this is due to a
jam with an external element, such as substrate in the print zone, or a substrate edge holder. It can also be
produced by high friction between the slider rods and the carriage bearings. Clean the carriage rails to ensure
that scan-axis maintenance is up to date. Check whether the carriage always shows the error at the same point
on the scan axis, which would indicate that the problem is with the encoder strip. If the carriage does not even
start moving, check the status of the motor and the electrical connection.

a. Sporadic problem
b. Carriage movement jammed
c. Carriage movement friction too high
d. Encoder strip reading failed
e. PWM signal not supplied to motor: PWM generator (driver) failure, motor failure, cable failure, or
disconnected
f. Motor or motor PCA damaged
Corrective actions
1. Ensure that there is no obstacle in the carriage path.
2. Run the Friction analysis diagnostic (86003). See Table 5-26 Carriage rail cleanliness on page 594.
3. Run the Scan-axis analysis diagnostic (86002). See Table 5-10 Scan axis on page 564.
4. Reinitialize the carriage.
5. Check the status of the encoder strip.
6. Check the connection of the scan-axis motor power cable and encoder cables.
7. Check that power is supplied to the motor (LED in the e-cabinet PCA, see Board name: E-cabinet PCA
on page 371).
8. Swap E-box Engine PCA #1 with Engine PCA #2 (Replace Engine PCA #1 if it is necessary).
Severity
ADVISORY
86.01.00:02
Scan-axis direction test failure. Run diagnostic.
Description
During start-up, the printer makes a small movement forwards and backwards to check the main system
functionality (motor moves, encoder signals are received). This error is produced when this test fails.
The scan-axis direction test has failed because the movement sent by the scan-axis motor does not correspond
with the one detected by the carriage encoder sensor. Thus, the problem can come from the motor, which does
not produced the expected movement, or the encoder sensor that is not reading properly.
As the movement is very small, this error usually represents a critical error such as cables disconnected, motor
failure, or a PCA fault.

a. A high friction point or something blocking the carriage path
b. Damage to the scan-axis encoder strip
c. PWM signal not supplied to motor: PWM generator (driver) failure, motor failure, cable failure, or
disconnected
Corrective actions
1. Run the Scan-axis analysis diagnostic (86002). See Table 5-10 Scan axis on page 564.
2. Check for possible obstructions in the carriage path (with the printer turned off). Manually uncap the
service station and move the carriage along the scan axis to search for possible high friction points. Look
for objects or possible problems in the carriage path, the rods, bushings, and platen area.
3. Check for possible damage to the scan-axis encoder strip and install a new one if necessary. See Impelling
encoder strip (K4T88-67044) on page 916.
4. Check for possible problems with the scan-axis motor.
Severity
ADVISORY
86.03.01:92
Scan stop triggered by rear safety sensor. Reinitialize carriage. If the problem persists, call your support
representative.
Description
The scan axis has stopped because the rear safety sensor was activated. Ensure that the sensor is not activated
and reinitialize the carriage.
Safety element activated
Corrective actions
1. Check that the loading table is properly closed, then reinitialize the carriage.
2. Call support.
Severity
ADVISORY

86.03.02:92
Scan stop triggered by front safety sensor. Reinitialize carriage. If the problem persists, call your support
representative.
Description
The scan axis has stopped because the rear safety sensor was activated. Ensure that the sensor is not activated
and reinitialize the carriage.
Safety element activated
Corrective actions
1. Check that the loading table is properly closed, then reinitialize the carriage.
2. Call support.
Severity
ADVISORY
86.05.00:92
Scan axis braking resistor activated. Run subsystem diagnostic. If the problem persists, call support.
Description
The braking resistor ensures that the carriage is able to stop when the power to the scan-axis motor is cut (for
example, when an interlock is opened). This system error is raised if the braking resistor has not been activated
when required.
a. The braking resistor is not properly connected
b. The braking resistor has failed
Corrective actions
1. Check all connections for the SAX brake (SVC Part: K4T88-50249): power input (42V) should be properly
connected to the E-cabinet PCA, power output (42V) should be properly connected to SAX motor, and the
contactor should be properly connected to TB-10.
2. Install a new SAX Brake system (SVC Part: K4T88-67046).

3. Install new cables for SAX Brake.
4. Install a new E-cabinet PCA.
Severity
ADVISORY
89. Illumination and buttons error codes

89.05.16:04
Motor Drive PCA (Print-zone top light LED) communication issue. If the problem persists, call your support
representative.
Description
There is a communication problem between the PCA controlling the Print-zone top light and the buttons. Usually
a result of disconnected or damaged cables, but it can also be the result of a defective PCA.
a. Power cable not providing power to Driver motor PCA.
b. Driver Motor PCA address not well set or missing. Address is set in the buttons connector (J4).
c. Data cable/connector problem (cable connected to J1 in Driver motor PCA).
d. Communication bus not well terminated (only if Double-sided Day and Night Kit is NOT installed).
e. E-box problem.
f. Driver motor PCA problem.
Corrective actions
1. Check power cable going from E-cabinet PCA to Motor Drive PCA (24V).
2. Check the buttons cable and connector (J4 in Motor Drive PCA). Address should be correctly configured.
3. Check data cable connected to J1 in Motor Drive PCA.
4. If the Double-sided Day and Night Kit is NOT installed, check that the bus is Terminated in the connector P2.
5. Run the subsystem diagnostics for E-box (see Table 5-21 E-box on page 585). Replace the faulty part with
a new one.
6. Install a new Driver Motor PCA (SVC Part: CZ056-67190).
Severity
SEVERE

90. Double-sided Day and Night Kit (accessory) error codes

NOTE: These system errors only apply if the Double-sided Day and Night Kit is installed in the printer.

(90.02.01:01 , 90.02.02:01 )
Printer is not able to detect light from printzone backlight X (X = 1 SVS Side, X = 2 ISS Side) when trying to adjust
it. Check if the LED Bar is working properly and that there is nothing covering it. If the problem persists, call your
Description
Before starting side A printing, printer tries to adjust light to verify the registration will be possible in the inserted
media. The light intensity of the printzone backlights is then adjusted until the Line sensor (Double-sided Day
and Night Kit) is saturated. This light intensity is stored in the NVM and will be used for the side B printing.
If no light is detected over the media during the adjustment, the line sensor will scan in a zone without media. If
no light is detected in that second zone, there is probably an issue with the light and this error will be raised.
a. Affected printzone backlight not correctly connected (either in the intermediate connector or in the Motor
drive PCA) or failing.
b. Double-sided Day Night E-cabinet not properly connected to the Motor drive PCA (Double-sided Day Night
Kit).
c. Power cable not properly connected to the Double-sided Day Night E-cabinet.
d. Line sensor (Double-sided Day Night Kit) not correctly connected or failing.
e. Motor drive PCA (Double-sided Day Night Kit) failure.
Corrective actions
1. Check if the printzone backlights are correctly working: Run the diagnostic 90002 Lights check and set the
Printzone backlights to different intensity levels (between 0 and 100). If no light is seen in one of the sides,
interchange the intermediate connectors for troubleshooting. Repeat the test, if the issue has not changed
of side, change the affected printzone backlight and remember to reconnect correctly the LED bars
intermediate connector. If the issue has changed of side, install a new cable between the Motor drive PCA
(Double-sided Day Night Kit) and the Printzone backlights intermediate connectors. If no light is seen in
both sides, go to step 2. If light is seen in both sides, go to step 3.
2. Reboot the printer. Check the cable going from the Motor drive PCA (Double-sided Day Night Kit) to the
Printzone backlights Intermediate connectors and change it if needed (SVC Part: P4P91-50003).
3. Run the diagnostic 90004 Scanning check. If the Line sensor is failing, check its connection to the PH
Interconnect 1 (OP) or install a new Line sensor if needed (SVC Part: K0Q45-60085).

4. Check all the Double-sided Day Night E-cabinet connections: it should be correctly plugged to the E-Cabinet
and the cable going to the Motor drive PCA (Double-sided Day Night Kit) should be properly connected.
Check visual indicators (LEDs) in the Motor drive PCA to verify the PCA is correctly powered and working. If
power is not correctly reaching the Motor drive PCA (Double-sided Day Night Kit) recheck all connections
and install a new Double-sided Day Night E-cabinet (SVC Part: P4P91-60014) if needed.
5. If power is correctly reaching the Motor drive PCA (Double-sided Day Night Kit) but the Printzone backlights
are not working, install a new Motor drive PCA (SVC Part: Q6702-60953). If this does not solve the issue,
install new printzone backlights (SVC Part: J8J14-60002).
Severity
ADVISORY
90.06.00:01
Line Sensor (Double-sided Day Night) malfunction. Run diagnostic Double-sided Day Night checks and
installation> Scanning check to troubleshoot the issue. If the problem persists, call your support representative.
Description
Before starting side A printing, printer tries to adjust light to verify the registration will be possible in the inserted
media. The light intensity of Printzone backlights is then adjusted until the Line Sensor (Double-sided Day Night)
is saturated. This light intensity is stored in the NVM and will be used for the side B printing.
This system error is raised if the Line sensor (Double-sided Day Night) signal is not reliable:
● With the lights still not powered, the Line sensor is already saturated (detecting too much light).
● The Line sensor signal is too stable. When scanning actual values, they are expected to present a certain
degree of noise. If there is absolutely no noise present, there could exist a problem with the Line sensor.
a. Line Sensor (Double-sided Day Night) connection issue: cable might be not properly connected or
disconnected.
b. Line Sensor (Double-sided Day Night) malfunction.
Corrective actions
1. Unload the used media and run diagnostic 90004 Scanning check to diagnose the issue. If this is confirmed,
continue with step 2. If the issue does not appear, the problem might be related to the media used (too
translucent).
2. Check the Line sensor (Double-sided Day Night) connection to the PH Interconnect 1 (OPT).
3. Interchange the Line sensor (Double-sided Day Night) with the Line sensor (front) and retry the operation.
If the issue disappears, then install a new Line sensor (SVC Part: K0Q45-60085).

Severity
ADVISORY
90.06.00:90
Fiducial line reading lost. If maintained, this situation could compromise registration accuracy between both
sides. Supervision is recommended until readings are restored or until you decide to cancel.
Description
This message is usually not related with a hardware issue. It is shown to the user as a message (not a system
error) but a SILENT SE is stored in the logs to be able to track possible issues.
If the missing fiducial policy (side B Double-Sided Backlit) is set to Cancel printing in the IPS Preferences, this
error will stop the current job. Otherwise, the printer can continue printing but supervision will be needed to
ensure the registration accuracy is acceptable. If the situation is maintained, the print quality might be affected.
When the reading is recovered, the message in the IPS will disappear.
a. Too much skew on substrate
b. Fiducials bad print quality

c. The platen protector is not correctly positioned
d. Problem with line sensor (Double-sided day night)
Corrective actions
1. Check that the media is not skewed and reload it if needed.
2. Check that the print quality of the fiducials is acceptable.
3. Ensure that the platen protector is correctly positioned.
4. If the problem consistently persists, check the line sensor (take in mind that if the line sensor were
damaged, double-sided day night jobs probably would not be able to start).
Severity
SILENT
90.06.00:92
The printer cannot follow the fiducial line. Ensure that the selected substrate is correct and that the Side B print
mode has not changed since Side A was printed. If it has changed, set the original Side B print mode and try
again.
Description
After the top fiducial row is read, the printer will start reading the next fiducials. If, at the very start of the
printing, it cannot detect the fiducials, there is probably an issue with the fiducials in the side A plot. This
message will appear and stop the current double-sided day night job.
a. Side B print mode has changed since side A was printed
b. Too much skew on substrate
c. Fiducials bad print quality
Corrective actions
1. Check that the media is not skewed and reload it if needed.
2. Check that the side B print mode has not changed since side A was printed. If changed, set the original side
B print mode and try again.
3. Check that the print quality of the fiducials is acceptable.

Severity
SILENT
90.06.00:93
The loaded substrate is too opaque for Double-sided Day Night printing. This application relies on a certain level
of transparency to work.
Description
Before side A printing, the printer will check the substrate inserted to ensure it is adequate for Double-sided Day
Night printing and will calibrate the amount of light needed for it. If, at maximum light intensity, the line sensor
cannot detect the light, the substrate used is probably too opaque and this message is shown.
a. Media too opaque for Double-sided Day Night printing
b. Line sensor issue
c. Print-zone backlights issue
Corrective actions
1. Check that the media used is adequate for Double-sided Day Night printing.
2. Visually check if the print-zone backlight is turned on. If it is not, run diagnostic 90002 Lights check. If the
light is failing, reboot the printer. If the problem persists, check the connections and install a new LED bar if
needed.
3. If this does not solve the issue, install a new Motor drive PCA (Double-sided Day and Night Kit).
4. Unload media, move the scan beam to printing position and run diagnostic 90004 to check line sensor.
Severity
SILENT
90.06.00:94
Fiducial row not found. Use the Move Substrate buttons to position the first fiducial row on the print-zone back
light line and try again. If the problem persists, call your support representative.

Description
The fiducial row has not been found before starting side B printing. It is possible that the media is incorrectly
loaded (fiducial row too far from the scan axis).
a. Fiducial row not situated under the print-zone back light line
b. Media edge to fiducial distance modified after side A was printed
c. Light adjustment issue. This could happen if, after a side A job is printed, a different side B job (for example,
one with a different media with side A already printed) is printed. Since light is adjusted when printing side
A and stored for its corresponding side B, in this case the adjustment might not be suitable for the new job
d. Line sensor issue
e. Print-zone backlights issue
Corrective actions
1. Use the Move Substrate buttons to position the first fiducial row on the print-zone back light line and try
again.
2. Measure the media edge to fiducial distance and compare it with the value stored in the printer (use
diagnostic 90022 Media edge to fiducial distance configuration). If they differ significantly, the value might
have been changed after side A was printed.
3. Ensure the side B job is being printer after its corresponding side A, and that no other Double-sided Day
Night job has been printed between these two.
4. Visually check if the print-zone backlight is turned on. If it is not, run diagnostic 90002 Lights check. If the
light is failing, reboot the printer. If the problem persists, check the connections and install a new LED bar if
needed.
5. If this does not solve the issue, install a new Motor drive PCA (Double-sided Day and Night Kit).
6. Unload media, move the scan beam to printing position and run diagnostic 90004 to check line sensor.
Severity
SILENT
90.06.00:95
Right-side fiducial measurement failed. Check whether the edge holder is too close to the marks, and ensure
that the fiducial line is not too skewed. If so, correct it by reloading the substrate. You can also check that the
platen protector is correctly positioned, not projecting any shadow that could affect the measure.

Description
When scanning the fiducial row before side B printing, the printer is not able to detect the right-side fiducial.
a. The edge holder is too close to the marks
b. There is skew in the fiducial line
c. Bad fiducial print quality
d. The platen protector is not correctly positioned
Corrective actions
1. Check that the right mark is visible and that there is space between it and the edge holder.
2. Check if there is skew in the fiducial line.
3. Check if the fiducial lines are correctly printed. If they are not, align printheads and reprint side A.
Severity
SILENT
90.06.00:96
Left-side fiducial measurement failed. Check whether the edge holder is too close to the marks, and ensure that
the fiducial line is not too skewed. If so, correct it by reloading the substrate. You can also check that the platen
protector is correctly positioned, not projecting any shadow that could affect the measure.
Description
When scanning the fiducial row before side B printing, the printer is not able to detect the left-side fiducial.
a. The edge holder is too close to the marks
b. There is skew in the fiducial line
c. The platen protector is not correctly positioned

Corrective actions
1. Check that the right mark is visible and that there is space between it and the edge holder.
2. Check if there is skew in the fiducial line.
Severity
SILENT
90.06.00:98
Cannot read fiducial row properly. Check the sharpness of the white line inside the fiducial marks printed on side
A. If a general defect is found, it can affect the reading. Align printheads and reprint side A.
Description
When scanning the fiducial row before side B printing, the printer is able to detect the fiducial row, but not able to
correctly read it.
a. Bad fiducial print quality (white lines inside the fiducial not sharp enough, dirtiness, etc.)
b. Fiducial row not horizontal, deformed (bow)
Corrective actions
1. Check if the fiducial lines are correctly printed. If they are not, align printheads and reprint side A.
2. Check if the fiducial row is horizontally printed (ensure there is no “bow” effect). If it is not, the printer might
not be able to see the fiducials in the middle of the row. In this case, reprint side A.
Severity
SILENT

Troubleshooting without system errors

Troubleshooting using board LEDs
All the printer boards have diagnostic LEDs to help in the troubleshooting. Although some LED information is
redundant and also known by the printer firmware, using the board LEDs can be very useful when trying to
diagnose power or communication problems. The following sections review each board LED and provide
information on:
● Board physical connector: Boards serigraphy together with cables labelling should be enough to perform
repais operations, but this information can be useful when providing remote support not being in front of
the printer.
● Diagnostic LEDs' physical location and meaning:
For further information regarding electric and electronic interactions, see the subsystems’ block diagrams.

Board name: E-cabinet PCA
Board picture pointing to connectors/LEDs—internal side
Internal side
Meaning of LEDs
Side LEDs
Most of the e-cabinet PCA LEDs are packed on the PCA side where they are most visible.
ENWW Troubleshooting without system errors 371

Interlocks
These LEDs give information about the safety interlocks, emergency stops, and watchdog timer.
STATE: refers to the current (real time) state
ACTIVATED: LEDs turn on whenever there is a condition. Only the firmware can turn them off.
1 (front door 2 (loading table 3 BY (Interlock ESTOP WDT (Watchdog

interlock) interlock) bypass) timer)
STATE GREEN: Door GREEN: Table NOT USED RED: Bypass ON GREEN: RED: Watchdog
closed closed emergency stops triggered
released
OFF: Door open OFF: Table open NOT USED OFF: Bypass OFF OFF: 1 or more OFF: Watchdog
emergency stops untrigg.
pressed
ACTIVATED RED: Door has RED: Table has NOT USED RED: 1 or more RED: Watchdog
been opened been opened emergency stops triggered
have been
pressed
OFF: Reset state OFF: Reset state NOT USED OFF: Reset state OFF: Reset state
Safety relay
These LEDs give information about the safety relay (X1)
POWER GREEN: Safety relay powered (all emergency stops released, and PCA supplying +24V)
OFF: Safety relay not powered (1 or more emergency stops pressed, PCA not supplying +24V)
STATE GREEN: Safety relay ON (lights after the enable button is pressed: power ON)
OFF: Safety relay OFF (power OFF)

PCA power
These LEDs give information on the PCA voltage status.
24V 24V_ACT 24V_ACT 8V 5V
GREEN: 24V Input GREEN: 24V to GREEN: 24V for internal GREEN: 8V Regulator GREEN: 5V Regulator OK
power present external components PCA use OK OK
(from PSU-2) OK
OFF: 24V not OFF: 24V to external OFF: 24V for internal OFF: 8V Regulator KO OFF: 5V Regulator KO
present (from components KO (fuse PCA use KO (PCA
PSU-2) blown or overcurrent malfunction, fuse blown
protection triggered) or component broken)
Fuses
These LEDs give information on the status of the PCA fuses. There is a mistake on the silk screen: where it says
5×20 it should say SMT, and where it says SMT it should say 5×20.
DS73 DS74
RED: SMT fuse blown (Internal 24V PCA not present) 5x20 fuse F24 blown (24V to external components not present)
OFF: SMT fuse not blown 5x20 fuse F24 not blown
If the fuse is blown, there is no communication with the PCA.

Fan
Fan rotation feedback
Fan (DS75)
GREEN: Fan rotation OK
OFF: Fan fault
If the fuse is blown, there is no communication with the PCA.
PSU power
These LEDs give information on the state of the DC power supplies.
1 (PSU-1) 2(PSU-2) 3(PSU-3) 4(PSU-4) 5(PSU-5) 6(PSU-6) 7(PSU-7)
GREEN: PSU ON
OFF: PSU OFF
Firmware
Firmware (e-box) controlled LEDs
DS64 DS65
Blinking GREEN: e-cabinet firmware alive NOT USED
Static (OFF of GREEN): e-cabinet firmware not communicating

ACT
LEDs for external actuators power: NOT USED
1 (DS66) 2 (DS67)
NOT USED NOT USED
Enable button feedback
DS32 reflects the state of the enable/rearm button.
DS32
GREEN: Enable button lit
OFF: Enable button not lit
Power output state (internal side)
Each power output has a state LED next to the output connector.

The meaning of these LEDs is:
Green Output is on
Off Output is off

Board picture pointing to connectors/LEDs—external side
External side
Meaning of LEDs
Power output fuse feedback (external side)
Accessible on the external side, there is a fuse for each power output, associated with each fuse is a red LED.

The meaning of these LEDs is:
RED Fuse blown or not present
OFF Fuse OK
NOTE: For a LED to turn red indicating that the fuse is blown, there must be DC power present (the
corresponding DC PSU must be ON); for PSUs 1, 3, 4, and 5 this means that the safety relay must be activated
and the front door and loading table closed.
Other e-cabinet LEDs and important test points
Safety relay LEDS
The safety relay X-1 has 3 LEDs: Power, CH-1, and CH-2.

The meaning of these LEDs is as follows:
● POWER:
– +24V present at the safety relay, for this LED to be ON the e-cabinet PCA must supply +24V (firmware
activated) and the emergency stops must be all released.
● CH.1 and CH.2:
– The safety relay has two redundant channels in series, each LED indicates the state of the channel,
for the safety relay to activate both channels must be good.
– These LEDs should be always be in the same state (lit when the safety relay is activated and unlit
otherwise). If one is lit and the other unlit, the safety relay is faulty and should be replaced.
DC power supply LEDs

Each power supply has a green LED that lights when the PSU is working normally (has AC voltage and the DC
voltage generated is good).
Even though the visibility of the LED on some of the PSUs is not very good, it’s easy to tell whether it’s lit or not.
There are seven DC PSUs in the e-cabinet from two different model families, here is the location of the feedback
LED for each family:
● PSU-1, 2, 4, 5, 6, 7

● PSU-3
External lights
On the e-cabinet side where the user interface is, there is one light and one illuminated pushbutton:

Printer-enabled light
This light gives direct feedback on the state of the safety relay:
● Safety relay activated: lit
● Safety relay deactivated: unlit
Rearm button
A blue illuminated pushbutton (the rearm button):
● The button is used to activate the safety relay.
● The light is controlled by the firmware through the e-cabinet PCA to indicate to the user when the machine
requires this activation.
AC protections
The AC protections are standard circuit breakers like the ones used in the electrical installation of any building.
● ACBs (automatic circuit breakers) protect against overcurrents, produced for example when a heater fails
and its actual electrical resistance is much lower than the nominal value.
● RCDs (residual current devices) protect against ground leakages, produced for example when a heater fails
and its wiring breaks and ends up in electrical contact with the machine structure.
The circuit breakers are off when their lever is down, and on when their lever is up. They are easily checked and
actuated from the e-cabinet exterior.
Important test points
This section describes some particular points where measurements can be made with a multimeter to
understand the state of the e-cabinet better.
WARNING! In most cases, these measures require operating the e-cabinet with its doors open. Take all
necessary precautions to prevent electrical shocks. Always check that the grounding cable is correctly installed
before powering up.

AC input voltages (power integrity check)
Verify the power configuration measuring the voltage between adjacent terminal blocks in TB1, all measured
voltages must be inside the 200–240 V ±10% as per the chosen configuration.
Measure the voltage between terminals TB1-3 and TB1-4
Configuration option Nominal line to line voltage Measured voltage
1 and 3 380V 220V
400V 230V
415V 240V
2 and 4 200V 200V
208V 208V
220V 220V
240V 240V
5 and 6 240V 240V
A lower-than-expected reading may indicate a loose screw on the electrical installation. Switch off the mains
through the branch circuit breaker in the building PDU and check that all the input power cables and the
configuration cross connectors are tightly screwed.

Power transformer AC output
The AC output voltage from the power transformer TF-1 should always be 230 V ±10%.
This can be measured with an AC voltage meter between TB6-2 and TB6-4:
Safety circuit DC power
To verify that the e-cabinet PCA is supplying 24V to the safety circuit, measure the DC voltage between TB8-5 (-)
and TB8-2 (+).

Emergency stop chain
To verify that the emergency stops are all released, measure the DC voltage between TB8-5 (-) and TB8-1(+).
Make sure to check that there is DC power on the safety circuit (see last paragraph).
Alternatively, with the printer powered off, measure the impedance between TB8-1 and TB8-2:
● When all emergency stop are released the impedance has to be low (~0Ω)
● When one or more emergency stops are pressed the impedance has to be high

Safety relay DC power
The DC power supply of the safety relay can be measured between terminals A1 and A2 of X1. Make sure that
there is DC power to the safety circuit and that the emergency stops are all released.
Rearm button
To determine if the rearm button and its cabling are in order, measure the impedance (ohms) between X1-Y1
and X1-Y2 with the button pressed and the button released. This has to be done with the safety relay
unpowered (press an emergency stop to make sure that the relay has no power).

● With the rearm button released, the measured impedance must be high (>1MΩ)
● With the rearm button pressed, the measured impedance must be low (~0Ω)
Contactor control
To test that the contactors are receiving the control voltage, measure the DC voltage between terminals A1 and
A2:
● When the contactor has to be closed (activated) the voltage has to be +24VDC
● When the contactor has to be open (not activated) the voltage has to be 0VDC
Contactor K-4 is shown here as an example, the same applies to K-1,2,3:

Interlock chain
To verify that the interlocks are all closed measure the DC voltage between TB8-5(-) and TB8-4(+). Make sure to
check that there is DC power on the safety circuit and the safety relay is activated.
Alternatively, with the printer powered off, measure the impedance between TB8-3 and TB8-4:
● When all interlocks are closed the impedance has to be low (~0Ω).
● When one or more interlocks are open the impedance has to be high.

Board name: Formatter
Board picture pointing to connectors/LEDs
Meaning of LEDs



Board name: Engine PCA

Meaning of LEDs

PCA Designator Color Description
DS10 Green 3V3_PCI presence
DS11 Green 3V3 presence
DS12 Not used
Board name: Engine adaptor PCA
Meaning of LEDs
Voltage LEDs
Four green LED’s (voltage supply)
One for each internal DC voltage
Light is proportional to voltage. For example, if the internal 24V drops to 14V, then the LED will still be on, but a
little bit dim.

Overcurrent LEDs
Four LEDs, one for each DC output voltage, lit in case of overcurrent.
In normal states these LEDs should be off.
12V to 5V3
VOK ON (Green!!) when 5V3 out of Regulation due to Failure
OFF in normal situation

Board name: E-box interconnect PCA
Meaning of LEDs
Zoom to LEDs and table with meaning
Each particular connector has a set of LEDs. The LED state (on/off) is directly related to the presence of voltage
at the pins of the connectors, because they are simply connected to the connector (through an isolation resistor).
Colors meaning:
● Green: good news; presence of power supply voltages (or “OK” signals)
● Yellow: neutral news; for data, clock, interrupt, encoder phase signals
● Red: bad news; for failure signals (currently only from Delta Sinewave converters)

Brushless motors connector
Optical encoder connector
Optical drop-detector connector
I2C connector
MICCI2 serial bus connector

CAN connector
Power output connector
CAN+I2C (CAN*) connector

Board name: Printhead interconnect PCA
Visible LEDs with covers

Meaning of LEDs
LED Function Color Description
DS1 Vs presence Green VS power supply ON
DS2 Vs_limits diagnosis Red Vs has been out of range.

(>50.02 V or <37.36 V)
DS3 nReset Diagnosis Red If this LED blinks, Horus reset

occurred
DS4 PVR Horus1 presence Green PVR of Horus1 ON
DS5 Trailing Cable Diagnosis Red Trailing cable badly connected
DS7 PH_CON Diagnosis Red Printhead is badly connected

DS8 VccExt0 presence Green VccExt0 power supply ON
DS9 IVCC_Dig Red VCC_DIG current out of limits
DS10 Vdd1 presence Green Vdd1 power supply ON
DS11 Board_location_OK indicator Green If LED ON, current board is being

controlled by current FUSION
DS14 Vcc_Dig presence Green Vcc_Dig power supply ON
DS15 Trailing Cable Diagnosis Green Trailing cable well connected
In the above table: bold font for the visible LEDs.
Normal operation: Green ON, reds OFF
Board name: Printhead interconnect optimizer PCA
Board illustrations indicating connectors/LEDs

Visible LEDs with covers

Meaning of LEDs
DS1 Vs presence Green VS power supply ON
DS2 Vs_limits diagnosis Red Vs has been out of range.

(>50.02 V or <37.36 V)
DS3 nReset Diagnosis Red If this LED blinks, Horus reset

occurred
DS5 Trailing Cable Diagnosis Red Trailing cable badly connected
DS7 PH_CON Diagnosis Red Printhead is badly connected
DS9 IVCC_Dig Red VCC_DIG current out of limits
DS11 Board_location_OK indicator Green If LED ON, current board is being

controlled by current FUSION
DS14 Vcc_Dig presence Green Vcc_Dig power supply ON
DS15 Trailing Cable Diagnosis Green Trailing cable well connected
In the above table: bold font for the visible LEDs.
Normal Operation: Green ON, reds OFF

Carriage PCAs cover

The carriage PCAs are covered with a metallic cover. This cover has some numbered holes that allow to check the
status of the LEDs. In the following image you can see the situation and numbering of the holes:

Board name: Carriage Interconnect PCA
Board illustrations indicating connectors/LEDs
Figure 4-1 Upper board
Meaning of LEDs
DS1 (LED marked as 9 in the 3V3 presence Green 3V3 power supply ON
carriage cover)
DS2 (LED marked as 5 in the 42 V presence I Green 42 V power supply ON

carriage cover)

DS3 (LED marked as 4 in the 42 V presence II Green 42 V power supply ON

carriage cover)
DS4 (LED marked as 8 in the 12V presence Green 12V power supply presence
carriage cover) (although 24 V appears in silk
screen)
Board name: Carriage power management PCA
1. (J1) 12V to Carriage Interconnect and Carriage Fiber-Optics PCA
2. (J3) 24V Main input
3. (J17) 12V to Carriage power management PCA cooling fan
4. (J16) 12V to Aerosol fans
5. (J14) Data from PH Interconnect PCA 1 and 2
Meaning of LEDs

LEDs DS1, DS2, DS3, DS5, DS6, DS7, DS14, DS15
LED name (PCA serigraphy Function Color Description

shown in brackets)
A (DS1) (LED marked as 3 in 42V Main INPUT Red 42V Input is arriving correctly to
the carriage cover) Carriage power management
PCA
B (DS6) (LED marked as 7 in 12V Internal Power supply 1: Green 12V internal supply 1 generated
the carriage cover) Aerosol Fans, Carriage in Carriage power management
interconnect PCA is OK
C (DS3) (LED marked as 2 in 12V Power Output to Carriage Orange 12V to the Carriage Interconnect
the carriage cover) Interconnect is OK
D (DS7 & DS15) (LEDs marked 12V Power Output to Aerosol Orange 12V Power Output to Aerosol
as 10 & 11 in the carriage Fans Fans is OK
cover)
E (DS14) 12V Internal Power supply 2: Green 12V internal supply 2 generated
Carriage Fiber-Optics PCA in Carriage power management
PCA is OK
F (DS2) (LED marked as 1 in 12V Power Output to Carriage Orange 12V to the Carriage Fiber-Optics
the carriage cover) Fiber-Optics PCA PCA is OK
G (DS5) (LED marked as 6 in 3V3 Internal Power supply 3 Green 3.3 V Generated in the board is
the carriage cover) OK

Troubleshoot errors with Carriage power management PCA LEDs
Carriage power management PCA 42V main input comes from the carriage interconnect PCA, and its main
function is to provide power to other elements in the carriage: the carriage fiber-optics PCA, the aerosol fans, the
carriage power management PCA cooling fan, and the 12V for the carriage interconnect. In this section the
status of the different LEDs are explained depending on the status of the powered elements.
Table 4-1 Power input
Main power
A (DS1) E (DS14) F (DS2) G (DS5) B (DS6) C (DS3) D (DS7&DS15) input (42V)
OFF OFF OFF OFF OFF OFF OFF Power input

from Carriage
Interconnect
OFF or fuse F2
broke
ON X X X X X X Power input
OK
Table 4-2 Carriage Fiber-Optics PCA
A (DS1) E (DS14) F (DS2) Carriage Fiber-Optics PCA
ON ON ON Carriage Fiber-Optics PCA output

OK
ON ON OFF Short-circuit in Carriage Fiber-

Optics PCA
ON OFF OFF Carriage power management

PCA damage
Table 4-3 Aerosol Fans and Carriage power management PCA cooling fan
A (DS1) B (DS6) D (DS7 & DS15) Carriage Fiber-Optics PCA
ON ON ON Power output to Aerosol Fans

and Carriage power
management PCA cooling fan OK
ON ON OFF Short-circuit in Aerosol Fans or

Carriage power management
PCA cooling fan

PCA damage
Table 4-4 Carriage Interconnect

A (DS1) B (DS6) C (DS3) Carriage Fiber-Optics PCA
ON ON ON Power output to carriage

Interconnect PCA OK

Table 4-4 Carriage Interconnect (continued)
A (DS1) B (DS6) C (DS3) Carriage Fiber-Optics PCA
ON ON OFF Short-circuit in Carriage

Interconnect PCA

PCA damage
Table 4-5 Internal power
A (DS1) G (DS5) Carriage Fiber-Optics PCA
ON ON Internal power OK
ON OFF Carriage power management PCA damage
Board name: Fiber-optics PCA
Meaning of LEDs

LEDs DS1..DS8
If the link is not up (DS12 is switched off), the meaning of the LEDs is the following:
PCA Designator Purpose Color Description
E-box side
DS1 LED7 Green Indicates e-box code
DS2 LED6 Green OFF
DS3 LED5 Green FO TX lane 3 detected
DS7 LED1 Green FO RX lane detected
DS8 LED0 Green FO connector detected
Carriage side
DS1 LED7 Green OFF
DS2 LED6 Green Indicates Carriage code
DS3 LED5 Green FO RX lane 3 detected
DS7 LED1 Green FO TX lane detected
DS8 LED0 Green FO connector detected
On the other had, if the link is up (DS12 is swithed on), these LEDs have another meaning and indicate
communication errors in the high speed link.

Voltage LEDs — LEDs DS9,DS10,DS12 and LEDs DS11, DS13, DS14, DS15, DS16
PCA designator Purpose Color Description
DS9 ENC_CHA Green Blinking: Carriage is moving
DS10 ENC_CHB Green Blinking: Carriage is moving
DS11 DONE bit Green ON: FPGA is programmed
DS12 LINK UP Green The fiber-optic link is up
DS13 1V2_VCCT Green 1.2V FPGA Transceivers
DS14 1V2_INT Green 1.2V FPGA
DS15 3V3_AUX Green 3V3 FPGA
DS16 3V3 Green 3V3 FPGA
DS17 5V Green 5V Board

Cable connection LEDs — LEDs D18,DS19,DS20,DS21,DS23,DS24,DS25,DS26
DS23 TC8 Red ON: There's no cable connected

to TC8 or it is pluggued
incorrectly

to TC7or it is pluggued
incorrectly

incorrectly

incorrectly

incorrectly

incorrectly

incorrectly

incorrectly
LEDs DS22, DS27, DS28
DS22 3V3_MAXIM Green 3V3 Line Driver
DS27 3V3_QSFP Green 3V3 FO
DS28 Vs Green Vin supply

Board name: IDS air PCA
1. (J2) To IDS Ink PCA
2. (J6) To LED arrays K, C, M and Y
3. (J7) To LED arrays Lc, Lm and OPT
4. (J10) Air Pumps and Relief valve
5. (J15) Broken Bag sensors K, C, M and Y
6. (J14) Broken Bag sensors Lc, Lm and OPT

Meaning of LEDs

shown in brackets)
A (DS1) 24V Main INPUT Red 24V Input is arriving correctly to

IDS Air PCA
B (DS6) 24V Internal Power supply Green 24V internal supply generated in
IDS Air PCA is OK
C (DS5) 3V3V Internal Power supply Green 3.3V internal supply generated in
IDS Air PCA is OK
D (DS12) Operative system status Red (flashing) When flashing, the programmed
system firmware is working
properly
E (DS11) Communication status Orange (flashing) When flashing, the IDS Air PCA is
properly connected to the printer
and communication is working
F (DS13) Extra indicator for unexpected Blue When flashing, it is used to show
situations some operation is being
executed. If it stays on, there is
probably a short-circuit event
G (DS8, DS9, DS10) IDS Air PCA Identifier Blue Identifier for the IDS Air PCA

Power input indicators
The 24V main power supply is provided through the J2 connector. When the connected and the PCA receives the
correct power, the LED A (DS1) glows. It provides feedback about whether the system is well powered or not.
Internal power supply indicator
Both green indicators (LED B and C) show whether main internal generated voltages are working or not. LED C
(DS5) refers to digital power supply 3V3 and LED B (DS6) (shown in the lower part) refers to 24V. The 24V power
supply rail is used to provide power to the air pumps and relief valve.
System status indicators
Used the same way as in other boards which use microcontrollers connected to the main system.
LED D (DS12), when flashing, indicates the programmed system firmware is working properly. It is a good
indicator of whether the microcontroller is programmed or not and is working as expected. Flashing has a
cadence of around 500 msec.
LED E (DS11) is related to the connection between the printer and the PCA. If the PCA is connected correctly to
the main system (printer) and it has a connection, it will be flashing in the same way as the red indicator (not at
the same time). The system is configured by default to restart the microcontroller in case of a disconnection
longer than 1 second.
LED F (DS13) is a general purpose indicator used to show some exceptions which could happen like pending
operations. If a short circuit event occurs, the blue LED will always appear ON.
NOTE: While the system updates firmware from the printer or standalone, all system LEDs appear OFF. The
program process takes a few seconds to be released.
IDS Air PCA identifier indicators
LEDs G (DS8, DS9, DS10) show the IDS air PCA address. Since there is only one IDS air PCA in the printer, the
identifier should never change, and the three LEDs should always be OFF.

Board name: IDS ink PCA
1. (J11) to IDS Air PCA
2. (J10) 24V (from E-cabinet PCA)
3. (J8) from E-box Interconnect PCA
4. (J16) to Ink Pumps
5. (J7) to electrovalves 1 (K), 2 (C), 3 (M) and 4 (Y)
6. (J4) to electrovalves 5 (Lc), 6 (Lm) and 7 (OPT)
7. (J2) to ink supplies acumen
8. (J13) to ink supplies presence sensors
9. (J15) to leakage sensor (bottom tray)
10. (J14) to PIP sensors

Meaning of LEDs

shown in brackets)
A (DS5) 24V Main INPUT Red 24V Input is arriving correctly to

IDS Ink PCA
B (DS6) 12V Internal power supply Green 12V internal supply generated in
IDS Ink PCA is OK
C (DS7) 3V3V Internal power supply Green 3.3V internal supply generated in
IDS Ink PCA is OK
D (DS2) Operative system status Red (flashing) When flashing, the programmed
system firmware is working
properly
E (DS3) Communication status Orange (flashing) When flashing, the IDS Ink PCA is
properly connected to the printer
and communication is working
F (DS1) Extra indicator for unexpected Blue When flashing, it is used to show
situations some operation is being
executed. If it stays on, there is
probably a short-circuit event
G (DS4) 24V Output Red 24V output in J11 connector OK
H (DS8 to DS15) Ink supply presence indicators Red When ON, it means that the
affected ink supply is NOT
detected to be present (but the
system is well connected). When
OFF, it means that the ink supply
is correctly connected

Power input indicators
The 24V main power supply is provided through the J10 connector. When this connector is connected and the
PCA receives the correct power (system spec 24V+/- 3V), LED A (DS5) glows. It provides feedback about whether
the system is well powered or not.
Internal power supply indicator
Both green indicators (LED B and C) show whether main internal generated voltages are working or not. LED C
(DS7) refers to digital power supply 3V3 and LED B (DS6) (shown in the lower part) refers to 12V. The 12V power
supply rail is used to provide power to ink pumps and to generate the analog 3V3 voltage used as the power
supply in all sensors.
System status indicators
Used the same way as in other boards which use microcontrollers connected to the main system.
LED D (DS2), when flashing, indicates the programmed system firmware is working properly. It is a good
indicator of whether the microcontroller is programmed or not and is working as expected. Flashing has a
cadence of around 500 msec.
LED E (DS3) is related to the connection between the printer and the PCA. If the PCA is connected correctly to the
main system (printer) and it has a connection, it will be flashing in the same way as the red indicator (not at the
same time). The system is configured by default to restart the microcontroller in case of a disconnection longer
than 1 second.
LED F (DS1) is a general purpose indicator used to show some exceptions which could happen like pending
operations. If a short circuit event occurs, the blue LED will always appear ON.
NOTE: While the system updates firmware from the printer or standalone, all system LEDs appear OFF. The
program process takes a few seconds to be released.
Power output
LEDs G (DS4) provides information about if the J11 output connector provides power supply or not. This output is
used to power IDS Air PCA. If nothing is connected to J11, LED G (DS4) could glow without output powered.
Ink supply presence indicators
Ink supply presence indicators give feedback about whether ink cartridges are connected and present or not.
When the indicator is ON this indicates that the system is well connected and the ink supply is not present.
When a cartridge is connected, the LED indicator which corresponds to it is OFF.
NOTE: If the system is not well connected (connector J2 in IDS Ink PCA disconnected), the ink supply presence
indicators could be OFF.

Board name: Curing PCA
* For connection between modules details, see the curing cabling block diagram.
Meaning of LEDs
LED Color Meaning Normal operation
DC voltages
LED 24V (DS5) Green 24 V present in the board On
LED 12V (DS6) Green 12 V generated in the board On
LED 5V (DS7) Green 5 V generated in the board On

LED Color Meaning Normal operation
LED 3V3 (DS27) Green 3.3 V generated in the board On
Up signals
Status LED (DS1) Orange On error, repeatedly flashes error codes Off
uC beat (DS8) Yellow Indicates firmware activity On, blinking
Control signals
Max reset (DS4) Red On if events supervisor is in error state Off
K1 relay (DS3) Orange On when the K1 relay is enabled On when the module is activated and curing
K2 relay (DS10) Orange On when the K2 relay is enabled On when the module is activated and curing
AC1 enabled (DS9) Orange On when the AC1 TRIAC is enabled On when the module is activated and curing
Ac2 enabled (DS2) Orange On when the AC2 TRIAC is enabled On when the module is activated and curing
Check curing PCA LEDs
1. Check that the 24V, 12V, 5V, and 3V3 LEDs are on.
● If the 24V LED is off, see Troubleshoot 24 V supply errors on page 421.
● If the 24V LED is on and any other 12V, 5V, or 3V3 LED is off, shut down the printer from the Internal
Print Server, wait for shutdown to complete, turn off the main switch, wait 10 seconds, and restart
the printer. If any of the 12V, 5V, or 3V3 LEDs is still off, install a new Curing PCA (see Curing and
Vapor removal PCA (CZ056-67384/1HA07-67015) on page 772).
2. Check the uC beat LED:
● It should be blinking; the number of blinks is the address of the module (1 beat for module 1 and 2
beats for module 2). If the blinks do not match the module number, there is an error in the curing fan
cable (CZ056-50281) configuration. Cable included in the Curing PCA cable kit (K4T88-67223). Check
the Figure 2-13 Curing Subsystem on page 87 for its correct configuration.
NOTE: If the curing module address is incorrect, printer errors will not refer to the correct module,
and curing module diagnostics will not run.
● If it is not blinking, update the printer firmware.
NOTE: The uC beat LED is on while a curing PCA firmware upgrade is in progress. This process takes
less than 2 minutes and is done during the printer start-up.
3. Check the Status LED:
● If it is on and not blinking, there is an error in the module, but communication with it should be
possible. Run the Monitor curing modules diagnostic (16003), depending on the module giving the
error. See Table 5-18 Curing on page 581.
If the connection fails, see Troubleshoot curing PCA communication errors on page 420.
● If it is blinking, there is an error in the module that may prevent communication with the e-box. Count
the number of blinks:

– 2 blinks: The curing PCA firmware does not match the hardware version, update the printer
firmware.
– 3 blinks: Invalid address, the curing fan cable has no valid address configuration, follow “Check
curing PCA LED uC beat is blinking” to check the address of the module.
– 4 blinks: Curing PCA voltage error. The curing PCA detects that the DC input voltage is out of
range. See Troubleshoot 24 V supply errors on page 421.
– 5 blinks: Communication reset; intermittent communication errors. See Troubleshoot curing PCA
communication errors on page 420.
– 6 blinks: Module reset, internal module error, update the printer firmware.
– 8 blinks: There is an internal module error, update the printer firmware.
If the problem persists, install a new curing PCA. See Curing and Vapor removal PCA
(CZ056-67384/1HA07-67015) on page 772.
Check curing PCA jumpers
● CAN TERM: jumper in curing PCA 6, but not in the other curing PCAs.
● IRQ TERM: no jumper
● ADR0, ADR1, ADR2: no jumper
● J5, J6: jumper should be present and should not be removed
Troubleshoot curing PCA communication errors
The curing modules’ control line is a daisy-chain (serial) connection between the different PCAs. To communicate
with an PCA in the chain, the communication with the previous ones must work. The boards connected from the
e-box to the last curing PCA are as follows (also see Figure 2-13 Curing Subsystem on page 87):
Engine PCA 3 > Engine adaptor PCA 3 > E-box interconnect PCA > Curing PCA 1 > Curing PCA 2 > Curing PCA 3 >
Curing PCA 4 > Curing PCA 5 > Curing PCA 6.
The fact that all elements in the curing modules’ control line are daisy-chained is relevant, as a communication
error with one curing PCA may not prevent communication with another curing PCA. It is important to find out at
which point of the link is the error.
To start troubleshooting when a communications error has been raised:
1. Check that the curing modules’ control line is properly connected. That is, ensure that the connection
between the different PCAs is correct (see explanation above).
2. Check curing PCA LEDs. All curing module PCAs should be correctly powered and have the correct address.
3. Check curing PCA jumpers. See Check curing PCA jumpers on page 420.
4. If there is an error inside the e-box (engine PCA 3, engine adaptor PCA 3, e-box interconnect PCA,
interconnecting cables) or in the control cable between the e-box and curing module 1, then all curing
modules are disconnected but only one error is reported, corresponding to the first module failing.
5. If all curing modules have a connection error, restart the printer. If the problem persists, investigate as
follows:

a. Ensure that all cables are properly installed and not damaged, pinched, or twisted.
b. Ensure that all PCAs are properly installed.
c. Add a new control cable between the e-box interconnect PCA and curing PCA 1, restart the printer,
and perform step 4 above. If one or more curing modules report connection OK, then the failure is in
the cable, replace it with a new one.
d. Replace the cable between engine adaptor PCA 3 and engine PCA 3 with a new one, restart the
printer, and perform step 4 above. If one or more curing modules report connection OK, then the
failure is in the cable, replace it with a new one.
e. Interchange engine adaptor PCA 3 with any other one, restart the printer, and perform step 4 above.
If one or more curing modules report connection OK, then the failure is in engine adaptor PCA 3,
replace it with a new one.
f. Interchange engine PCA 3 with any other one, restart the printer, and perform step 4 above. If one or
more curing modules report connection OK, then the failure is in engine PCA 3, replace it with a new
one.
g. Interchange curing PCA 1 with a curing PCA from another module, restart the printer, and perform
step 4 above. If one or more curing modules report connection OK, then the failure is in the replaced
curing PCA, replace it with a new one.
6. If not all modules have a connection error, restart the printer. If the problem persists, perform the following
checks for each of the curing modules with a connection error (one module at a time). The first module to
check is the failing one with the lowest address number.
a. Check that the control cable to the module is well connected at both ends, and that it is not damaged,
twisted, or pinched.
b. Disconnect control cable from the module. As a result, all modules with an address number higher
than the current module will have a communication error. Ignore those modules in the tests below.
c. Restart the printer and check communication following step 4 above, from the first module up to the
current module under test.
● If the current module reports connection OK, the error is after the current module. Connect the
control cable leaving the module and repeat step 6 for the next failing module.
● If the current module reports a connection error, add a control cable between the current
module and its immediate predecessor, and repeat step 4 above. If the communication error
disappears, replace the control cable with a new one, connect the control cable leaving the
module, and repeat step 6 for the next failing module.
If the communication error persists, replace the curing PCA from this module with the curing PCA of a
working module, and repeat step 4 above. If the communication error moves with the curing PCA,
replace it with a new one, connect the control cable leaving the module, and repeat step 6 for the
next failing module.
Troubleshoot 24 V supply errors
Troubleshooting this type of error can be divided into two areas: the e-cabinet and the curing system. The whole
chain of connections between the e-cabinet and the curing system is as follows:
AC network (input power depending on the country) > two 24 V PSUs > E-cabinet PCA > Power cable > Curing
PCAs 1 to 6.

When a 24V supply out of range error is raised, run the power supplies diagnostics from the E-cabinet menu.
From the results:
● If voltage is ≤ 21.5V and current is ≤ 10A, the problem should be in the e-cabinet.
Check the voltage at the PSU. If necessary, install a new PSU. If the problem persists, install a new e-
cabinet PCA. See E-cabinet PCA (K4T88-67288) on page 880.
● If voltage is ≤ 21.5V and current is ≥ 24A, the problem should be in the curing system.
Check the voltage at the connection points to find which element is failing or causing a short-circuit (thus
the drop in voltage and high current consumption).
You are recommended to disconnect all the PCAs in the curing system (only the ones listed at the
beginning of this section) except one of the curing PCAs. Then check the voltage at the last element
connected until the failing element is found (the voltage will drop again).
WARNING! Before disconnecting anything, turn the printer off.
To check the voltage, restart the printer in diagnostic mode and run the e-cabinet power supplies and
monitor one curing module diagnostics again.
If necessary, install a new PCA to replace whichever one has failed. See Curing and Vapor removal PCA
(CZ056-67384/1HA07-67015) on page 772.
Troubleshoot curing resistor errors
This section explains how to check errors related to curing chamber resistors (how to measure impedance, and
so on). These errors are as follows:
● Short circuit 16.15.0X:01
● Open circuit 16.14.0X:15
● Overcurrent warning 16.01.0X:41
IMPORTANT: A multimeter is required to measure resistance. These checks cannot be done without one.
1. Turn off the printer and ensure that no AC power is present.
2. Set the multimeter to measure resistance.
3. Check resistance between points A and B of J10 on the heater control PCA.
4. Check resistance between points C and D of J10 on the heater control PCA.

5. Both measurements should be between 32 and 37 Ω (±1 Ω approximately). If both are correct, the check
ends successfully. If one or both are wrong, continue to follow these steps.
6. Disconnect both heaters and measure the resistance between terminals 1 and 2 of each heater.
7. Both measurements should be between 32 and 36 Ω (±1 Ω approximately). If both are correct, the problem
must be in the cable between the heater control PCA and the heater; replace it with a new one. If one or
both measurements are wrong, the heater is faulty, replace it with a new one.
Board name: Drying PCA

Meaning of LEDs
Name Reference Color Normal state Meaning Error state
3.3V DS27 Green On PCA powered Off
Firmware status DS1 Orange Off Error code Blinking
uC beat DS8 Orange Blinking Code works Off
OVC DS5 Green On No OVC problem Off
Hardware status DS4 Red On Power disabled N/A
Check drying PCA LEDs
1. Check that the 3V3 LEDs are on.

NOTE: The 12V and 5V LEDs are inside the electronics cover and cannot be seen from the outside
If the LEDs are off, see Troubleshoot 24 V supply errors on page 427.
beats for module 2). If the blinks do not match the module number, there is an error in the drying fan
cable. See Figure 2-16 Drying Subsystem on page 90.
NOTE: If the drying modules address is incorrect, errors will not refer to the correct module and the
drying module diagnostic will not run.
NOTE: The uC beat LED is on while a drying PCA firmware upgrade is in progress. This process takes
less than 2 minutes and is done during the printer start-up.
3. Check the Firmware status LED:
possible. Run the Drying PCA functional check, depending on the module giving the error. See Table
5-20 Drying on page 583.
If the connection fails, see Troubleshoot drying PCA communication errors on page 426.
– 2 blinks: The drying PCA firmware does not match the hardware version, update the printer
firmware.
– 3 blinks: Invalid address, the drying fan cable has no valid address configuration, follow 'Check
drying PCA LED uC beat is blinking' to check the module address.
– 4 blinks: Drying PCA voltage error. The drying PCA detects that the DC input voltage is out of
range. See Troubleshoot 24 V supply errors on page 427.
– 5 blinks: Communication reset; intermittent communication errors. See Troubleshoot drying PCA
communication errors on page 426.
– 6 blinks: Module reset, internal module error.
If the problem persists, install a new drying PCA. See Drying PCA (K4T88-67070) on page 784.
Check drying PCA jumpers
● ADDR: no jumper
● CAN TERM: jumper in drying PCA 4, but not in the other Drying PCAs
● J5, J6: Jumper should be present and should not be removed

Troubleshoot drying PCA communication errors
The drying modules’ control line is a daisy-chain (serial) connection between the different PCAs. To communicate
with an PCA in the chain, the communication with the previous ones must work. The boards connected from the
e-box to the last drying PCA are as follows (also see Figure 2-16 Drying Subsystem on page 90):
Engine PCA 1 > Engine adaptor PCA 1 > E-box interconnect PCA > Drying PCA 1 > Drying PCA 2 > Drying PCA 3 >
Drying PCA 4
The fact that all elements in the drying modules’ control line are daisy-chained is relevant, as a communication
error with one drying PCA may not prevent communication with the other drying PCA. It is important to find out
at which point of the link is the error.
1. Check that the drying modules’ control line is properly connected. That is, ensure that the connection
between the different PCAs is correct (see explanation above).
2. Check drying PCA LEDs and jumpers. See Check drying PCA jumpers on page 425.
3. If there is an error inside the e-box (engine PCA 1, engine adaptor PCA 1, e-box interconnect PCA,
interconnecting cables) or in the power cables between the e-box and drying modules, then drying
modules are disconnected but only one error is reported, corresponding to the first module failing. Run the
Drying PCA functional check. See Table 5-20 Drying on page 583.
4. If all the drying modules have a connection error, restart the printer. If the problem persists, investigate as
follows:
a. Ensure that all cables are properly installed and not damaged, pinched, or twisted.
b. Ensure that all PCAs are properly installed.
c. Add a new control cable between the e-box interconnect PCA and drying PCA 1, restart the printer,
and perform step 4 above. If one or more drying modules report connection OK, then the failure is in
the cable, replace it with a new one.
d. Replace the cable between engine adaptor PCA 1 and engine PCA 1 with a new one, restart the
printer, and perform step 4 above. If one or more drying modules report connection OK, then the
failure is in the cable, replace it with a new one.
e. Interchange engine adaptor PCA 1 with any other one, restart the printer, and perform step 4 above.
If one or more curing modules report connection OK, then the failure is in engine adaptor PCA 1,
replace it with a new one.
f. Interchange engine PCA 1 with any other one, restart the printer, and perform step 4 above. If one or
more drying modules report connection OK, then the failure is in engine PCA 1, replace it with a new
one.
g. Interchange drying PCA 1 with a drying PCA from another module, restart the printer, and perform
step 4 above. If one or more drying modules report connection OK, then the failure is in the replaced
drying PCA, replace it with a new one.
5. If not all modules have a connection error, restart the printer. If the problem persists, perform the following
checks for each of the drying modules with a connection error (one module at a time). The first module to
check is the failing one with the lowest address number.

a. Check that the control cable to the module is well connected at both ends, and that it is not damaged,
twisted, or pinched.
b. Disconnect control cable from the module. As a result, all modules with an address number higher
than the current module will have a communication error. Ignore those modules in the tests below.
c. Restart the printer and check communication following step 4 above, from the first module up to the
current module under test.
● If the current module reports connection OK, the error is after the current module. Connect the
control cable leaving the module and repeat step 6 for the next failing module.
● If the current module reports a connection error, add a control cable between the current
module and its immediate predecessor, and repeat step 4 above. If the communication error
disappears, replace the control cable with a new one, connect the control cable leaving the
module, and repeat step 6 for the next failing module.
If the communication error persists, replace the drying PCA from this module with the drying PCA of a
working module, and repeat step 4 above. If the communication error moves with the drying PCA, replace it
with a new one, connect the control cable leaving the module, and repeat step 6 for the next failing module
with the lowest address number.
Troubleshooting this type of error can be divided into two areas: the e-cabinet and the carriage. The whole chain
of connections between the e-cabinet and the drying system is as follows:
AC network (input power depending on the country) > 24 V PSU > E-cabinet PCA > Power Cable > Drying PCA 1 to
4.
From the results:
● If voltage is <21.5V and current is >24A the problem should be in the drying system.
the drop in voltage and high current consumption).
You are recommended to disconnect all the PCAs on the drying system (only the ones listed at the
beginning of this section) except one of the drying PCAs. Then check the voltage at the last element
connected until the failing element is found (the voltage will drop again).
WARNING! Before disconnecting anything, turn the printer off.
To check the voltage, restart the printer in diagnostic mode and run the e-cabinet power supplies and
drying PCA functional check diagnostics again.
If necessary, install a new PCA to replace whichever one has failed. See Drying PCA (K4T88-67070)
on page 784.

Board name: Vapor removal PCA
1. 24V IN
2. LAN IN
3. 24V to fans array
4. Control to pump blower
Meaning of LEDs

LED name (PCA

serigraphy shown in
brackets) Function Color Description Normal operation
A (DS1) Status LED Orange On error, repeatedly Off

flashes error codes
B (DS27) 3V3 Internal power Green 3.3 V generated in the On

supply board
C (DS8) uC beat Yellow Indicates firmware On, blinking

activity
D (DS5) 24V main input Green 24V present in the board On
E (DS6) 12V internal power Green 12V generated in the On

supply board
F (DS7) 5V Internal power supply Green 5V generated in the board On
Check curing PCA LEDs
1. Check that the D (24V), E (12V), F (5V), and B (3V3) LEDs are on.
● If the 24V LED is off, see Troubleshoot 24 V supply errors on page 430.
● If the 24V LED is on and any other 12V, 5V, or 3V3 LED is off, shut down the printer from the Internal
Print Server, wait for shutdown to complete, turn off the main switch, wait 10 seconds, and restart
the printer. If any of the 12V, 5V, or 3V3 LEDs is still off, install a new Vapor removal PCA (see Vapor
removal PCA (K4T88-67069) on page 1304).
beats for module 2). If the blinks do not match the module number, there is an error in the vapor
removal fan cable (K4T88-50159) configuration.
NOTE: If the vapor removal address is incorrect, printer errors will not refer to the correct module,
and vapor removal diagnostics will not run.
NOTE: The uC beat LED is on while a vapor removal PCA firmware upgrade is in progress. This
process takes less than 2 minutes and is done during the printer start-up.
3. Check the Status LED:
possible. Run the Vapor removal electronics check (30001). See Table 5-28 Vapor removal
on page 598.
If the connection fails, see Troubleshoot vapor removal PCA communication errors on page 430.

– 2 blinks: The vapor removal PCA firmware does not match the hardware version, update the
printer firmware.
– 3 blinks: Invalid address, the vapor removal fan cable has no valid address configuration, follow
“Check vapor removal PCA LED uC beat is blinking” to check the address of the module.
– 4 blinks: Vapor removal PCA voltage error. The vapor removal PCA detects that the DC input
voltage is out of range. See Troubleshoot 24 V supply errors on page 430.
– 5 blinks: Communication reset; intermittent communication errors. See Troubleshoot vapor

removal PCA communication errors on page 430.
– 6 blinks: Module reset, internal module error, update the printer firmware.
If the problem persists, install a new vapor removal PCA. See Vapor removal PCA (K4T88-67069) on page 1304.
Check vapor removal PCA jumpers
● CAN TERM: jumper should be present and should not be removed
● ADR0, ADR1, ADR2: no jumper
Troubleshoot vapor removal PCA communication errors
1. Check that the Vapor removal control line is properly connected. That is, ensure that the connection
between vapor removal PCA and the e-box is correct (J_262 E-box to J12 VR PCA).
2. Check vapor removal PCA LEDs. It should be correctly powered and have the correct address.
3. Check vapor removal PCA jumpers. See Check vapor removal PCA jumpers on page 430.
4. Ensure that all cables are properly installed and not damaged, pinched, or twisted.
5. Ensure that vapor removal PCA is correctly installed.
6. Change the control cable between the e-box interconnect PCA and vapor removal PCA, then restart the
printer.
7. Replace the cable between the engine adaptor PCA 2 and engine PCA 2 with a new one, then restart the
printer.
8. Interchange engine adaptor PCA 2 with any other one, restart the printer. If the printer can communicate
with the vapor removal PCA, the failure is in engine adaptor PCA 2, so replace it with a new one.
9. Interchange engine PCA 2 with any other one, restart the printer. If the printer can communicate with the
vapor removal PCA, the failure is in engine PCA 2, so replace it with a new one.
10. Replace vapor removal PCA by a new one, then restart the printer.
Troubleshooting this type of error can be divided into two areas: the e-cabinet and the vapor removal system.
The whole chain of connections between the e-cabinet and the vapor removal system is as follows:

AC network (input power depending on the country) > 24 V PSU > E-cabinet PCA > Power cable > Vapor removal
PCA.
From the results:
● If voltage is ≤ 21.5V and current is ≥ 24A, the problem should be in the vapor removal system.
the drop in voltage and high current consumption), you may have to change the power cable or the vapor
removal PCA.
Board name: Drop-detector PCA
* See Subsystem block diagrams on page 79 for connection details

Meaning of LEDs
DS1 5V Green 5V power supply ON
Board name: Vacuum control PCA
* For the Vapor removal VACUUM Ctrl PCA, only data & power cables from the e-box Int PCA and the Control
cable for the pump are needed.

Meaning of LEDs
DS1 CAN Activity Green Shows CAN Bus activity
Board name: OMAS control PCA

Meaning of LEDs

DS1 Done Green Shows the FPGA has been

booted correctly
DS2 Internal 3V3 Green 3V3 Internal Power Supply ON
DS3 24V Input Green 24V Power supply ON
DS4 5V Input Green 5V Power supply ON
Board name: Motor drive PCA
The motor drive PCA controls motors on different subsystems. See the corresponding block diagram for specific
subsystem details.

Meaning of LEDs
LED COLOR Description
SDA & SCL Green Communication (blinking in normal

operation)
24V IN Green 24V arrive to the board (green in normal

operaton)
OUT A/B Green Green if motor turning, depending on motor

direction
5V Green 5V ON (green in normal operation)
6&7 Green Indicates encoder activity
Rest Green Indicate switches operation (depends on

printer subsystem)
Board name: PPS safety PCA
1. (J7) to motor drive PCA 1 (SVS side)
2. (J6) to motor drive PCA 2 (IDS side)
3. (J1) from TB-9 in e-cabinet
Connectivity errors
Using the system configuration tool
This chapter explains how to use the HP Latex 3000 System Configuration Tool to fix connectivity issues
between the printer’s internal network and the customer’s network.

The HP Latex 3000 System Configuration Tool is available from the following link: http://www.hp.com/embed/
hpbrain?action=download&id=4609063
Network connection scheme
Two Ethernet ports at the IPS PC

● Upper port (on board, blue): this port should be used to connect the IPS PC to the eBox, and is for printer to
IPS PC communication.
● Lower port (PCI board, green): this port should be used to connect the IPS PC to the Customer’s network,
and is for IPS PC communication with the RIP PC and the Internet.
These ports are not interchangeable, so using the wrong port will result in failure to connect.
The Internet Protocol (IP) address conventions used in this document are as follows:
● <IP_Printer>: the IP address of the eBOX, connecting to the IPS PC.
● <IP_IPS-ToPrinter>: the IP address of the upper (on board) IPS PC network connection.
● <IP_IPS-ToNetwork>: the IP address of the lower (PCI board) network connection on the IPS PC, used to
connect to the customer’s network.
IP addresses used
<IP_Printer> <IP_IPS-ToPrinter>
172.22.22.22 172.22.22.23

192.168.88.88 192.168.88.89
10.0.0.10 10.0.0.11
192.168.0.10 192.168.0.11
<IP_IPS-ToNetwork> depends on the customer network setup, and can have a wide range of values.
The <IP_Printer> and <IP_IPS-ToPrinter> addresses shown in the table are the four options that can be used to
connect the printer to the IPS PC. The printer’s factory settings are the addresses 172.22.22.2x.
The HP Latex 3000 system configuration tool helps you to set the correct addresses. The tool detects any
potential conflicts with the customer’s network and sets the <IP_Printer> and <IP_IPS-ToPrinter> addresses to
avoid these conflicts.
For example, if the customer uses IP addresses in the range 172.x.x.x in their network, the tool will enable you to
modify the <IP_Printer> and <IP_IPS-ToPrinter> addresses to the second, third or fourth options to avoid network
conflicts.
How to use the HP Latex 3000 System Configuration Tool

The HP Latex 3000 System Configuration Tool must be installed on the IPS’s Hard disk in order to execute it. It
should not be run from a memory stick or similar external device.
When the tool is launched, it will automatically run a connectivity test, retrieving information from:
● Operating System > checks the OS version.
● Firewall > checks the firewall/Symantec status.
● Network Interface Controller (NIC) > checks each network card IP configuration.
● IPS > checks the IP addresses in the.xml file.
● Proxy > checks port configuration.
● eBox > pings the eBox to check that the device responds.
● Shared Folder > not currently used (intended for future releases).
While running the test, the tool will disable the connection to the customer network in order to avoid any
conflicts. When the test is concluded, the network connection will be re-enabled. The test can be refreshed at
any time by pressing the Refresh button (denoted by two arrows), located at the bottom left of the application.
The following pictures show the results of a successful connectivity test, with green indicators next to each
connectivity check:

When the connectivity test is successful (all indicators green), the application can be closed, as this shows that all
of the network connections are working properly.
If the Global Connectivity Test detects an issue, however, a red indicator, a tool button, and a short error
message will be displayed next to each of the tests that have been failed.
In the following example, the tool has discovered connectivity problems in the IPS Configuration, the Proxy
Configuration and the eBox Connectivity. Each of these issues must be addressed individually, in the order in

which they are displayed. In this example, pressing the tool button next to the IPS configuration displays the
following pop-up window:
Clicking ‘Yes’ launches the IPS configuration utility, which will proceed to test for suitable IP pairs, beginning with
172.22.22.2x. The IPS must be closed in order to run the operation, so the following alert message will be
displayed if the IPS is running:
To fix this issue, go to the IPS, close it, and then press OK. Once effective suitable IP pair has been discovered, the
tool will display another prompt, reminding you to restart the IPS:

In this case, the IPS configuration issue has now been solved, so the next step is to fix the Proxy Configuration.
Clicking the tool button next to the Proxy Configuration will launch a process that is similar to that described
above.
Finally, the eBox connectivity needs to be re-established based on the new IPs (in this case, 172.22.22.2x). The
tool will proceed to modify the <IP_IPS-ToPrinter> to the appropriate value (172.22.22.23):

When the test has successfully finished, you will be presented with the option of changing the IPs. To do so, click
on the tool icon at the bottom left of the window. There is a drop down menu with the four IP pairs detailed in
the table above. In this example, the current <IP_Printer> is 10.0.0.10, which will be changed to 172.22.22.22.
After selecting the new IP set, press the button ‘Change IPs and reboot printer’. The change will only come into
effect after the printer has been rebooted.
Note that it is not necessary to change the <IP_Printer> through Print Care, as the tool already manages it.

Figure 4-2 JMF Service OK

Figure 4-3 JMF Service Error
The two most common failures of a service error are:
● Service is not running
● Service can’t connect
In both cases click on the tools button. The IPS Configurator window appears:

In the IPS IP, set the computer IP of your preferred LAN and click Set Configuration.

If all works well JMF Configuration will turn green:

The motor has stopped and the fault LED is off (no system error)
Input spindle motor internal fault.

b. Motor problem
c. EE problem
Corrective actions

The fault LED is off (no system error)

Main roller motor internal fault.

b. Motor problem
c. EE problem
Corrective actions
2. Restart the printer, retry substrate load, and check whether the main roller motor fault LED is off. See the
MA LED in Board name: Engine adaptor PCA on page 393.
3. Run the Main roller motor test diagnostic (41003). See Table 5-5 Substrate path mechanics on page 551.
4. If the motor is faulty, and after being restarted by firmware it remains faulty, then the motor’s internal
electronics may be damaged. Install a new motor. See MA motor (CZ056-67269) on page 1182.
5. If the roller has abnormally high friction, install a new helical gear, clean the worm, and grease the whole
transmission.
6. Call support.
Output spindle motor internal fault.
Corrective actions
3. Run the input motor (MI) calibration diagnostic and follow the instructions provided (see Table 5-5
Substrate path mechanics on page 551).

Tension roller motor internal fault.

b. Motor problem
c. EE problem
Corrective actions

Printer calibration
Align the printheads
Precise alignment between printheads is essential for color accuracy, smooth color transitions, and sharp edges
in graphical elements.
NOTE: You are recommended to align the printheads only when using a single-roll-to-roll configuration. In
particular, printhead alignment with dual rolls is not recommended.
Printhead alignment is recommended in these situations:
● After replacing or reseating a printhead.
● When a new substrate is loaded and the printhead-to-paper spacing changes significantly.
● When there are print-quality problems that could be caused by printhead misalignment.
To align the printheads, go to the Internal Print Server and select Printer ►Printhead alignment. There are two
alignment types to choose from, automatic and manual.
Printhead alignment can be affected by wrinkles or other substrate deformations in the print zone. Therefore, if
the printer has recently been printing, you should wait for some minutes while it cools down. Just in case, the
printer advances the substrate before aligning the printheads.
Automatic alignment procedure

Automatic alignment is a fully automated procedure that ensures optimal print quality in most cases.
The printer prints three blocks of patterns and scans them with the built-in line sensor. This method is intended
for any smooth, high-quality substrates (including vinyl and banner substrates).
Automatic alignment takes about 15 minutes. It is an unattended process, and uses printed substrate with
dimensions 35 cm (13.8 in) wide by 54 cm (21.3 in) high. To launch, go to the Internal Print Server and select
Printer ►Printhead alignment ►Automatic ►Align.
The picture below shows the three printed patterns:
● Scan axis alignment of each colorant, speed of 50 ips
● Scan axis alignment of each colorant, speed of 40 ips
● Substrates axis alignment of each colorant

IMPORTANT: Automatic alignment does not align the optimizer. If trying to align the optimizer or install a new
printhead optimizer, manual alignment is required. Modify the A and B values as shown in the manual alignment
table.
NOTE: If automatic alignment fails, see ‘Automatic Printhead Alignment fails’ in the user guide.
Manual Alignment procedure
To launch Manual Alignment, go to the Internal Print Server and select Printer ►Printhead alignment ►Manual
►Align.
The printer prints 21 series of patterns, each one named with a letter (A–U). You must choose the best result
from each of the series (for example, number 10 in the picture below).
ENWW Printer calibration 451

The alignment procedure includes both the colored printheads and the optimizer printhead, and takes about 10
minutes. It consumes printed substrate of 72 cm width x 37 cm height (28.3 × 14.6 in).
NOTE: Depending on the firmware version, this pattern could be slightly different.
The picture below shows the distribution of printheads in the carriage. It also shows the correspondence
between printhead and patterns, with guidance on the direction of the corrections (0–40) applied.

The following table summarizes the correction type controlled by each pattern:
Pattern Affected printheads Correction type
A Optimizer Substrate Axis
B Optimizer Scan Axis
C K Scan Axis, Bidirectional 40 ips
D K Scan Axis, Bidirectional 50 ips
E Y Scan Axis, Bidirectional 40 ips
F Y Scan Axis, Bidirectional 50 ips
G C Scan Axis, Bidirectional 40 ips
H C Scan Axis, Bidirectional 50 ips
I lc Scan Axis, Bidirectional 40 ips
J lc Scan Axis, Bidirectional 50 ips
K lm Scan Axis, Bidirectional 40 ips
L lm Scan Axis, Bidirectional 50 ips
M M Scan Axis, Bidirectional 40 ips
N M Scan Axis, Bidirectional 50 ips

Pattern Affected printheads Correction type
O lc Scan Axis
P lm Scan Axis
Q C Scan Axis
R Y Scan Axis
S M Scan Axis
T lm, lc Substrate Axis
U M, Y Substrate Axis
Take this into account when trying to compensate for any misalignment observed in the printhead alignment
diagnostics plot.
The central correction is 20 (15 for A), being the default value for each pattern in the Internal Print Server.
Aligning the optimizer printhead
The optimizer ink is transparent, so it is not easy to detect visually. To make it easier, a background of composite
ink has been added on top of it. It highlights the optimizer, making it visible most of the time.
The patterns A and B are intended to align the optimizer printhead to the colored printheads in both directions
(scan axis and substrate axis).
The image below shows the background with the optimizer lines on top of it.
Possible difficulties with printhead alignment

The optimizer ink is invisible or hardly visible
The composite background to highlight the optimizer ink works for most substrates, but occasionally, with some
substrates, there is not enough contrast to highlight the optimizer ink. In these cases there are two possible
solutions:

● Load a different substrate with more contrast to perform the alignment.
● Insert an intermediate correction (A=15, B=20), assuming the optimizer is well aligned. In this case, take a
close look afterwards for associated defects, such as bleed, halo, or wicking. See ‘Bleed, halo, wicking’ in
the user guide.
Another possibility is that the optimizer printhead or the colored printheads may have too many clogged
nozzles, resulting in a poor background area fill, which makes it difficult to detect the optimizer bars. In this case,
see ‘Check and clean the printheads’ in the user guide.
The optimizer printhead is still misaligned in the substrate axis after alignment
The optimizer printhead is staggered and there is a gap between it and the other printheads, so in the patterns A
and B a substrate advance is needed to align it to the background and the reference black. If the substrate
advance is inaccurate, the optimizer correction for the substrate axis (pattern A) may not be valid. You may
detect some bleed in the boundaries between colors in the substrate axis direction, usually when passing from
high ink density areas to lower ink density areas. In this case, ensure that the substrate advance is accurate (see
Substrate-advance compensation on page 460) before performing alignment.
A pattern shows more than one good correction

Occasionally you may find that a pattern has two or more possible good corrections, separated by two or more
steps. This could be due to wrinkles on the substrate that change the printhead-to-paper spacing along the scan
axis. To avoid this, ensure that the substrate is cold before starting the alignment, and advance it at least 70 cm
to ensure that it is not deformed by the curing of the previous job.
Printhead alignment diagnostics plot

The printer offers a printhead alignment diagnostics plot, to assess the quality of the current printhead
alignment. To print it, in the Internal Print Server select Printer ►Printhead alignment ►Verify alignment
►Print.
NOTE: You can use the diagnostics plot to check printhead alignment, then fine-tune the values by following
the instructions on the diagnostics plot. Also, if the substrate is similar to one that you already use, you can print
only the diagnostic plot (much faster than printhead alignment) and fine-tune the values in the Internal Print
Server.
IMPORTANT: The diagnostic plot is not designed to fine-tune automatic printhead alignment; in that case, the
diagnostic plot is only used to check printhead alignment.
The next picture shows an example of the diagnostics plot. Each part is described following the terminology of
the manual alignment. Row0 is the row of printheads closer to the substrate output, while Row1 is the row of
printheads closer to the substrate input. In the same plot there is an area in which the carriage layout is
described with the appropriate labels, just for reference.

Zone 1: Printhead alignment check Scan Axis and Substrate Axis

This area shows printhead-to-printhead alignment. Each printhead has crosses, where it is compared to a
reference printhead. In this case the black printhead has been chosen as a reference.
The colors are labeled C, M, Y, c, m. In each case, the inner cross should be aligned with the outer cross.
In case of misalignment the arrows indicate the pattern of the manual alignment that will correct the
misalignment. Also, the ‘40’ label indicates the direction towards where the line will be moved when a ‘40’ value
is applied. For example, imagine that in the manual alignment the chosen value for S is 23, and the chosen value
for U is 17. Imagine also a misplacement in the M:
● Scan axis misplacement: The M line is displaced to the right. Since the ‘40’ arrow points to the right, if you
apply values bigger than your actual value it will be moved further to the right. But, since the vertical M line
is displaced to the right, you need to move it to the left. Therefore, a value lower than your actual selection
(S=23) is needed.
● Substrate axis misplacement: The M line is displaced to the top. Since the ‘40’ arrow points to the bottom, if
you apply values bigger than your actual value it will be moved to the bottom. This is just what you want,
so a value higher than the actual selection (U=17) is needed.

Zone 2: Optimizer printhead alignment check
This area shows the optimizer-to-color printhead alignment. The optimizer is referenced to the black ink. It
works exactly the same as Zone 1. However, there is a background color that highlights the presence of the
optimizer.
Zone 3: Scan-axis bidirectional alignment check
This area shows scan-axis bidirectional alignment between colors. As in the descriptions of the previous areas, in
case of misalignment the bottom arrows indicate the pattern of the manual alignment that will correct the
misalignment (I, J patterns). Also, the ‘40’ label indicates the direction in which the line will be moved if a ‘40’
value is applied. There are two areas for scan-axis bidirectional check, one for each speed (40ips and 50ips).
This pattern is formed by a series of vertical lines, printed unpaired as follows:
The correct bidirectional alignment has been found when the Fwd and Rev lines are perfectly aligned.
The following example shows a misalignment situation with an existing correction G=24, and how to correct it:

In this case, the diagram shows the need to change the value corresponding to the G pattern, it also indicates
that the correction needs to be moved towards lower values, because the ‘40’ value would move it in the wrong
direction.
Color calibration
Color calibration enables your printer to produce consistent colors with a particular substrate type, even if
printheads, ink cartridges, and environmental conditions change.
Color calibration sets the ink restriction and linearization, which varies with the drop weight of the printhead. This
calibration has been designed to provide consistency as the printhead ages (drop-weight degradation) and from
one printer to another. For example, to reach a maximum cyan density of 0.6, one printhead may require 3 drops
while another one may require 3.5 drops (lower drop weight).
There are no factory-reference color-calibration values in the printer or within the presets: the first calibration for
each substrate sets the color reference for future calibrations. The future calibrations will therefore try to match
the colors of the first calibration. In this way you maintain consistency as the printhead ages.
Good nozzle health is important, and the printheads should also be as new as possible for best performance
when you make the first calibration.
It is also important to have the printheads well aligned (see Align the printheads on page 450), and to make sure
the substrate is advancing correctly (see Substrate-advance compensation on page 460), otherwise the color
pattern may appear blurry or with slightly different colors.
To start color calibration from the Internal Print Server, select Substrate ►Color calibration, then click the
Calibrate button.
NOTE: Only non-porous substrates wider than 61 cm (24 in) can be calibrated. Porous substrates cannot be
calibrated.
NOTE: Color calibration is not recommended when the carriage beam is in a higher position than normal.
The calibration process is fully automatic and can be performed unattended after you have loaded substrate of
the type you wish to calibrate. The process takes about 15 minutes and consists of the following steps:
1. The color calibration test chart is printed, which contains patches of different densities of each ink used in
your printer.

2. The test chart is scanned and color-measured using the embedded spectrophotometer. If the scan cannot
be completed successfully, a message is displayed by the Internal Print Server; see ‘Color calibration fails’
in the user guide.
3. From the measurements made by the spectrophotometer, the printer calculates the necessary correction
tables to apply to your print jobs for consistent color printing on that substrate type—except in the case of
the first calibration, which sets the reference for later ones.
Calibration should be done in any of the following circumstances:
● Whenever a new substrate type is introduced that has not yet been calibrated: to set the reference.
● Whenever you notice excessive color differences between prints. Such color differences can be caused by
aging and wear of the printheads, installing new printheads, changes in substrate characteristics between
one roll and another, changing environmental conditions, and so on.
You can check the color calibration status of your substrates with the Internal Print Server: select Substrate
►Color calibration ►Show all.
● Default status indicates that this substrate has never been calibrated, and therefore no reference state is
defined.
● Done status indicates that a color calibration has been performed successfully on this substrate, the
reference state is defined and still up to date.
● Obsolete status indicates that the printer status has changed since the reference was defined, so a new
calibration must be done in order to maintain color consistency.
Color calibration is based on the color measurement of printed color patches, using the embedded
spectrophotometer. Some characteristics of substrates, such as surface roughness or transparency, may make

reflective color measurement of some substrate types very inaccurate. Color calibration of these substrates may
fail or produce unacceptable printing results.
TIP: If color calibration fails at the first attempt, it is worth trying again.
To delete the reference for a given substrate, so that you can create a new reference for that substrate, you
must reset the color calibration. In the Internal Print Server, select Substrate ►Color calibration ►Reset.
You should calibrate a substrate type before creating its color profile; however, you can later recalibrate without
needing to recreate the color profile.
Color consistency between different HP Latex printers

It is possible to print consistent colors on different HP Latex printers by exporting a calibrated substrate preset
(see user guide ‘Substrate presets‘) from one calibrated printer to another. This process ensures that both
printers use the same color references.
1. Create the reference for the first printer: do at least the first color calibration with the substrate in question.
2. Export the substrate preset from the first printer. The reference is also exported.
3. Import the substrate preset to the second printer.
4. Perform color calibration with the same substrate for the second printer, to make it consistent with the
reference imported with the preset.
Now both printers have the same reference for the same substrate, and all the consecutive color calibrations will
be trying to match this reference state.
Color profiles
Color calibration provides consistent colors, but consistent colors are not necessarily accurate. For instance, if
your printer prints all colors as black, its colors may be consistent but they are not accurate.
In order to print accurate colors, it is necessary to convert the color values in your files to the color values that
will produce the correct colors from your printer, your inks, and your substrate. An ICC color profile is a
description of a printer, ink, and substrate combination that contains all the information needed for these color
conversions.
These color conversions are performed by your Raster Image Processor (RIP), not by the printer. For further
information on the use of ICC profiles, see the documentation for your application software and for your RIP.
Substrate-advance compensation
Accurate substrate advance is important to print quality because it is part of controlling the proper placement of
dots on the substrate. If the substrate does not advance the proper distance between printhead passes, light or
dark bands appear on the print, and there may be an increase in graininess.
The printer has a substrate-advance sensor and is calibrated to advance correctly with most of the substrates
that appear in the Internal Print Server. When the substrate is loaded, the substrate-advance sensor checks the
substrate and decides whether it can be adjusted automatically or not. If not, the automatic adjustment is
disabled.
If the substrate cannot be adjusted automatically by the substrate-advance sensor and the substrate advance is
not correct, you may wish to change the substrate-advance compensation manually. See Image quality
troubleshooting on page 475 in the user guide for steps to determine whether substrate-advance

compensation will help you. In general, substrate-advance calibration is recommended when you see print-
quality problems related to substrate advance, or when you define a new substrate.
NOTE: Manual substrate-advance compensation is available only when the substrate-advance sensor is
disabled—automatically, or manually through the Printing adjustments button in the Internal Print Server main
window.
The substrate-advance sensor may not work correctly if it is dirty. See ‘Clean the substrate-advance sensor’ in
the user guide.
If the sensor was dirty, after cleaning it the advance compensation already calculated may not be valid, so you
are recommended to set the advance compensation for this substrate to zero and check that the advance is
correct. If the advance is still not accurate, follow the advance compensation process, bearing in mind that the
sensor is not dirty and probably your substrate type is not compatible with it.
Manual substrate-advance compensation

While printing, you can view and change the substrate-advance compensation of the currently loaded substrate
at any time from the Internal Print Server by selecting the print job and then the Printing Adj. button, or by
selecting Printer ►Printing adjustments.
Alternatively, you can use the Print adjustment button in the Internal Print Server main window. This opens a
dialog box with an advance compensation section, in which there are three main areas:
1. Check the box to enable the OMAS (substrate-advance sensor). If it is disabled automatically while loading,
you cannot enable it. However, if you disable it yourself, you can re-enable it.
2. If the substrate-advance sensor is disabled, you can increase or decrease the substrate-advance
compensation.
3. Three images of possible defects due to substrate-advance issues, to help to you decide whether the
substrate-advance compensation should be increased or decreased.
In order to apply and save the values, press the Apply button in the dialog box before closing it. Then the
substrate-advance compensation value is saved for that particular substrate. Other substrates are not affected.

If you are using a generic substrate preset, you are recommended to clone the preset (Substrate ►Clone) and
work with that before adjusting the substrate-advance compensation, as the print adjustment is not available for
generic presets. See ‘Edit a substrate preset’ in the user guide.
Substrate-advance test print

The substrate-advance test print can help you to adjust the substrate advance more accurately. In the Internal
Print Server, select Printer ►Advance calibration. The printer prints several repetitions of a special numbered
pattern that help you to apply the correct substrate-advance adjustment. Locate the pattern in the center of the
substrate.
The calibration pattern consists of several numbered columns.
Locate the lightest of the columns and enter its number as the advance parameter for the Printer ►Printing
adjustments dialog. The value chosen in this example should be −3.
Afterwards, reprint the test and fine-tune: increase the value if there is a thin dark line, decrease it if there is a
thin white line.
TIP: The value used for the substrate advance depends directly on the thickness of the substrate, and needs to
be changed only when you are suffering print-quality issues that are caused by the substrate advance, as
explained in ‘Substrate-advance sensor’ in the user guide. To obtain the right value faster and more accurately,
see the following table:
Normal substrate advance value based on substrate thickness
150 µm (5.9 250 µm (9.8 400 µm (15.7 550 µm (21.7 700 µm (27.6 850 µm (33.5 1000 µm
50 µm (2 mil) mil) mil) mil) mil) mil) mil) (39.4 mil)
+1.8 ‰ +0.9 ‰ 0 −1.0 ‰ −1.8 ‰ −2.7 ‰ −4.5 ‰ −6.8 ‰

Calibrations specific to one substrate preset

Some calibrations that the printer performs are specific to the substrate preset in use at the time the calibration
was performed and some are not. The calibrations that are specific to one substrate must be performed again if
the substrate or preset is changed. Shown below are the calibrations showing which ones are specific to one
preset and which ones are not:
● Printhead Alignment: This is applied to all presets and print modes. Usually, when switching from one
substrate to another, there is no need to realign the printheads. However, if the printhead-to-paper
spacing has changed significantly (different thickness, etc.), then the printheads should be realigned.
● Substrate Advance Compensation: This is specific to each substrate preset.
● Color Calibration: This is specific to each substrate preset.
Recommended calibrations after particular events

Printhead New substrate New substrate New substrate Print mode
replacement created imported loaded changed Poor print quality
Printhead Recommended Not needed Not needed Not needed Not needed Recommended if
alignment unless new unless carriage relevant
substrate has beam has moved
different
thickness
Color calibration Recommended Recommended Recommended Not needed, Not needed Recommended if
unless never relevant
done before
Substrate advance Not needed Not needed, as Not needed, as Not needed, as Not needed Recommended if
compensation long as the long as the long as the relevant
substrate- substrate- substrate-
advance sensor advance sensor advance sensor
is working is working is working
Tools and prints for service engineer

Service alignment check plot
The service alignment test plot is printed from Print Care diagnostics, in the Print Quality section.
Compared with the customer’s Verify alignment print, this one offers:
● Finer resolution (one-pixel lines)
● Printheads fired in one pass; total plot length is two passes
● No optimizer
The plot does not indicate how to correct the alignment; it is used to check finer problems, after which you
should rerun the alignment to fix them. It can also be used to check for skew.
Substrate-advance sensor pixel-size calibration

See Theory of operation (roll-to-roll configuration) on page 28 for background information about the substrate-
advance sensor.

Substrate-advance sensor pixel-size calibration is executed from Print Care diagnostics, in the substrate-
advance sensor section. It may be done automatically or manually; the automatic process is not available with
early firmware releases.
The second step consists of reprinting the same plot to check that the entered values have properly calibrated
the sensor.
The plot is similar to the substrate-advance adjustment plot: see Substrate-advance test print on page 462. It
should be printed on self-adhesive vinyl, preferably HP Permanent Gloss Self-adhesive Vinyl or a similar
material. It consists of a series of interference patterns:
1. From the image, pick the last portion of the most central pattern, which is usually the one that is closest to
the substrate-advance sensor.
2. In the pattern, disregard the incomplete areas and look at the last eight complete passes.

3. Locate the lightest column and, in the diagnostic test dialog boxes, enter the correction for each of the
eight passes. If there are two equally light columns, for example +3 and +4, the dialog boxes have an
option for entering both values: “3-4” instead of “3” or “4”.
4. The firmware uses these values to calculate the pixel size of the current sensor.
Enable or disable the substrate-advance sensor

A service engineer can disable and re-enable the substrate-advance sensor from Print Care diagnostics, in the
substrate-advance sensor section. Select Disable advance sensor or Enable advance sensor. Disabling the
substrate-advance sensor can be useful to check whether the sensor is faulty and producing random advance
errors. Follow these steps:
1. Print the substrate advance adjustment plot (see Substrate-advance test print on page 462).
2. Look at the last portion of the three most central patterns. The lightest column should be in approximately
the same position in each case (±1). If this is not the case, the substrate roll is skewed and should be
reloaded properly.
3. If there is no skew, focus on the most central pattern.
4. If the sensor is not working properly, random errors will appear as abrupt changes in the lightest of the
columns.
5. Disable the substrate-advance sensor and reprint the plot. Now there should be a clear lightest column,
possibly not at “0” but at least constant.
If you find a problem, clean the substrate-advance sensor and retry, before replacing it.
NOTE: Disabling the substrate-advance sensor is not permanent: after restarting the printer, the sensor will be
enabled again.
Scan-axis encoder strip check

The scan-axis encoder strip check is printed from Print Care diagnostics, in the Print Quality section.
This plot shows the printhead-to-printhead registration along the scan axis. The error is revealed by means of an
interference or vernier pattern that spans the whole scan axis of the printer. The plot can be printed only on
substrates of maximum width (at least 125 inches) to ensure a complete check of the scan axis.
In general, the registration between colors should not show abrupt changes. A smooth variation along the scan
axis is expected; the main cause is substrate expansion.

Abrupt changes signal serious problems with the scan-axis encoder strip.
In the cyan band, a faulty encoder strip causes glitches about 3 mm apart that correspond to the printhead
arrays.
In the yellow and magenta band, the abrupt glitches measure about 120 to 125 mm apart.
Generally, you should always find both of these glitches when there is a problem with the encoder strip.
NOTE: If you recognize both of these patterns in the same plot, even slightly, replace the encoder strip. See
Impelling encoder strip (K4T88-67044) on page 916. This problem should not be tolerated.

Basic printer check for correct printing

The following tests will help set the printer in a correct status to print with good image quality, as it is a review
and set of the main subsystems directly related to the output quality. For more information related to any of the
subsystems, please refer to the corresponding chapter on the Service Manual.
Requirements:
● inspection to be done by a trained Customer Experience
● material required:
– Roll of HP self-adhesive vinyl, or at least on self-adhesive vinyl
– Just in case, one set of new set of Printheads
– Up to date documentation (user guide, installation guide, etc.) and FW, Print Care and IPS
Items to test:
● Ensure the printer is in the ready status
● Extract the service plot and check the contents
● Load the substrate
● Do a hard cleaning on all Printheads (to ensure the best possible Printhead quality) (could take 15 - 25
minutes)
● Print the pre-ripped file (refer to the installation guide) in 6 and 8 pass. Use this image as a reference file to
compare results after completing the check.
● Run the diagnostic test Show sensor status (50005)(OMAS section, see Table 5-8 Substrate-advance
sensor (OMAS) on page 559), and ensure that the OMAS is fully working.
● Run a Check Height and tilt Calibration (47005) and calibrate height if needed (see Table 5-16 Printhead
cleaning on page 580.
– Check that there is no white line as in the example below.
ENWW Basic printer check for correct printing 467

In the case of white lines, check the homogeneity of the upper part of the blade by passing your
finger along all the length of the blade as follows:
○ The printer must be in ready status
○ Open the Printhead cleaning assembly by opening the latch, loosen the cleaning material so
that you can pass your finger under the material.
If it is rough in the same location as the white line, replace the blade.
● Move the carriage to the service position and switch off the printer.
● Check the printer is clean. See Summary of maintenance operations on page 1467:
– Clean the OMAS
– Clear print platen if needed.
– Check encoder strip of scan axis: clean it by pointing the air pressure run to the encoder strip (you first
need to remove the cover of the encoder).
– Check (and clean scan axis rods if needed). The Carriage rail cleaning will be done later when
restarting the printer.
– Check under the carriage to see if is clean.
– Check vapor removal system — make sure it is clean and there is no condensation.
– Weigh each intermediate tank by hand to confirm that all each has approximately at least 500g — no
intermediate tank should be empty.
– Clean drive roller if needed.
● Restart the printer (with a new blade if the defect described above was detected).
● Run the 100l maintenance, to ensure good lubrication of the scan axis rods.
● Load the substrate.
● Check that the scan beam can lift up and down (from the IPS).
● Check the drop detector and printhead nozzle health:

– Print the nozzle check, from the IPS: Printer ►Printhead cleaning ►Verify printhead status.
– Once curing is done, from Print Care: Diagnostics ►Capping/Drop Detection ►Force drop detection
(52005).
Compare the results from the number of nozzles out displayed on the screen and the real number of
nozzle out visible from the previous printer plot (verify printhead status). The number should
approximately match — It will not be a 100% match.
● Check printhead alignment: Printer ►Printhead alignment ►Verify alignment ►Print. See Align the
printheads on page 450.
● Check the substrate advance from the IPS: Printer ►Advance calibration ►Plot.
● Reprint the flower plot, pre-ripped file in 6 and 8 passes (refer to the installation guide).
● Check the image quality. When inspecting the print, observe that there are no defects from a viewing
distance of one meter if printing with six or eight passes, or from three meters if printing with four or five
passes. Should any defect appear diagnose it using the recommendations in the Image quality
troubleshooting on page 475.
Ink density vs number of paths
ENWW Ink density vs number of paths 469

* Non-porous textile or canvas. See ‘Check the porosity of your substrate’ in the user guide.

Media path troubleshooting

Media advance main checks and calibrations (media path)
Before starting with the media advance troubleshooting and calibrations is interesting to perform some
hardware checks to verify that all the components involved in Media Advance are working correctly.
Hardware checks
MI/MO Motors
● Check if there is any strange noise related to the motor and transmission movement.
● Check that the motors are correctly tighten to the Side plates.
● Check if there is any degradation on the Side plate gear. Check if there is clearance between the gear and
the shaft.
● Check if there is any damage on the Encoder disc.
● Check that the cables are correctly connected.
Media drive motor
● Check if there is any degradation on the Drive roller gear.
● Check if there is remaining grease between the worm gear and the Drive roller gear.
● Check if there is clearance between the Media drive mounting structure and the printer’s Side plate.
● Check if there is any damage on the Encoder disc.
● Check that the cables are correctly connected.
Spindles
● Make sure the core is reliably fixed on the spindle by air pressure, otherwise there can slip affecting the
required front tension of the substrate.
● Check if there is any degradation on the Spindle gear.
Side plates
● Check that the Side plates are correctly tighten to the stand structure.
● Check if there is any damage on the Spindle latch.
● Check that the Upper bearing is correctly adjusted.
Pinch assembly
● Check that there are no broken Pinch wheels.
● Verify that there is contact between the Pinch assembly and the Drive roller.
Vacuum
● Check that the Vacuum blower is working.
ENWW Media path troubleshooting 471

OMAS
● Check using the IPS OMAS display to verify if the OMAS is working or not.
If any of these issues has appeared, please find the proper information in this Service Manual or contact with
your Service representative Team.
Adjustment checks
After performing the Hardware checks, please make sure that the printhead alignment has been done reliably.
For calibration purposes, Self-adhesive vinyls such as Avery MPI3001 or HP Permanent Gloss self-adhesive vinyl
are suitable.
Please make sure that you use the substrate advance check bars on both sides of the image to help you
diagnose if the advance is working correctly. You can add them on the Add job window as a nesting. Path: C:
\Users\hplatex\Documents\HP IPS\Advance Calibration. Choose the suitable resolution for
your job, 150-300 or 600 dpi.
Main checks before troubleshooting the advance:
1. Check that the tensions and the vacuum are balanced and according to the media type:
2. Check whether the media is advancing correctly or not:

a. With the advance bars on the side of the image, diagnose and determine if there is an advance issue
or not.
b. You can also run Advance calibration from the IPS and read if the lightest line is centered on zero. If
the line is not centered or is moving cyclically, execute the Print Care OMAS tests described bellow.
3. Check if OMAS is navigating the substrate on the print area:
a. Make sure the OMAS window is clean (this is part of the weekly maintenance as well). The operator
can use isopropyl alcohol for cleaning. To check if it is clean, run the Cleanliness check (50003) test in
Print Care.
b. Check that the OMAS is working (check for the light in the OMAS to work during print). If OMAS has
problems to navigate the substrate, there will be no warning message in the monitor. You can run the
Show sensor status (50005) test in Print Care to check this.
c. If you think that there are problems with OMAS:
i. Disable OMAS: run the Disable advance sensor (50002) test.
ii. Print test prints and check for quality defects, compare against former results with OMAS
enabled.
Calibrations
If the OMAS is still not working correctly, perform the following calibrations in this order (all media path):
1. Calibrate all the motors in the substrate path: Motor calibration (41004) (MI/MO/MF), run without spindles.
2. Run the Encoder calibration (41005) - MA.
3. Substrate goes to substrate advance roller
a. Make sure that the substrate advance roller is clean (this is part of the weekly maintenance). The
operator can use isopropyl alcohol to clean it.
b. Make sure that the analog drive roller sensor is clean and not damaged.
c. Perform the drive roller calibration: Drive roller calibration (41006).
d. Perform the drive roller calibration check (this will fine-tune the substrate advance): Drive roller check
(41007).
4. OMAS
a. Calibrate OMAS once all the other mechanics have been calibrate: diagnostic (50004).
b. If not working: replace OMAS.
Calibration name What it does When to run calibration
Analog encoder Calibrates electronic analog offset and gain of the Encoder disc and PCA replacement
calibration (41005) encoder PCA
MI-MO calibration Calibrates the main characteristics of the motors ● MI-MO replacement
(41004)
● Substrate-advance problems
OMAS calibration Corrects OMAS pixel-to-microns size and nominal OMAS replacement
fiducials distance
ENWW Media path troubleshooting 473

Drive roller calibration Corrects drive roller eccentricity ● Drive roller replacement
(41006)
● Encoder disc and PCA replacement, after
analog encoder calibration
Drive roller calibration Checks OMAS readings against encoder readings, ● MA motor replacement
check (41007) applying current calibration values to verify that drive
roller eccentricity is corrected, and fine-tuning the ● After OMAS calibration
(available to roller’s slope factor.
customers) ● After drive roller calibration

Image quality troubleshooting

General advice
The HP Latex 1500 printer has been designed and qualified to the highest standards to provide the optimal
compromise between print quality and productivity. Prints for outdoor use can accommodate more visible
defects as they are viewed from a long distance. For shorter distances, as in indoor advertising, defects need to
be less visible. To decide whether a defect is considered acceptable, as a rule of thumb, the table below shows
the appropriate viewing distances.
Print mode m²/h ft²/h To view output at…
3 pass (outdoor) 74 800 3m–5m
4 pass (outdoor plus) 57 610 3m–5m
6 pass (indoor high quality) 45 480 1m–3m
You are recommended to review the acceptability of a defect according to this table before proceeding to
diagnose it to make sure the selected print mode is the most appropriate for the purpose of the job. Increasing
the number of passes to 8 or more enables higher ink quantities if needed and/or the use of difficult printing
materials thanks to the longer drying and curing times. Print modes with more passes are more resistant to
banding. In general, follow these recommendations:
● Avoid touching the substrate while printing is in progress.
● Judge the print quality after the print has completely emerged from the printer. In some cases, defects
seen while printing disappear after the image is completely cured.
● Check that the environmental conditions (room temperature and humidity) are in the recommended range.
See the User Guide: Environmental specifications.
Before troubleshooting, check the following points:
ENWW Image quality troubleshooting 475

● To achieve the best performance from your printer, use only genuine HP supplies and accessories, whose
reliability and performance have been thoroughly tested to give trouble-free performance and best-quality
prints.
● Check that the substrate type selected in the Internal Print Server is the same as the substrate type loaded
into the printer.
CAUTION: If you have the wrong substrate type selected, you could experience poor print quality and
incorrect colors, and perhaps even damage to the printheads.
● Check that you are printing on the right side of the substrate.
● Check that you are using in the RIP software the correct substrate preset, which includes the ICC profile for
your substrate and print mode.
● Check whether there are any outstanding printer alerts in the Internal Print Server. React to the alert as
instructed in this guide.
In particular:
● Make sure the substrate is flat and has no wrinkles. See the User Guide: Troubleshoot substrate issues.
● Check that the substrate has no skew or telescoping. Check that you are loading the substrate using the
correct process. See the User Guide: Load a roll into the printer.
● For color consistency issues, check that the color calibration was performed when the substrate was added
to the Internal Print Server. See the User Guide: Use a new substrate.
● Make sure it has also been performed in the current conditions, especially considering substrate batch and
printheads. See Color calibration on page 458.
Basic and advanced troubleshooting

The print-quality troubleshooting process is divided here, for convenience, into two levels: basic and advanced.
● Basic troubleshooting will help to resolve the majority of the typical print-quality issues related to banding,
graininess, and printhead alignment.
● Advanced troubleshooting helps to resolve the above issues when the basic steps did not work, but it also
covers other possible print-quality defects, diagnosis, and resolution.
Basic print-quality troubleshooting

1. Identify the defect. This basic procedure applies to the following defects:
● Horizontal banding
● Graininess
● Color misalignment
– Blurred lines, edges, and text, horizontally and vertically
– Halo of a different color around color lines and at the edges of color areas or text
– Ink bleeding or wicking or different gloss at the edges of color areas
2. Perform the actions described in the following table.

Printhead check and Substrate-advance Possible causes (for

Defect clean sensor check Printhead alignment reference only)
Horizontal banding X X X ● Blocked nozzles
● Substrate advance
accuracy
Isolated bands (usually of X ● Substrate-advance

different texture or grain) accuracy and
navigability
Graininess X X ● Substrate advance

accuracy
● Color alignment
Blurry edges or text lines, X X ● Substrate advance

horizontally accuracy
● Color alignment
Blurry edges or text lines, X ● Color alignment

vertically
Color halo on objects X ● Color alignment

(e.g., magenta shows up
under a blue line)
Ink bleeding, wicking, or X ● Optimizer

different gloss at the alignment
edges of color areas
Printhead check and clean
See the User Guide: Check and clean the printheads. The check and clean process will check the printheads,
recover the ones with blocked nozzles, and replace the nozzles that are not recovered with healthy ones for
printing.
Substrate-advance sensor check
Run the OMAS Diagnostic Test from the HP Print Care window.
NOTE: OMAS stands for Optical Media Advance Sensor, usually known as the substrate-advance sensor in this
guide.
The test will tell you whether the substrate-advance sensor is working correctly or not (either dirty or damaged).
If the substrate-advance sensor is dirty, clean the sensor. See the User Guide: Clean the substrate-advance
sensor.
Even if the sensor is working correctly, the substrate may not be navigable, meaning that the substrate-advance
sensor cannot see it properly (as in the case of transparent substrates or substrates with very smooth back
side). In this case, the substrate-advance sensor disables itself automatically. You are then recommended to
adjust the substrate-advance compensation: see Substrate-advance compensation on page 460.
For best results, cleaning the substrate-advance sensor is included in the printer’s weekly maintenance.
Printhead alignment
Automatic alignment is recommended. See Automatic alignment procedure on page 450.

In case you want to perform manual printhead alignment, see Manual Alignment procedure on page 451.
The result of the alignment can be verified with the printhead alignment diagnostics plot. See Printhead
alignment diagnostics plot on page 455.
Advanced print-quality troubleshooting

If the basic print-quality troubleshooting does not solve the problem, here are some further procedures that you
can try.
One of the most important parts of print-quality troubleshooting is to ensure that the printheads are healthy.
See Printhead health troubleshooting on page 514.
Print-quality artifacts troubleshooting
Horizontal banding
Horizontal banding means that your print suffers from added horizontal lines or bands, in a regular pattern. They
can look different depending on the cause.
Thin dark lines
These are thin dark lines across the entire image with certain frequency, more easily seen in solid area fills.
There are two likely causes:
● Printhead alignment. This is a clear contributor to banding. If printheads are not correctly aligned, the
misplaced dots could correlate directly with the severity of the banding, by putting more ink in the same
place and thus creating darker lines.
To check printhead alignment, print the printhead alignment diagnostics plot (see Printhead alignment
diagnostics plot on page 455). As a general rule, the biggest contributors to thin-dark-line banding caused
by printhead alignment are (in this order):
– Inter-color alignment (alignment between different colors)
Here are some tips for solving this problem:
– If the printhead alignment was done with a different substrate of different thickness, probably a new
printhead alignment is needed.
– Fine-tune the alignment by identifiying the offenders in the printhead alignment diagnostics plot. See
Automatic alignment procedure on page 450.
● Substrate advance. Before trying to adjust any parameter, make the following checks:
– Check that no substrate-advance factor was set earlier that could prevent the substrate-advance
sensor from working correctly.
– Run the diagnostics to check that that the substrate-advance sensor is not dirty.
If the substrate advance is not well adjusted, particularly if it is under-advancing, a dark line can appear
between passes.
A clear symptom of this is when the dark lines appear across all colors, because the cause is common to all
of them. To confirm it, in the Internal Print Server, select Printer > Advance Calibration to check the
substrate advance. See Substrate-advance test print on page 462.

You can usually correct this problem by adjusting the substrate advance compensation (see Substrate-
advance compensation on page 460). However, you are recommended to run the OMAS Diagnostic Tests
from the Print Care window as soon as the substrate is unloaded, to avoid having the same problem with
other substrates. See the User Guide: Clean the substrate-advance sensor.
If the problem persists, try adjusting tension and vacuum settings according to the table below, step by
step (a to c), until you find settings that work.
Thin white lines
These are thin white/light lines across the entire image at regular intervals, more easily seen in solid area fills.
There are three likely causes:
● Nozzle clogging. A printhead nozzle can be sealed temporarily, by some fibers or dirt in the ink bore. Then
not all the ink is fired and a lighter horizontal band appears. Sometimes a bigger drop with all the
accumulated ink appears at the end of this light thin line, meaning that the bore is clear then. See
Printhead health troubleshooting on page 514.
misplaced dots could correlate directly with the severity of the banding, by leaving lighter bands where the
ink should have been placed.

diagnostics plot on page 455). As a general rule, the biggest contributors to thin-white-line banding caused
by printhead alignment:
– Execute automatic alignment.
– Fine-tune the alignment by identifying the offenders in the printhead alignment diagnostics plot. See
– Run the diagnostics to check that the substrate-advance sensor is not dirty.
If the substrate advance is not well adjusted, particularly if it is over-advancing, a white line can appear
between passes.
A clear symptom of this is when the white lines appear across all colors, because the cause is common to
all of them. To confirm it, in the Internal Print Server, select Printer > Advance Calibration to check the
substrate advance. See Substrate-advance test print on page 462.

Bands of light and dark zones
These are periodic horizontal bands formed of a lighter band and a consecutive darker band. This pattern is
mostly seen in solid color area fills (such as light purple or gray).
● Coalescence. This is due to an excessive amount of ink, and the ink being misplaced as it is deposited on
the substrate, generating bands with more ink than other alternate bands. It can also be caused by firing
too much ink in a short time. Coalescence is most likely to be seen in areas of high ink density.
– Use lower ink density.
– Increase the number of passes.
– Change the type of mask (large/small).
misplaced dots could correlate directly to the severity of the banding.
diagnostics plot on page 455). As a general rule, the biggest contributors to light-and-dark banding caused
by printhead alignment are (in this order):
– Bidirectional alignment
– Execute automatic alignment.

When the substrate advance is incorrect, some light and dark horizontal bands can appear from the
misplacement of the ink.
To confirm it, in the Internal Print Server, select Printer ►Advance Calibration to check the substrate
advance. See Substrate-advance test print on page 462.
Gloss banding
This appears in dark, high-density areas as horizontal gloss or matte bands about 1 cm wide. It can happen
when the curing system settings are not correct for the substrate.
If the bands are more apparent when tilting the print or changing your viewing position, then it is likely to be
gloss banding.
To solve the problem, check your curing settings (airflow, curing temperature). You could also try using a
different print mode.
Aeroworms
Aeroworms consist of thin bands with higher density than the surrounding area. They are about 6 cm long and
have a horizontal tendency, but they tend to curve like worms. They are not continuous across the substrate,
and seem to appear at random.

When the ink is being fired, there are airflow turbulences under the carriage that can affect the positioning of the
drops. Therefore, some waves of ink can be formed and deposited on the substrate to create this effect.
● Increase the number of passes.
● Reduce the ink density.
● Check the printhead-to-ribs spacing in the Internal Print Server. If it is higher than normal, try reducing it.
● Check that the aerosol filters are not saturated or broken. See the User Guide: Replace the aerosol filters.
Vertical banding
Vertical banding means that your print suffers from added vertical lines or bands, in a regular pattern.
Microbanding
This consists of vertical lines less than 2 mm (0.08 in) wide, of very high frequency, that appear in some area
fills. Often they are hardly visible.
Microbanding is probably caused by a faulty printhead. Print the printhead alignment diagnostics plot (see
Printhead alignment diagnostics plot on page 455) to find which printhead is responsible, and replace the
printhead.
Wide bands 2 cm apart
If the bands are about 2 cm (0.8 in) apart, it means that the substrate is well controlled in the print zone and is in
contact with all the ribs in the platen as intended. However, if the suction is too high, a difference in grain can be
seen, and bands appear 2 cm apart.

● Align the printheads.
● Check the scan-beam height in the Internal Print Server. If it is higher than normal, try lowering it.
● Decrease the drying temperature to reduce deformation.
● Change from 4 to 6 colors to reduce grain.
● Decrease vacuum and tension settings according to the table below, step by step (a to c), until you find
settings that work.
Wide bands at least 4 cm apart
A small amount of vertical banding (like waves) can be seen, with a frequency from about 4 cm (1.6 in) to 10 cm
(3.9 in), when printing large area fills of the same color.
The substrate is not in contact with all the ribs in the platen, which means that it is not fully controlled, so wide
wrinkles appear on the print zone. As the height of the printhead above the substrate varies, there are local
differences in grain that can be seen as lighter or darker wide bands (see picture). To solve this, it is important to
improve substrate control in this zone and reduce the wrinkles.

● Check the scan-beam height in the Internal Print Server. If it is higher than normal, try lowering it.
● Align the printheads.
● Decrease the curing temperature to reduce deformation.
● Change from 4 to 6 colors to reduce grain.
● Increase vacuum and tension settings according to the table below, step by step (i to iv), until you find
settings that work (by improving control in the print zone).
Color misalignment
Colors appear misaligned. Typically, lines and text are most affected by this issue.
It can happen in both axes: the substrate axis and the scan axis.

Color misalignment is most likely to be caused by printhead misalignment. To check printhead alignment, print
the printhead alignment diagnostics plot (see Printhead alignment diagnostics plot on page 455).
Bleed, halo, wicking
Sometimes a small color migration may be observed at the border between different colors (bleed). It may also
happen at the border between a color and blank substrate (no ink), reducing the sharpness of the shape. On
some substrates, a gloss halo can be observed at the border between colors.
● Optimizer misalignment: There may be misalignment between the optimizer printhead and the other
printheads. To check the printhead alignment, print the printhead alignment diagnostics plot (see Printhead
alignment diagnostics plot on page 455). If necessary, perform a manual alignment, then reprint the
printhead alignment diagnostics plot.
If the problem is in the substrate axis direction, it may also be caused by incorrect substrate advance. See
Substrate-advance test print on page 462 and Substrate-advance compensation on page 460.
● Optimizer level, which may be too low for this substrate and ink density. Other associated defects may also
appear, such as coalescence or grain in the area fills due to low wetting of the ink on the substrate. You can
correct this problem by increasing the optimizer percentage in the substrate preset.
● Drying temperature, which may be too low for this substrate and ink density. Other associated defects may
also appear, such as coalescence or grain in the area fills due to low wetting of the ink on the substrate.
You can correct this problem by increasing the drying temperature in the substrate preset.
Low gloss, haze
On glossy substrates, the print may have lower gloss than expected, which is probably due to the optimizer level.
To investigate and correct this problem, try increasing and decreasing the optimizer percentage in the substrate
preset.

Color accuracy
Ideally, the colors that you see on the screen should match the colors in the print. In practice, you may find that
the colors are not sufficiently accurate. There are three possible causes:
● Color calibration provides consistent colors, but consistent colors are not necessarily accurate. However, if
the combination of substrate and printheads has not been calibrated recently (or ever), that is a possible
source of color inaccuracy. You can eliminate the possibility by performing a color calibration (see Color
calibration on page 458).
● ICC profile. If you are using the wrong profile, your colors are likely to be inaccurate. Check which profile you
are using. If necessary, you can make your own ICC profile for the printer, printheads, print mode, and
substrate that you are using.
● Ink density, which affects color saturation. If the color saturation of your print seems wrong, try changing
the ink density in the substrate preset; you may need to change the number of passes at the same time.
Local color variations
In some cases, at the edges of area fills, a small number of ink drops may be missing or slightly darker,
producing a local color variation.
These defects are due to the printheads travelling from side to side without printing.
● In each pass, the first 1 or 2 drops of a color are missing or smaller.
● In each pass, the first 1 or 2 drops of a color are darker because they are more concentrated with pigment.
To resolve these defects, add spit bars at each side of the image, to make sure nozzles are refreshed before
printing each pass. If possible, you could also rotate the image to avoid situations such as shown in the example.
Color variations when tiling

When tiling, it is important that all tiles have the same length and that the colors of the mating edges match.
This section focuses on color variations; for recommendations about length consistency. See the User Guide:
How to achieve better consistency between jobs of the same length.

Possible causes
● Uniform variations from tile to tile. When color changes uniformly it must be within the color consistency
specification; see the User Guide “Color consistency” for more details. Usually grays are much more
sensitive: differences of much less than 2 dE 2000 may be visible, although other colors would not show a
difference.
● Small color variation left to right. The tile itself looks uniform, but when putting it beside the adjacent tile
the differences become visible.
● Local color variations. See Local color variations on page 487. Sometimes these defects become visible
only when printing tiles, showing in one of the tiles but not in the adjacent. They are also more visible when
printing grays.
Possible solutions
● Try to ensure uniform printing of all tiles, and all tiles printed in the same run.
● Rotate every other tile, to compensate for left to right differences.
● Adding spit bars at both sides of the image helps overall, especially when there are local color variations.
Edge roughness, text quality
The edges of objects may appear rough or blurred; this is especially noticeable in text.
There are five possible causes:

● Bleed: see Bleed, halo, wicking on page 486.
● Printhead alignment. As ink could be deposited by a combination of different colored printheads, it is

important that all printheads are correctly aligned. To do so, print the Printhead alignment diagnostics plot
on page 455, and correct any misalignment.
– Run the diagnostics to check that the substrate-advance sensor is not dirty.
If the substrate advance is incorrectly adjusted, particularly if it is under-advancing, a dark line can appear
between passes. When the problem of line roughness or text quality applies to all colors and appears in the
substrate axis direction, it is likely to be related to incorrect substrate advance. Another clue that could
point to substrate advance as a cause is to observe that the defect is not constant, appearing and
disappearing along the print in the substrate axis.
To confirm it, go to the Internal Print Server and select Printer ►Advance Calibration to check the substrate
advance. See Substrate-advance test print on page 462.
To correct the substrate advance, see Substrate-advance compensation on page 460. In most cases, this
will solve the problem. However, you are recommended to run the OMAS Diagnostic Tests from the Print
Care window as soon as the substrate is unloaded, to avoid having the same problem with other
substrates. See the User Guide: Clean the substrate-advance sensor.
● Printhead-to-ribs spacing. Check the printhead-to-ribs spacing in the Internal Print Server. If it is higher
than normal, try reducing it.

● Vacuum. In some thin substrates, if the vacuum is too high, the substrate follows the shape of the platen
ribs, modifying the printhead-to-substrate spacing and causing vertical line roughness. In this case, as the
substrate advances, vertical lines get wider after each pass, while horizontal lines are not affected.
To correct this problem, try adjusting tension and vacuum settings according to the table below, step by
Graininess
The print shows a higher level of grain than expected, either throughout the print or in some specific areas. The
example below shows more grain in the lower half than in the upper half.
This can occur for various different reasons.
● Coalescence. Some substrates, in some particular conditions, can produce a type of grain due to wetting
issues. For example, in high humidity or low temperature environments, the ink may not dry fast enough in
fast print modes, producing a grainy effect on the print. The example below shows worse coalescence on
the right-hand side.

It is difficult to decide whether this kind of problem is due to wetting or to dot placement error (described
below). The type of grain could be a clue: in the case of wetting issues, dots tend to aggregate into bigger
dots, with empty spaces in between. A magnifying glass can be useful to examine the print in more detail.
– Increase the optimizer level.
– Increase the drying temperature.
– Increase the number of passes.
– Change from 6 to 4 colors (less ink on the substrate).
● Printhead alignment. This is a clear contributor to grain. If printheads are not correctly aligned, the
misplaced dots could correlate directly with the severity of the graininess.
diagnostics plot on page 455). As a general rule, the biggest contributors to grain caused by printhead
alignment are (in this order):
– Bidirectional alignment
Grain in a print can be increased by incorrect substrate advance, due to mispositioning of the dots.
To check the substrate advance, go to the Internal Print Server and select Printer ►Advance Calibration.
See Substrate-advance test print on page 462.
To correct the substrate advance, see Substrate-advance compensation on page 460. In most cases, this
will solve the problem. However, you are recommended to run the OMAS Diagnostic Tests from the Print

Care window as soon as the substrate is unloaded, to avoid having the same problem with other
substrates. See the User Guide: Substrate-advance test print.
● Substrate wrinkles. If you see patches of high grain in some local areas of the print, this could be caused by
wrinkles in the substrate. See the User Guide: There are wrinkles and ink smears on the substrate.
● Color usage. In general, 4-color printing produces more grain than 6-color printing.
Physical deformation marks

You may occasionally see physical deformation of the substrate. This issue is not a mispositioning of the dots,
but a physical deformation of the substrate that usually occurs after the dots have been printed. There are
various kinds of deformation that may occur:
● Diverter horizontal marks: Deformations of the substrate in the shape of straight lines (about 6 cm long)
towards the printed side of the substrate. They are separated about 2 cm vertically and 1 cm horizontally.
● Diverter vertical marks: These physical marks have the appearance of a braid. They consist of small
wrinkles just below the curing module, forming a vertical line of small deformations.
Both kinds of deformations can be the result of an excessive curing temperature. See the User Guide: There are
physical marks on the substrate.
Poor curing
When the heat applied to the printed substrate is not enough for the quantity of ink laid down, the print may
appear wet or with some gloss marks. The heat needed to cure is directly dependent to the combination of: ink
density, time under the curing module (printmode), curing temperature, airflow, and drying power. These are the
defects you may see:
● Perforated plate gloss marks: The print suffers from an added matte pattern over the areas with more ink
density. You can see small circles scattered over the picture with different levels of gloss.

● Wet print: The ink comes out of the curing module not perfectly dry, and in severe cases the ink can be
smudged by touching it.
Here are some tips for solving both problems:
● Increase the curing temperature and/or airflow.
● Decrease the ink density.
● Reduce throughput.
● Repeat the Add New Substrate procedure in case you had wrong settings in the substrate preset.

Printhead and ink cartridge troubleshooting

Ink cartridges
Cannot insert an ink cartridge
1. Check that the cartridge is designed for your printer.
2. Use the correct procedure to change ink cartridges, through the Internal Print Server. See Remove an Ink
Cartridge in the user guide.
3. Check that there is no obstruction in the ink cartridge connector.
4. Check that the ink cartridge is of the correct color. A connector will refuse to connect to a cartridge of the
wrong color.
5. Check that the ink cartridge is correctly oriented (compare with the others).
The Internal Print Server does not recognize an ink cartridge

1. Ensure that you have inserted the cartridge correctly and fully. You should hear a click.
2. Ensure that the tabs on each side of the cartridge connector are opened but in place, showing a successful
connection.
3. If the problem persists, check the ink cartridge connector (see Bent ink cartridge connector on page 494).
4. If the problem still persists, call your service representative (see LogMeIn rescue on page 1400).
The Internal Print Server recommends replacing or reseating an ink cartridge

1. Disconnect the ink cartridge.
2. Reconnect the ink cartridge and check the Internal Print Server message.
3. If the problem persists, check the ink cartridge connector (see Bent ink cartridge connector on page 494).
4. If the problem persists, insert a new ink cartridge.
5. If the problem still persists, call your service representative (see LogMeIn rescue on page 1400).
Bent ink cartridge connector

You may find that the ink cartridge connectors have become bent while the cartridge was disconnected (see
Remove an Ink Cartridge in the user guide). This means that they cannot connect properly, and you will see a
reseat message.
To correct this problem, use pliers to straighten the connectors so that they will fit into their slots.
Printheads
Cannot insert a printhead
1. Check that you are inserting the printhead into the correct slot.
2. Use the correct procedure to change printheads, through the Internal Print Server. See Remove a printhead
and Insert a printhead in the user guide, bearing in mind the special tips for the optimizer printhead.

3. Check that there is no obstruction in the printhead slot.
4. Check that the printhead is correctly oriented (compare with the others).
Printhead reseat errors

Printhead Reseat error messages indicate an error condition that prevents the heads from proper performance.
There are many causes or factors that can trigger these error messages. This section describes the steps to
perform basic troubleshooting to identify and fix the cause of the errors.
1. When a printhead reseat message appears, the first action is to perform a specific diagnostic test in Print
Care to gather detailed information on the internal cause: Diagnostics Printhead Control Link (These tests
can be run by the printer operator).
IMPORTANT: These diagnostic tests must be run while the RESEAT error is still active in the IPS Error
Window or the condition is still present, and not after the error has been cleared.
Figure 4-4 Printhead Control Link diagnostic test
● Run all the tests 11001, 11002, 11003, 11006. If any of the tests fail, please call your support
representative.
ENWW Printhead and ink cartridge troubleshooting 495

● Take a screenshot of the result of the last test: Printhead electrical status (11006).
NOTE: This test will perform an internal check on the printheads and try to determine the cause of
the printhead reseat error.
Figure 4-5 Result of the Printhead electrical status test results
2. Collect the internal logs and prepare them to be delivered to your service provider. If unsuccessful, call your
service provider to perform this task for you. See LogMeIn rescue on page 1400.
3. Check electrical connections/printhead board:
● Clean printhead electrical connections. You can follow the instructions in:
– HP Print Care Maintenance Wizard: Clean Printhead Pocket and Printhead Electrical Contacts.
– User guide, chapter Hardware maintenance: “Clean the printhead contacts”.
● Once cleaned, reseat the printhead placing a new printhead in the slot.
– If the problem is still present, call your service representative (may be electrical board related).
– If the problem is gone, continue printing. If it appears again, call your support representative.
4. Check the preliminary data (the printhead electrical status result and the steps previously executed by the
operator). If the printer operator did not execute any of the actions, start with step 1. Remember to collect
the internal logs if the operator did not do it correctly (step 2), and prepare them to be shared with GBU CA.
5. Check the Print Care error log for errors of a possible jam. If there are Possible Jam errors triggered
occurrences, it is a direct cause for reseats. Actions to prevent or minimize these crashes should be
performed, such as substrate settings check and proper edge holder usage.
6. Web Wipe Z check through Print Care:
● First check the Z calibration and take a picture of the Initial calibration (lines on the wiper roll). Go to
Diagnostics ►47. Printhead cleaning roll ►47005: Printhead cleaning Z calibration check.

● Calibrate the Web wipe: Diagnostics ►47. Printhead cleaning roll ►47006: Set printhead Z
calibration. Follow the instructions on the screen until you see 4 lines. Take a picture of the final
calibration (lines on the wiper roll) and keep it with the rest of the data to be sent.
● Check the status of the web wipe rubber blade (if it is damaged, ask for a new one). It may be not
cleaning correctly.
7. Run the 11006: PH electrical status test (on Print Care ►Diagnostics ►11. Printhead control link). The
other tests must have been executed already (if not, do so). The printhead electrical status test will give
you the status of each printhead and therefore the failure reason for the reported printhead reseat. Refer
to the following for all the possible outcomes: (See step 8 for troubleshooting steps depending on the
process #). Take a snapshot of the test result.
Troubleshooting
Error message Description process
OK OK. N/A
Not inserted Not inserted. #1
Fails continuity Electrical continuity failure. Communication between printhead and #2

interconnect board is not working properly.
Voltage failure Voltage failure. This error may have been caused by a short circuit in the #2
printhead electrical pad or the printhead board.
CSDATA not responding Printhead is not responding to communication attempts from printhead #2
interconnect board. The printhead may not be correctly inserted or
electrical pads may be dirty or damaged.
Temperature extremely high Printhead temperature is extremely high. A likely cause for this error is #3
that printhead nozzles are blocked and ink cannot be fired. It can also be
that there is air inside the ink circuit (printhead or tubes).
Temperature too high Printhead temperature is extremely high. A likely cause for this error is #3
that printhead nozzles are blocked and ink cannot be fired. It can also be
that there is air inside the ink circuit (printhead or tubes).
Temperature extremely low Printhead temperature extremely low. Operating temperature could not #4
be reached. The most likely cause is printhead damage in its resistors due
to crash with substrate.
Temperature too low Printhead temperature too low. Operating temperature could not be #4
reached. The most likely cause is printhead damage in its resistors due to
crash or substrate smear.

Troubleshooting
Error message Description process
Bad acumen information Wrong printhead data. The information encoded in the printhead is #4
incorrect. Maybe not a valid HP printhead.
Bad acumen access Printhead internal data cannot be accessed. The printhead may not be #2
correctly inserted or electrical pads may be dirty or damaged.
Wrong model Wrong printhead model. This is not a valid printhead for the HP Latex #4
3000 printer.
Mismatch Wrong printhead internal data. This is not a valid printhead for the HP #4
Latex 3000 printer.
Energy calibration failure Energy calibration failure. This can either be a printhead problem or a #2
printhead interconnect PCA problem.
8. Follow the troubleshooting steps depending on the printhead electrical status test result. Please refer to
the table above for guidance on which troubleshooting you need to execute:
Troubleshooting process #1
a. Printhead not inserted. Please check that there is a printhead in the slot and if there is, reinsert it.
b. Run the test again and check the status. If the result is the same, replace printhead.
a. Clean the electrical connections of the printhead and board. You can follow the instructions in: HP
Print Care Maintenance Wizard “Clean Printhead Pocket and Printhead Electrical Contacts”, and in the
user guide, chapter Hardware maintenance, “Clean the printhead contacts”. Make sure they are clean
and nothing is creating a short-circuit.
1. Clean the sides of the printhead with a cloth moistened with alcohol.
IMPORTANT: Do not touch the nozzle plate.
2. Carefully clean the carriage contacts with a cloth moistened with alcohol.
3. Wait for some minutes until printhead and carriage contacts dry before reinserting the
printhead.

b. Inspect the printhead interconnect board electrical contacts and make sure they are not dirty, bent, or
damaged. Make sure the board is correctly mounted on the black metal back support and that the
screws are tight.
c. Once cleaned and reviewed, insert a new printhead:
1. If the problem still appears, there may be damage on the printhead interconnect board. To
discard a transient electrical perturbation, shut down the printer, re-start it a minute later, and
perform a printhead replacement again. If the same problem occurs, the printhead interconnect
board may be faulty.
● When the printhead Interconnect board is disassembled, check if the plastic spoiler is
damaged:
If the spoiler is damaged (as in the picture above), replace the printhead Interconnect
board. Please, insert the printhead Interconnect board carefully in the Pen Pocket to avoid
damaging this part.
2. If the problem is gone, continue printing. If it happens again, start troubleshooting.
a. Check nozzle health for blocked nozzles. Go to IPS ►Printer ►Printhead cleaning ►Verify printhead
status. If the nozzles are blocked, please perform a hard clean from the same IPS window. If the error
does not disappear, please replace the printhead.
b. Check there is no air inside the printhead:
i. Check the nozzle plate for any evident damage (probably due to a crash).
ii. Weigh the printhead if possible (must be approximately 260-270 g). If the weight is significantly
lower, there is air inside the printhead and you must replace it (not recoverable)
c. Check the IDS for any air leakage or damage:

i. Turn off the printer.
ii. Check the intermediate tanks are not empty using a syringe.
iii. Execute test on Print Care ►22. Ink delivery system ►[22002]: Air Pressure System, if it fails,
troubleshoot IDS with the pertinent diagnostics (see service manual for more information).
▲ Replace the Printhead.
Sending logs to GBU (Customer Assurance)

IMPORTANT: This procedure requires an HP Google+ account for secure data sharing, so only HP employees
can upload the files. Follow instructions given by HP to create the account, or ask CA for assistance on how to
create it. If you are not an HP employee, please share this data with your HP contact so that he/she can deliver it
to us.
Please collect all the indicated data above (logs and snapshots), and create a compressed zip folder with the
following name format: (use the date and time of the printhead reseat, so that the logs can be browsed easily by
CA to find the printer error).
printerSN_ddmmyyyy_hhmm (e.g. SG41N1P001_22072014_1240)
Then upload the file to: https://drive.google.com/a/hp.com/folderview?

id=0B7eQp6uXxmWMVElFbTNHV0NOanM&usp=sharing
This information is indispensable for the printhead reseat fix. Please share with GBU even if the printhead reseat
issue for your customer has been fixed.
Downloading multiple LOGs from the tmp folder

We have unified the process of collecting logs using the same tool. From now on WinWGet will be the tool for
that purpose, as Info retriever was not delivering all the needed logs. This tool is an open source program and
needs to be installed on the IPS PC. Follow the instructions as indicated below, and once done, the tool will
automatically gather the needed files from the /tmp, and prepare them in a folder ready to be sent to GBU CA.
Install Winwget in the IPS PC
1. Download and installWinWGet from http://sourceforge.net/projects/winwget/.

2. Click Run.
3. Click Next.

4. Click Next.
5. Click Next.

6. Click Next.
7. Click Next.

8. Check Create a desktop Icon and Create a desktop Icon (to allow easy access), then click Next.
9. Once the Installation is complete, it is recommended to pin it to the taskbar in order to have fast access to
the tool (Right mouse click on the icon and Pin it to taskbar).
Configure a new task in WinWget to gather specific logs
1. Run the WinWget application: Go to desktop and double-click on the icon.

2. Add New job (click on the first Icon under File).
3. Add New job (click on the first Icon under File).

4. An Add job window will appear:
5. Fill in the fields for the new job: (check points below to know how to fill the fields).

6. In the Address box, enter the tmp folder path. This is usually:http://172.22.22.22/hp/device/3432/8828/
tmp/. If the path is not known; Go to Print Care test in Print Care ►Diagnostics ►99.Utilities ►99009: Get
printer logs and run the test. The output of this test is the tmp older path:

7. Destination folder/Local downloads folder: Create new directory in the IPS PC C: drive(Ex. c:\datafromTMP),
and add its path in the Local downloads folder.

8. In the Additional Params, type the following: -A.gz -A.log -R "*Supply*" -R "*dddata*".
This will download only the specific files specified above:.log and.gz
9. In Directories click -nd –no directories (Do not download folder structure).

10. In the Recursive retrieval tab, click [-r] recursive.
11. Press OK & Run to start transferring the files to the PC. Once the transfer is complete a green arrow will
appear next the Job name.

12. Check if the directory C:\datafromTMP is filled in with various files:
13. Delete all of these ‘test’ files from this directory (keeping the directory C:\datafromTMP empty for the next
time).
The Internal Print Server recommends replacing or reseating a printhead
General recommendations
1. Remove the printhead.
2. Reinsert the printhead into the carriage and check the Internal Print Server message.
3. If the problem persists, exchange the printhead with the printhead of the same color in the other row.
4. If the problem persists, check the printhead contacts for dirt or aerosol and clean them if necessary. See
Clean printhead contacts in the user guide.
5. Find more troubleshooting information in the following sections, Problem due to overheating
on page 512 and Problem due to the primer system on page 512.
6. If the problem persists, insert a new printhead.
7. If no printhead works in that slot, call your service representative (see LogMeIn rescue on page 1400).

Problem due to overheating
A printhead may overheat for several reasons:
● The room temperature may be too high.
● The printhead may be suffering from blocked nozzles. You may be able to cure this problem by cleaning
the printheads (see Clean the printhead contacts in the user guide).
● The printhead may be faulty, in which case it should be replaced.
Problem due to the primer system
Primers are important to the printheads’ nozzle health. When there is a problem with a primer, the Internal Print
Server displays the following messages.
During a printhead replacement
● A reseat message for a particular printhead
● A printhead replacement incomplete message
● A numerical error code starting with 46 (46.0X.0Y:ZZ)
During a printhead servicing routine
● A reseat message for a particular printhead
● A numerical error code starting with 46 (46.0X.0Y:ZZ)
The message 46.02.0Y:06 – Primer 0Y leakage detected indicates that one of the primer systems leaks. The
number 0Y, where Y ranges from 1 to 7, indicates which primer is leaking.
You are recommended to:
● Run the primer diagnostic test from the Print Care window to confirm the cause of the error.

● Reseat the printhead. Make sure to push the primer into position before securing the latch. While running
the test, you will already have done it at least once.
● Check that the O-rings in the primer ports are not broken or damaged. Replace the primer if any O-ring is
missing or dented.
● Replace the primer. See Replace a primer in the user guide.
If none of these actions resolve the problem, call your service representative.
If you see the message 46.01.0X:YY, run the primer diagnostic test from the Print Care window to confirm the
cause of the error.
If the test instructs you to replace the primer, replace it. See Replace a primer in the user guide. Otherwise, call
your service representative with the test results at hand.

Printhead health troubleshooting

There are two diagnostics to check the status of the printheads: the printhead status plot and the drop detector
diagnostics in Print Care. Always use both, as they provide complementary information.
Printhead status plot
To print the printhead status plot, go to the Internal Print Server, select Printer ►Printhead cleaning and press
the Print button.
The following image is printed.
Each section is used for a different purpose.
1. Section 1 is a set of mid-tone areas printed with a single ink using a 6-pass print mode with nozzle
substitution.

2. Section 2 shows plainly which nozzles in each printhead are printing and not printing.
For reference, each one of the 5 areas (square in the picture and 1 to 5) of each color corresponds to
approximately 1000 nozzles.
Drop detector diagnostics
Execute the Drop Detector diagnostics from the Print Care window. This will identify blocked nozzles in each
printhead.
Decision table
The following table summarizes the data that can be seen in each diagnostic, the possible causes, and the
decisions.
Mid-tones (section 1) Nozzle health (sectiion 2) Drop detector Possible cause Action
No banding < 300 blocked (all colors) < 300 blocked (all colors) Other Continue banding
troubleshooting.
Banding in all colors < 300 blocked (all colors) < 300 blocked (all colors) Substrate advance, or Check the substrate-
other advance sensor.
Continue banding
troubleshooting.
Banding in one color < 300 blocked (that color) < 300 blocked (that color) Other Continue banding
troubleshooting.
> 300 blocked > 300 blocked Printhead failure Hard-clean the
printhead, twice if
necessary.
Replace the printhead.
N/A < 300 blocked (at least > 300 blocked (at least Drop detection failure Call your service
one color) one color) representative.
Hard clean
To perform a hard cleaning routine, go to the Internal Print Server, select Printer ►Printhead cleaning, select the
printhead(s) to clean and press the Hard clean button.

Sometimes, when the printhead is quite damaged, running the hard-clean routine twice helps to recover its
performance.
New printhead is rejected

If the printer will not accept a new printhead, try the following steps in sequence:
1. Ensure that the printhead was correctly stored in its orange cap.
2. Ensure that the electrical contacts are clean.
3. Run the primer system diagnostic.
4. Exchange the printhead with the printhead of the same color in the other row.
5. Assume that the printhead is faulty, and try another one.
6. If no printhead works in that slot, call your service representative.
Printhead cleaning roll errors

You should not touch the printhead cleaner roll except when you need to replace it.
When the printhead cleaning roll reaches its end, it should be replaced. Always do this by following the Internal
Print Server wizard. See Replace the printhead cleaning roll, filters and spittoon in the user guide.
Any handling of the roll may prevent the printer from keeping track of roll usage, in which case you may see
spurious error messages, and a printing job may be cancelled unnecessarily.

How to extract and read the service plot

The service plot and its structure
The service plot is an XML file containing information useful for printer maintenance and troubleshooting.
The file is divided into four different sections:
● Current Substrate, Printhead, Ink System and Sensors Information: This section lists the status of supplies,
relevant sensors, and calibration values for servicing the machine.
● Printer Usage Information: This section lists the usage (consumption) of printheads, cartridges, and
substrate. It also contains counters of usage for hardware elements that require preventive maintenance
when the counter reaches a certain value.
● Event Logs: List of system errors, warnings, and printhead errors.
● Substrate Settings and CLC: Report of the substrate settings and calibration status.
See How to interpret the service plot on page 520 for a deeper understanding of each section of the service
plot.
How to extract and view the service plot

1. Prerequisites: The machine must be in Ready status; if the machine is printing, the job may be cancelled.
The service plot cannot be extracted with the machine booted in diagnostic mode.
2. How to generate the service plot:
The service plot is generated through the IPS, by selecting Information ►Service information.
After some seconds needed to create the plot, a Web browser window pops up showing the service plot.
A copy of this file is recorded in the following path of the built-in computer in XML format: c:\Users\user
\Desktop\Service Information.
NOTE: This XML file (service plot) is named automatically using the date of creation. For example, a plot
created on the 20th of February 2013 might be named 2013-02-20T16_59_08_MasterXML.xml. Check
that the date is correct; if not, the date maintained in the printer is wrong and should be corrected.
3. How to view the service plot:
You can view the service plot using the HPInfoRetriever software already installed in the built-in computer.
a. Start the application by clicking on the HPInfoRetriever icon on the desktop:
ENWW How to extract and read the service plot 517

b. Open a service plot by selecting File ►Open Service Info.
c. Browse the Service Information folder on the desktop, looking for the latest service plot (the one with
the latest date in the name of the file).
A Web browser opens, showing the service plot.
HP InfoRetriever also allows you to collect other information that may be required if HP support is
needed.
d. If extra information is required, log in as a service engineer and run Print Care.

e. Select Diagnostics ►System Diagnostics ►Utilities as shown below.
f. Check the box Get printer logs.

g. A pane appears with a link to the folder in which the log files have been stored. Click the link, copy the
specific file requested by HP and send it to the HP support team.
How to interpret the service plot

1 Current Substrate, Printhead, Ink System and Sensors Information
The first section of the service plot shows the overall printer status, followed by the printer configuration and
loaded substrate information:
1.3, 1.4 Current printhead info
This section shows information about each printhead.

● Warranty status: This field can be: ‘In warranty’, ‘Out of warranty’, or ‘See warranty note’. ‘See warranty
note’ indicates that non-HP ink has been used. See the limited warranty document or
http://www.hp.com/go/learnaboutsupplies for more details.
● Status
● Error code ID
0 WORKING (= OK in Status column)
1 NO PRINTHEAD (= Missing in Status column)
2 REPLACE
3 RESEAT
8 REMOVE
16 REPLACEMENT INCOMPLETE
● Product number
● Product name
● Serial number
● Warranty date
● Used non-HP ink
● Used expired ink
● Ink used
● % warranty used (ml)
● Usage time
● Scan-axis shutdown
1.5, 1.6 Current cartridge info
This section shows information about each ink cartridge.

● Error ID Code: Reports the status of the cartridge. The Error ID given converts to the following status:
0 = OK 128 = EXPIRED
1 = NOT PRESENT 256 = WRONG_INSERTION_FAMILY
2 = EMPTY 512 = WRONG_INSERTION_MODEL
4 = ERROR 1024 = WRONG_INSERTION_MISMATCH
8 = LOW LEVEL 2048 = WRONG_INSERTION_SIZE
16 = RESEAT 4096 = NOT_TOTALLY_TESTED
32 = UNKNOWN 8192 = PREPARING_SYSTEM
64 = VERY_LOW_LEVEL
● Install Date: Shows when the cartridge was installed (check that the date is correctly set in the printer
configuration).
1.7 Supply status, 1.8 ISS temperature sensor, and 1.9 Pressure sensor calibration values

1.10 Intermediate tank values, 1.11 Air pressure system, 1.12 PPS system, and 1.13 PPS homing switch status
In this section you can see the status of various hardware elements: the intermediate tanks, the air pressure
system, PPS status, and PPS homing switches.
PPS Status can be any of the following: HOMING, LOW, HIGH, HIGH_PRINT, MEDIA_LOAD, UNKNOWN, HALT. If the
PPS is in an unknown position and needs to be recovered, see Table 5-11 Scan-beam on page 565.
See Pen to Rib Space (PRS) on page 41 for information that will help you to understand what values should be
expected for every element.
1.14 Vacuum system, 1.15 Voltage configuration, and 1.16 Sensor system
The three-phase system voltage configuration shows the voltage configuration that has been set during
installation (which must match site specifications). The possible values are: 200, 208, 220, 380, 400, and 415 V.
1.17 Substrate advance calibration values
If all the values are zero, substrate-advance calibration has not been done.
1.18 Analog encoder calibration, 1.19 Motor type configuration, and 1.20 Printhead cleaner roll
This information is shown if escalation is needed.

2 Printer usage information

These sections contain information about usage of printer supplies and substrate.
● Total printed substrate reports the printed substrate surface as well as the subtotal for each configuration:
dual-roll, roll-to-free-fall, and take-up reel.
● Total Ink used is the total volume of ink used for each color, in liters.
2.2 Usage per printhead slot and 2.3 Usage per cartridge slot
● Printheads Used is the number of different printheads (with different serial numbers) used by the printer.
● Total Insertions is the number of times the current printhead has been inserted.
2.4 Substrate per substrate type
This section reports the usage of each substrate type.
2.5 Component usage
This section gives a list of various hardware counters.

2.6 Job accounting
This section shows the print mode selectors used for the print jobs (number of passes, number of colors, ink
density).
3 Event logs
3.1 System errors and 3.2 System warnings
System errors are classified depending on the severity:
● Severe: Process stopper, requiring a restart of the printer
● System Warning/silent: Informative
The error codes are documented in Troubleshooting system error codes on page 140. Every event specifies the
system error, the substrate usage at the time the system error appeared (total quantity of substrate at the
moment of the error), and the date when it happened. These elements let us know the frequency with which the
customer is experiencing problems.

3.3 Printhead error log
The Error Code is a decimal number that must be converted into binary code in order to use the attached error
table conversion (see below). You can use the Windows calculator to convert the number from decimal into
binary.
The following table explains the meaning of the different bits (0 or 1). When the value of the error code is
reported as 0, it means that the printhead is working correctly:

● Example 1: Error code 4099 (decimal) is 1000000000011 (binary). Using the table above, the error code
means “FAILS_LOGICAL_V”, “FAILS_CONTINUITY” and “MISMATCH”.
● Example 2: Error code 532512 (decimal) is 10000010000000100000 (binary). Using the table above, this
errors tells us: TEMP_EXTREMELY_LOW, CSDATA_NOT_RESPONDING and EXPIRED (used expired ink). The
connection between the printer and the printhead does not seem to work.
Here you can see a more detailed table:
Diagnostic log
This section shows which tests or calibrations have been run. For each test, there are two entries: 1) starting
time and 2) brief result after ending the test/calibration (pass, fail or cancelled). In the event the printer is
stopped during the test, through emergency stop or energy cutoff, the result is not logged.

● Starting time
● A brief result after ending the test/calibration (pass, fail, or cancelled)
NOTE: If the printer is stopped during the test, by emergency stop or power cutoff, the result is not
logged.
4 Substrate settings and CLC
4.1 Loaded substrate
Lists the settings of the loaded substrate.
● Substrate input: may be ‘inwards’ or ‘outwards’
● Substrate output: may be ‘inwards’ or ‘outwards’, plus the settings established by the user for this specific
substrate
4.2 Substrate-specific calibrations
The Substrate Name with its corresponding Substrate ID (which appears in the XML of the job sent from the RIP
to the IPS) and the color calibration information (Color Status: done, default) and the date of the last color
calibration done. If the date is set to 1970, no color calibration has been done for this substrate.
Looking at this list, you can identify the parent of a custom-made substrate. A custom substrate has its parent
indicated afterwards between parentheses.

Troubleshoot non-HP ink usage

Warranty statement
Printer
This is an extract of the printer warranty statement related to the use of non-HP inks:
“For HP printer products, the use of a refilled or non-original HP consumable product (ink, printhead, ink
cartridge, or maintenance kit) does not affect either HP’s Limited Warranty or any HP support contract. However,
if printer failure or damage is attributable to the use of a non-HP or refilled ink cartridge or an expired ink
cartridge, HP's authorized representative will charge its standard time and materials charges to service the
printer for the particular failure or damage.”
See the HP Limited Warranty Statement document for more information.
Ink cartridges and printheads

This is an extract of the warranty statement for HP ink cartridges and customer-replaceable printheads:
“This warranty does not cover HP ink cartridges or customer-replaceable printheads that have been refilled,
remanufactured, refurbished, misused, or tampered with. If failure or damage to ink cartridges or customer-
replaceable printheads is attributable to the use of a non-HP, expired, or refilled ink cartridge, or to their use with
a non-designated HP or unauthorized OEM printing device, HP is not responsible for the cost of replacement or
refund of the purchase price.”
You can find more information about how the use of non-HP inks affects the warranties of ink cartridges and
printheads at http://www.hp.com/go/learnaboutsupplies.
Ink cartridges
Ink cartridge non-HP ink alerts
When non-HP ink usage is detected while replacing an ink cartridge, the customer is alerted about the
implications in performance and warranty. These alerts must be acknowledged twice for the printer to continue
working.
ENWW Troubleshoot non-HP ink usage 529

Troubleshooting usage of non-HP ink cartridges
Internal Print Server
The Internal Print Server shows clearly in the supplies information when non-HP ink usage is detected.
Service plot
Similar information can be found in the service plot.
Printheads
Printhead non-HP ink alerts
When non-HP ink usage is detected and the customer acknowledges the warnings, the installed printheads in
question are automatically marked as used with non-HP ink.
When a new printhead is installed, the customer is once again alerted about the performance and warranty
implications, and the customer must acknowledge such alerts.
Troubleshooting usage of non-HP inks in printheads
Internal Print Server
The Internal Print Server shows clearly in the supplies information when non-HP ink usage is detected.

Service plot
Similar information can be found in the service plot.
Safe mode
When using non-HP inks, the printer operates in safe mode to protect itself and its printheads from failures. Drop
detector functionalities will be disabled. In safe mode:
● A warning icon is displayed by the Internal Print Server.
WARNING! Image quality would be affected.
ENWW Troubleshoot non-HP ink usage 531

Returning to HP inks
There are two ways to resume using non-HP inks:
● Install HP original cartridges and wait until 9 liters of HP ink have gone through the affected tubes of the ink
delivery system to the printheads.
● Flush the non-HP ink, reset the printer flags, and install HP original cartridges.
Option 1: Install HP original cartridges and wait for 9 liters

During the time it takes to use these 9 liters, the warranty is not recovered.
● Any new printhead installed will automatically lose its warranty.
● The lost-warranty terms still apply.
When the 9 liters have gone through the affected tubes of the ink delivery system:
● Any printheads that have been used with non-HP ink do not recover their warranties.
● Any new printhead installed after this point maintains its warranty.
● All other warranties are recovered.
Option 2: Flush the non-HP ink

This procedure must be performed by a service engineer. HP engineers or authorized support partners will make
their standard travel and labor charges for this procedure.
1. Flush the non-HP ink.
2. Reset the printer flags. Contact the LFP Customer Assurance team for instructions.
3. Install HP original cartridges.
When this process has been completed:
● Any printheads that have been used with non-HP ink do not recover their warranties.
● Any new printhead installed after this point maintains its warranty.
● All other warranties are recovered.

5 Diagnostics
● Overview
● General diagnostics
● How to run a diagnostic test
● Boot mode permissions
● Phone support
● Service tests, diagnostics, and calibrations
ENWW 533
Overview
This chapter guides you through the procedures for diagnostic tests, service utilities, and service calibrations.
Diagnostics in this printer are managed from Print Care, so review the Print Care documentation before using the
diagnostics.
General diagnostics
NOTE: Some diagnostic tests or calibrations must be performed after removing a component. Read carefully
the instructions given by Print Care.
NOTE: To return the carriage to the capping position after work in diagnostic mode, restart the printer in
normal mode.
534 Chapter 5 Diagnostics ENWW

How to run a diagnostic test

Diagnostic tests are accessible through the Diagnostics tab in Print Care and organized by subsystems.
Diagnostic availability can change depending on the role logged in Print Care and printer boot mode. For
example, logged in as Operator, the user has access to tests that can be useful not only for self-diagnosis, but
also to guide the operator when receiving remote support.
NOTE: The Operator account cannot select individual tests, and subsystem tests are executed sequentially.
If the user account is changed to Service, the full set of tests is available for the current boot mode and individual
tests can be selected. To change the user account, go to File ►Switch User.
ENWW How to run a diagnostic test 535

Accessing diagnostic test menus
1. Log in
● The user account is ‘ServiceEngineer’.
● The password is generated by the Print Care Password Manager.

2. If the printer can start in normal mode and if the diagnostic test allows it, the test can be executed without
starting in diagnostic mode. However, for certain tests, or in the event the printer is not able to start in
normal mode, it is necessary to start the printer in diagnostic mode.
To start the printer in diagnostic mode, go to Printer tools ►Power options ►Reboot in diagnostic mode.
NOTE: There is no password to start in diagnostic mode, as the operator is allowed to do it.
Boot mode permissions

Table 5-1 Boot mode availability by user type
Boot modes
Normal Diagnostic
When the printer is able to start When the printer is unable to start
normally normally, or for specific cases in
which the diagnostic works better if
the printer is not fully started
User accounts << None >> (i.e. Operator) Partial list of diagnostics for each Partial list of diagnostics for each
subsystem subsystem
- Not selectable: the whole list is
executed for each subsystem.
- Only diagnostics that do not require

engineer intervention (such as
opening the e-cabinet, and so on).
Engineer Full list of diagnostics, if feasible (for Full list of diagnostics, if feasible (for
some diagnostics it may not be some diagnostics it may not be
Selectable feasible) feasible).
ENWW Boot mode permissions 537

Phone support
The customer can be guided to perform nearly all diagnostic tests, utilities, and calibrations.
However, there are some procedures that the customer should not perform:
● Save Factory Defaults
● Restore Factory Defaults
● Reset Maintenance Kit Usage
● Reset Life Counters
Diagnostic availability can change depending on Print Care login and boot mode.
The following table lists the diagnostics and their availability.
Available in boot
Subsystem ID Test name Available to users modes
Safety interlocks
(See Table 5-2 Safety interlocks on page 545).
51001 Safety interlocks Operator or engineer Normal
51002 Safety circuit Operator or engineer Diagnostic
Print quality
(See Table 5-3 Print quality on page 545).
35002 Service alignment plot Engineer Normal
35003 Printhead alignment plot Engineer Normal
35004 Encoder-strip plot Engineer Normal
Printhead control link
(See Table 5-4 Printhead control link on page 546.)
11001 E-box fiber-optics PCA Operator or engineer Normal or diagnostic
11002 Optical link Operator or engineer Normal or diagnostic
11003 Carriage fiber-optics PCA Operator or engineer Normal or diagnostic
11004 Printhead interconnect connectivity Operator or engineer Diagnostic
11005 FO PCAs version check Engineer Diagnostic
11006 Printhead electrical status Operator or engineer Normal
11007 Printhead insertion Engineer Normal or diagnostic
11008 Fiber-optics test Operator or engineer Normal or diagnostic
Substrate path mechanics
(See Table 5-5 Substrate path mechanics on page 551.)
41001 Substrate path sensors Operator or engineer Normal or diagnostic
41002 Motors check Operator or engineer Normal or diagnostic

Available in boot
41003 Main roller motor test Operator or engineer Normal or diagnostic
41004 Motors calibration Engineer Normal or diagnostic
41005 Encoder calibration Engineer Normal or diagnostic
41006 Drive roller calibration Engineer Normal
41007 Drive roller check Operator or engineer Normal
41008 Substrate Path lights Operator or engineer Normal or diagnostic
Roll-to-free-fall kit
See Table 5-6 Roll-to-free-fall Kit on page 557.
41010 Install kit Engineer Normal or diagnostic
41011 Electronic check Operator or engineer Normal or diagnostic
41012 Sensors check Operator or engineer Normal or diagnostic
41013 MF motor check Operator or engineer Normal or diagnostic
41014 Motor calibration Engineer Normal or diagnostic
Printhead primers
See Table 5-7 Printhead primers on page 558.
46002 Primer check Engineer Normal
Substrate-advance sensor
See Table 5-8 Substrate-advance sensor (OMAS) on page 559.
50001 Enable-advance sensor Engineer Normal or diagnostic
50002 Disable-advance sensor Engineer Normal or diagnostic
50003 Cleanliness check Operator or engineer Normal or diagnostic
50004 Sensor calibration Engineer Normal
50005 Show sensor status Operator or engineer Normal or diagnostic
50006 Read PixelSizeOffset value from NVM Operator or engineer Normal or diagnostic
50007 Write PixelSizeOffset (decimicrons/pixel) Engineer Normal or diagnostic

value to Nvm
50008 Media navigability test Operator or engineer Normal or diagnostic
Substrate path vacuum system
(See Table 5-9 Substrate path vacuum on page 563.)
43001 Vacuum system diagnostic Operator or engineer Normal or diagnostic
43002 Reset vacuum pump usage Engineer Normal or diagnostic
43003 Vacuum sensor defaults Engineer Normal or diagnostic
Scan axis
(See Table 5-10 Scan axis on page 564.)
ENWW Phone support 539

Available in boot
86001 Scan-axis encoder manual check Operator or engineer Normal or diagnostic
86002 Scan-axis analysis Engineer Normal or diagnostic
86006 Move to service position Engineer Diagnostic
Scan beam
(See Table 5-11 Scan-beam on page 565.)
48001 Scan-beam EE check Operator or engineer Normal or diagnostic
48002 Scan-beam motor and encoder check Operator or engineer Normal or diagnostic
48003 Scan-beam movement Engineer Normal or diagnostic
48004 Scan-beam motor open-loop movement Engineer Normal or diagnostic
Ink Delivery System
(See Table 5-12 Ink delivery system on page 571.)
22001 ISS electronics Operator or engineer Diagnostic
22002 Air pressure system Engineer Normal or diagnostic
22004 Ink cartridge LEDs Operator or engineer Diagnostic
22005 Intermediate tanks information Operator or engineer Normal or diagnostic
22009 Ink supplies check Engineer Diagnostic
22010 Electrovalves Engineer Diagnostic
22016 IT broken bag recovery Engineer Diagnostic
22017 Ink system leakage Engineer Diagnostic
22018 Intermediate tanks replacement Engineer Diagnostic
22019 Calibrate pressure sensor Engineer Diagnostic
22020 Ink pressure at printhead Engineer Diagnostic
22024 Intermediate tanks refill Engineer Diagnostic
Carriage aerosol
(See Table 5-13 Carriage aerosol on page 575.)
49001 Aerosol extraction status Operator or engineer Normal or diagnostic
Carriage sensors
(See Table 5-14 Carriage sensors on page 576.)
55001 Line sensor check Operator or engineer Normal or diagnostic
55002 Line sensor counter reset Engineer Normal or diagnostic
55003 Line sensor calibration Engineer Normal
55004 Lstok calibration Engineer Normal
58001 Color sensor check Operator or engineer Normal or diagnostic

Available in boot
58002 Color sensor open/close door test Engineer Normal or diagnostic
Drop detection
(See Table 5-15 Drop detector on page 578.)
52001 Check DD electronics Operator or engineer Normal or diagnostic
52002 DD mechanics Operator or engineer Normal or diagnostic
52003 DD calibration Engineer Normal or diagnostic
52004 Move drop-detector station to service Operator or engineer Normal or diagnostic

position
52005 Force drop detection Operator or engineer Normal or diagnostic
52010 Display printing nozzle health data Operator or engineer Normal or diagnostic
Printhead cleaning roll
(See Table 5-16 Printhead cleaning on page 580.)
47002 Visual movement check Operator or engineer Normal or diagnostic
47003 Manual movement check Operator or engineer Normal or diagnostic
47004 Motor direction tests Operator or engineer Normal or diagnostic
47005 Printhead cleaning Z calibration check Operator or engineer Normal or diagnostic
47006 Set printhead cleaning Z calibration Operator or engineer Normal or diagnostic
Monitor curing temperatures
(See Table 5-17 Monitor curing temperatures on page 581.)
16001 Monitor curing temperatures Operator or engineer Normal
Curing
(See Table 5-18 Curing on page 581.)
16002 Status of the curing modules Operator or engineer Normal
16003 Monitor one curing module Operator or engineer Normal
Monitor drying temperatures
(See Table 5-17 Monitor curing temperatures on page 581.)
17001 Status of the curing modules Operator or engineer Normal
Drying
(See Table 5-20 Drying on page 583.)
17002 Status of the drying modules Operator or engineer Normal
17003 Monitor one curing module Operator or engineer Normal
E-cabinet
(See Table 5-22 E-cabinet on page 586.)
10001 Fan Operator or engineer Normal or diagnostic

Available in boot
10002 Safety interlocks Operator or engineer Normal
10003 Safety circuit Operator or engineer Diagnostic
10004 Power supplies Operator or engineer Normal or diagnostic
10005 E-cabinet state Operator or engineer Normal or diagnostic
10006 Communication Operator or engineer Normal or diagnostic
10007 All outputs state change Engineer Diagnostic
10008 Watchdog Operator or engineer Diagnostic
10009 Activate/deactivate outputs Engineer Diagnostic
10010 Temperature Operator or engineer Normal or diagnostic
E-box
(See Table 5-21 E-box on page 585.)
01005 Engine PCAs Operator or engineer Normal or diagnostic
01007 Engine adaptor PCA communication Operator or engineer Normal or diagnostic
Printer installation and purge
(See Table 5-23 Printer installation and purge on page 588.)
10100 Set input voltage Engineer Diagnostic
22511 Force normal boot Engineer Normal or diagnostic
22515 IDS Purge Engineer Diagnostic
22516 Set Printer as purged Engineer Diagnostic
22517 IDS Purge process status reset Engineer Diagnostic
Utilities
(See Table 5-25 Utilities on page 589.)
99001 Set date and time Engineer Normal or diagnostic
99002 Report firmware version Engineer Normal or diagnostic
99003 Save NVM Engineer Diagnostic
99004 Restore NVM Engineer Diagnostic
99006 Force boot mode Engineer Normal or diagnostic
99007 Enable advanced logging Engineer Normal or diagnostic
99009 Get printer logs Engineer Normal or diagnostic
99010 Set IP address Engineer Normal or diagnostic
99012 Recover 01_60_03_03 SE SN mismatch Engineer Diagnostic
Reshipment
(See Table 5-24 Printer reshipment preparation on page 589.)

Available in boot
22603 Set ISM as not purged Engineer Diagnostic
22604 Set TRS as not purged Engineer Diagnostic
22605 Move carriage Operator or engineer Normal or diagnostic
Carriage rails cleanliness
(See Table 5-26 Carriage rail cleanliness on page 594.)
86003 Friction analysis Operator or engineer Normal or diagnostic
Double-Sided Day Night Kit (Accessory)
(See Table 5-27 Double-sided Day and Night Kit on page 594.)
DSDN kit checks
90001 Electronic check Operator or engineer Normal or diagnostic
90002 Lights check Operator or engineer Normal or diagnostic
90003 Buttons check Operator or engineer Normal or diagnostic
90004 Scanning check Operator or engineer Normal or diagnostic
DSDN kit installation
90011 Electronic check Engineer Normal or diagnostic
90012 Buttons check Engineer Normal or diagnostic
90013 Lights check Engineer Normal or diagnostic
90014 Scanning check Engineer Normal or diagnostic
90015 Install kit Engineer Normal or diagnostic
DSDN kit configuration
90021 Offsets calibration Operator or engineer Normal or diagnostic
90022 Media edge to fiducial distance configuration Operator or engineer Normal or diagnostic
Vapor removal
(See Table 5-28 Vapor removal on page 598.)
30001 Vapor removal electronics check Operator or engineer Normal or diagnostic
30002 Vapor removal blower check Operator or engineer Normal or diagnostic
30003 Heat exchanger FANs check Operator or engineer Normal or diagnostic
Reset printing nozzle health data
(See Table 5-15 Drop detector on page 578.)
52012 Reset printing nozzle health data Operator or engineer Normal or diagnostic
NOTE: If you get a severe error when restarting the printer, the diagnostics in normal mode may not work. In
this case, you are recommended to start the printer in diagnostics mode to fix the problem.

NOTE: While printing, only diagnostics for monitoring curing temperature can be executed; and you are
recommended to start the diagnostic before sending the job.

Service tests, diagnostics, and calibrations

This section describes tests, together with pass and fail criteria, as well as actions to be taken.
Table 5-2 Safety interlocks

Test Safety interlocks (10002 and 51001)
Description This test activates the safety circuit and checks that the interlocks work properly.
Interlocks are responsible for disabling carriage movement and the power supply to the curing and drying system.
There are two circuits. One of them disables the contactors. The other provides feedback to the firmware. This test
checks the feedback circuit only. If it fails, the feedback circuit should be checked. The interlock may also be defective or
the interlock actuator may not be properly activating the interlock due to a bad attachment or a misalignment. The
proper function of the safety circuit can be seen from the e-cabinet PCA Interlock CHAIN STATE (DS40) LED. It should
turn off when the front door or the loading table is opened.
Front door Loading table Chain start LED (DS40)
Open Open Off
Open Closed Off
Closed Open Off
Closed Closed On (green)
Pass criteria You can see that the status changes if you open or close the safety interlocks.
Fail criteria You can see no change in status after opening or closing the front door or loading table. In this case, you need to find
the components that are not closing throughout the interlock chain (in case of failure of the front door or loading table).
See Simplified diagram and general electrical explanation on page 6.
Test Safety circuit (10003 and 51002)
Description This test activates the safety circuit and checks that the safety relay, contactors, e-stops, and interlocks work properly.
Pass criteria You can see that the status changes if you open or close the safety interlocks and check whether the safety relay or
emergency stops are activated.
Fail criteria With this test you can determine whether the safety locks, safety relay, and emergency stops are working properly prior
to their replacement. in case of failure, you need to find the components that are not closing thoughout the interlock
chain (if the front door or loading table has failed), or the emergency stop chain (if the emergency stop safety chain has
failed). See Simplified diagram and general electrical explanation on page 6.
Table 5-3 Print quality

Test Service alignment plot (35002)
ENWW Service tests, diagnostics, and calibrations 545

Table 5-3 Print quality (continued)

Description Prints a plot to check alignment problems. See Service alignment check plot on page 463.
Test Printhead alignment plot (35003)
Description Prints a plot to diagnose certain print quality issues. The plot is a simple area fill for all the printheads so possible
problems can be easily identified.
Test Encoder-strip plot (35004)
Description Prints a plot to check the scan-axis encoder strip. It should be executed mainly after changing the encoder strip or the
scan-axis encoder in the carriage. See Scan-axis encoder strip check on page 465.
For more information, see Image quality troubleshooting on page 475.
Table 5-4 Printhead control link

Test E-box fiber-optics PCA (11001)
Description This test checks the e-box electronics needed for the processing of printing data and the transfer of the data to the
printheads through the fiber-optic cable. It will verify that the e-box Fiber Optics PCA is properly connected to the
corresponding Engine PCAs. Note: This diagnostic does not check the fiber-optic connection between the e-box Fiber
Optics PCA and the Carriage Fiber Optics PCA. In orden to verify this is working run the diagnostic 11002.
Test steps:
● Formatter test
● Engine board test
● E-box fiber-optics PCA connectivity test
– It accesses the e-box fiber-optics PCA internal registers.
● Engine board to e-box fiber-optics PCA connectivity test
– It checks that all the cables going from the engine board to the e-box fiber-optics PCA are not only
connected but also plugged into the correct connectors.
● E-box fiber-optics module
– It checks that the fiber-optic connector is plugged in, reads the internal registers in the fiber-optics module,
and verifies the data is reaching the fiber-optics module.
In summary, this test checks the formatter, the engine boards, the cables between the engine boards and the e-box
fiber-optics PCA, the e-box fiber-optics PCA, and the e-box fiber-optics transceiver. Regarding the e-box fiber-optics
PCA, it checks everything except the high-speed lane coming from the carriage.
Pass criteria All electronics before the fiber-optic connection work well.
Fail criteria There is a failure in the processing of the data needed for printing. This failure is located before the fiber optics.
Test Optical link (11002)

Table 5-4 Printhead control link (continued)

Description This test checks the optical fiber cable connection to the fiber-optics PCA. It will verify that the cable is properly plugged
and functioning correctly. The test is performed when the firmware tries to communicate with the fiber-optics PCAs:
first the one in the e-box, and then with the fiber-optics PCA located on top of the printhead carriage. Thus, it can be
checked whether the communication of these PCAs through the fiber-optics cable presents any problem.
NOTE: This test does not check the connection between the e-box fiber-optics PCA and the Engine PCAs. If this test
fails, first run the diagnostic 11001 to verify that the problem is not before the fiber-optics communication.
Test steps:
● Carriage fiber-optics PCA connectivity Test
– It accesses the carriage fiber-optics PCA internal registers.
● If the above check fails, then the test requires user interventation in order to check the status of some LEDs in the
e-box and in the carriage.
– E-box:
○ If LED0 is OFF → Plug the fiber-optics module in the e-box Side
○ If LED2 is OFF → Change e-box fiber-optics PCA
○ If LED7 is OFF → Plug or change the ID cable
○ If LED10 is OFF → This LED is ON when the link is up
– Carriage:
○ If LED0 is OFF → Plug the fiber-optics module in the e-box Side
○ If LED1 is OFF → Change Carriage fiber-optics PCA
○ If LED2 is OFF → Change fiber-optics
○ If LED6 is OFF → Plug or change the ID cable
○ If LED10 is OFF → This LED is ON when the link is up
○ If LED1 in the Carriage is ON and LED1 in the e-box is OFF, then the fiber-optics needs to be changed.
● Fiber-optics PCA link layer errors


– It checks that the fiber-optic connection has no breaks and works perfectly.
A sketch of the LED distribution is shown below:
Pass criteria Fiber-optic cable is working correctly.
Fail criteria There is no communication through the fiber-optic cable. This can occur when the fiber-optic cable is damaged, broken,
or not connected.
1. Check fiber-optic LEDs in fiber-optics PCA (e-box or carriage).
2. Replaced any broken or malfunctioning parts.
Test Carriage fiber-optics PCA (11003)
Description This test checks the link to the fiber-optics PCA in the carriage and its connections to the printhead interconnect boards.
Success means that the optical fiber link is up and running and each connector in the fiber-optics PCA has a properly
inserted cable connector.
Test steps:
● Carriage fiber-optics PCA to printhead board connectivity test
– It checks that all the cables going from the carriage fiber-optics PCA to the printhead board are plugged in.
● Initialize the Horus interface
– If it fails, then the user needs to run a test and check the status of one LED.
● Printhead connectivity test
– It checks that the printhead is well connected in the printhead pocket.
If the printhead boards are not connected to the correct carriage fiber-optics PCA interface, the user will notice printing
errors. In that case, the user needs to check that all the cables going from the carriage fiber-optics PCA to the printhead
board are plugged into the correct interface.
Pass criteria Successful connection to the printhead
Fail criteria There is no correct connection between the carriage fiber-optics PCA and the printhead interconnect boards. This could
be due to:
● A disconnected cable
● Failure to initialize the printhead interconnect board
● A disconnected printhead

Test Printhead interconnect connectivity (11004)
Description This test checks the data lines from the fiber-optics PCA to the printhead interconnect board. If these data lines are OK,
the green LED on the printhead interconnect board is turned on.
Pass criteria The data lines reach the printhead interconnect board correctly from the fiber-optics PCA. This test lights up the DS1
and DS15 LEDs of the printhead interconnect PCA. If one of them is not lit, replace the printhead interconnect PCA
and/or the cable to the fiber-optics PCA.
Fail criteria The data lines going from the fiber-optics PCA to the printhead interconnect board do not transmit the data properly.
This test lights up the DS1 and DS15 LEDs of the printhead interconnect PCA. If one of them is not lit, replace the
printhead interconnect PCA and/or the cable to the fiber-optics PCA.
Test FO PCAs version check (11005)
Description This test checks the versions of the fiber-optics PCAs in case you have a hardware or firmware mismatch.
Pass criteria This test is purely informative and has no pass or fail criteria.
Fail criteria This test is purely informative and has no pass or fail criteria.
Test Printheads electrical status (11006)
Description This test displays the electrical state of the printheads. It should be executed when the printer is idle.
Pass criteria If the test returns #OK, there is no problem.


Fail criteria ● #Not inserted: The printhead is not inserted.
● #Fails continuity: Electrical continuity failure. Communication between printhead and interconnect board is not
working properly. Clean the printhead and the board electrical pads and re-insert the printhead. If the problem
persists, swap the printhead with one of the same color in the adjacent slot. If the error moves with the printhead,
replace the printhead. If the error persists in the same slot, there may be a physical problem in the
interconnection. Make sure that the black metal back support of the printhead interconnect board is correctly
mounted and screws are tight, and call your support representative if the problem persists in the same slot.
● #Voltage failure: This error may have been caused by a short-circuit in the printhead electrical pad or the
printhead board. Remove the printhead and inspect the electrical pads, making sure they are clean and nothing is
creating a short-circuit. Also, inspect the printhead board electrical contacts and make sure they are not bent or
damaged. You can swap the printhead with another one of the same color. If the problem persists in the same slot,
call your support representative, as the printhead board may have to be replaced. If the error follows the
printhead, replace the printhead.
● #CSDATA not responding: The printhead is not responding to communication attempts from the printhead
interconnect board. The printhead may not be correctly inserted, or the electrical pads may be dirty or damaged.
Clean the printhead electrical pads and the printhead board contacts and re-insert the printhead. Make sure it is
correctly inserted. If the problem persists, swap the printhead with one of the same color in the adjacent slot. If
the error moves with the printhead, replace the printhead. If the error persists in the same slot, there may be an
electrical problem. To discard a transient electrical perturbation, shut down the printer, restart it a minute later,
and do a printhead replacement again. If the same problem occurs, the printhead interconnect board may be
faulty. Contact your support representative.
● #Temperature extremely high: The printhead temperature is extremely high. Make sure the printing operating
conditions are OK, and reseat the printhead. A likely cause of this error is that printhead nozzles are blocked and
ink cannot be fired. Try recovering the printheads by manual cleaning or by hard cleaning through the Internal
Print Server. If the error does not disappear, replace the printhead.
● #Temperature too high: The printhead temperature is too high. Make sure the printing operating conditions are
OK, and reseat the printhead. A likely cause of this error is that printhead nozzles are blocked and ink cannot be
fired. Try recovering the printheads by hard cleaning through the Internal Print Server. If the error does not
disappear, replace the printhead.
● #Temperature extremely low: The printhead temperature is extremely low. The operating temperature could not
be reached. The most likely cause is printhead damage in its resistors due to a substrate crash. Replace the
printhead.
● #Temperature too low: The printhead temperature is too low. The operating temperature could not be reached.
The most likely cause is printhead damage in its resistors due to a substrate crash or smear. Replace the
printhead.
● #Bad acumen information: The information encoded in the printhead is incorrect. If it is a genuine HP printhead,
return it to HP.
● #Bad acumen access: The printhead’s internal data cannot be accessed. The printhead may not be correctly
inserted, or the electrical pads may be dirty or damaged. Clean the printhead electrical pads and the printhead
board contacts, and retry the printhead replacement process. If the problem persists, try another printhead of the
same color. If the problem still persists in the same slot, there may be an interconnection problem. Make sure that
the black metal back support of the printhead interconnect board is correctly mounted and screws are tight.
● #Wrong model: The printhead is not the correct model to be used in this printer.
● #Mismatch: Wrong printhead internal data. The printhead is not the correct model to be used in this printer.
● #Energy calibration failure: This can be either a printhead problem or a printhead interconnect PCA problem.
Remove the printhead and retry the printhead insertion process. If the problem persists, replace the printhead. If
the problem still persists, the printhead interconnect board may need to be replaced. Contact your support
representative.
Test Printhead insertion (11007)


Description This test checks the printhead insertion mechanism. You should use it only if insertion problems have repeatedly been
observed in a particular printhead slot. The test will move the carriage to the access position. There you can select any
specific slot to check, remove, or insert any printhead, and check that it is properly detected.
Test steps:
● Slinky board to printhead board connectivity test
– It checks that all the cables going from the Slinky board to the printhead board are plugged in.
● Initialize the Horus interface
– If it fails, then the user needs to run the Trailing Cable Connectivity test and check the status of LED DS15.
● Printhead connectivity test
– It checks that the printhead is well connected in the printhead pocket. If it fails, then the user needs to run a
test and check the status of LED DS7.
If the printhead boards are not connected to the right Slinky interface, the user will notice printing errors. In that case,
the user needs to check that all the cables going from the Slinky board to the printhead board are plugged into the
correct interface.
Pass criteria The printhead is correctly inserted into the printhead pocket.
Fail criteria The printhead is not correctly inserted into the printhead pocket.
Test Fiber-optics test (11008)
Description This test is used to test the fiber-optics cable. It recursively reads the communication signals of the fiber-optics cable.
Pass criteria All the signal readings of the fiber-optics cable have been successful.
Fail criteria Some of the readings have not been received correctly. In this case, there might be a communication problem from the
E-box to the Carriage. If the problem persists, install a new Fiber-Optics cable.
Table 5-5 Substrate path mechanics

Test Substrate path sensors (41001)
Description This test allows you to check that the following sensors are working properly: spindle latches (loading table latches).
Pass criteria If all of them work properly (check that they open and close), you can see changes in screen status.
Fail criteria Check the connections and replace those don’t work.
Test Motors check (41002)
Description This test checks motor movement through PWM and reading encoders. This test can be done with substrate loaded.
Very small movements are made, which can be felt by touching the corresponding spindle with a finger.
Pass criteria If the test is able to read movement.
Fail criteria If movement is not detected.

Table 5-5 Substrate path mechanics (continued)

In case of failure, run the following tests depending on the failure:
● Substrate advance motor failure: Run the Main roller motor test (41003). See below.
● Substrate input, output: Run the Motors calibration(41004). See below.
NOTE: While running the Motors calibration, the motor must be unmounted.
If the failure comes from the motor (and not from the mechanism), run the following tests:
● Check the power supplies, running the Power supplies test (10004). See Table 5-22 E-cabinet on page 586.
● Check e-cabinet to e-box communication, running the Check e-cabinet e-box communication test (10006). See
● Check e-cabinet to engine adaptor PCA communication, running the Engine adaptor PCA comm. test (01007). See
● Check e-cabinet to e-box connectivity, running the Engine adaptor PCA comm. test (01007). See Table 5-21 E-box
on page 585.
Test Main roller motor test (41003)
Description This test checks how the roller moves, and its friction.
Pass criteria Automatically provided
Test Motor calibration (41004)
Description This test makes a series of movements to ensure that substrate movement accuracy is OK, and performs a statistical
analysis; so it takes some time to complete. The following motors can be tested: MI and MO.
Pass criteria Automatically provided.


Fail criteria The test takes 8 minutes per motor. You can select MI and MO in order to calibrate servos and diagnose motors; in
addition, you can start the printer in diagnostic mode and run this test with the motor detached, in case you are not sure
whether the problem comes from motor or gearbox.
More details of the test flow and pass/fail criteria:
Test Encoder calibration (41005)
Description This test calibrates the analog encoder, which calibrates the whole gain chain to obtain an optimized reading of the
encoder disc by the encoder reader PCA.
Pass criteria The test itself provides feedback about whether calibration was successful or not.
Test Drive roller calibration (41006)
Description This test calibrates substrate advance, slope, and roller eccentricity.
Pass criteria When the calibration is successful, feedback is provided by the test.
Note: Beware that not all substrate types are suitable for this calibration. Preferably use self-adhesive vinyls of around 78 in
width, such as Avery MPI3000 and HP Permanent Gloss Self-Adhesive, or papers such as HP Photorealistic. Do not use
any backlit, PP, PE/PET, or PVC substrates. Before proceeding, make sure that the substrate is correctly loaded and
aligned. The calibration takes about 25 minutes and the substrate will be advanced about 8 meters. Check that there is
enough substrate on the input roll before proceeding. Press Continue to proceed or Cancel to exit.
Test Drive roller check (41007)
Description This test checks that the calibration is OK.


Fail criteria Automatically provided
Test Substrate path lights (41008)
Description This test checks substrate path lights installed in the printer (Print-zone top light). During the process, the printer allows
the user to switch the light on and off.
Pass criteria If the light is able to switch on/off correctly and the feedback shown on the screen is also correct, the print-zone top
light LED bar is working properly.
Fail criteria a. The light is not switching on/off:
1. Install a new LED Bar
2. Install a new Motor Drive PCA (Illumination and buttons) if the Print-zone front light is failing
b. Some LEDs are not working in the LED Bar > Install a new LED Bar)
The substrate path troubleshooting workflows integrated with the tests are shown in the following flowcharts.


As a summary, the table below shows which calibrations are required after a component replacement:

Analog encoder Calibrates electronic analog offset and gain of the encoder Encoder disc and PCA replacement
calibration (41005) PCA
MI-MO calibration Calibrates the main characteristics of the motors ● MI-MO replacement
(41004)
OMAS calibration Corrects OMAS pixel-to-microns size and nominal fiducials OMAS replacement
distance
Drive roller calibration Corrects drive roller eccentricity ● Drive roller replacement
(41006)
● Encoder disc and PCA replacement, after
analog encoder calibration
Drive roller calibration Checks OMAS readings against encoder readings, applying ● MA motor replacement
check (41007) current calibration values to verify that drive roller
eccentricity is corrected, and fine-tuning the roller’s slope ● After OMAS calibration
(available to customers) factor.
● After drive roller calibration
If the substrate-advance sensor (OMAS) is replaced, the calibration order is:
1. OMAS calibration
2. Drive roller calibration
Table 5-6 Roll-to-free-fall Kit

Roll-to-free-fall kit checks and Installation
NOTE: 41011, 41012, 41013 and 41014 will FAIL if the Roll-to-free-fall Kit is not properly installed (using diagnostic 41010).
Test Install kit (41010)
Description This diagnostic sets the Roll-to-free-fall Kit as installed in the NVM. In order to be able to use the kit it should be set as
installed by using the diagnostic. This diagnostic is to be executed once all the hardware upgrades have been done.
After execution, reboot the printer is required to finish installation, then run diagnostics 41011 to 41014 to ensure the
kit is calibrated and properly working.
Pass criteria The kit is properly set as installed.
Fail criteria The printer is not able to set the kit as installed.
Test Electronic check (41011)
Description This test checks Roll-to-free-fall electronics. In the test, the printer checks if the kit is set as installed in the NVM. Then,
the communication with the Motor Drive PCA (SOL Solenoid Motor Drive PCA, the Roll-to-free-fall accessory is
connected to this PCA) is checked, and the result is shown on screen.
Pass criteria The SOL Solenoid Motor Drive PCA is properly communicating with the printer.
Fail criteria The printer is not able to communicate with the SOL Solenoid Motor Drive PCA or the Roll-to-free-fall Kit is not installed
in the printer.
Test Sensors check (41012)

Table 5-6 Roll-to-free-fall Kit (continued)

Description This test allows you to check that the following sensors are working properly: Tension roller latch, tension roller lever
(tension roller pinchwheel system) and substrate collector sensor. It also shows the status of the spindle latches
(loading table latches) which are already installed without the Roll-to-free-fall kit and can be also checked individually
with test 41001 Substrate path sensors.
Pass criteria If all the sensors work properly (check that they open and close), you can see changes in screen status. The substrate
collector sensor should register as closed if the sensor is blocked by something opaque, otherwise open.
Fail criteria Check the connections and replace those not working. The test could also fail because the Roll-to-free-fall Kit is not
installed in the printer.
Test MF and MO motors check (41013)
Description This test checks motor movement through PWM and reading encoders. This test can be done with substrate loaded.
Very small movements are made, which can be felt by touching the corresponding spindle with a finger.
NOTE: During the kit installation, the MO motor needs to be disconnected. To ensure that it is working, this test also
includes the MO motor check.
Pass criteria The test is able to read movement. This means that the motor and encoder are working properly.
Fail criteria The movement is not detected. The test could also fail because the Roll-to-free-fall Kit is not installed in the printer.
In case of failure, run the following tests depending on the failure:
● Run diagnostic 41014 Motor calibration to calibrate the Media Floor motor (Roll-to-free-fall motor)
NOTE: While running the Motor calibration, the motor must be unmounted.
If the failure comes from the motor (and not from the mechanism), run the following tests:
● Check the power supplies, running the Power supplies test (10004). See Table 5-22 E-cabinet on page 586.
● Check e-cabinet to e-box communication, running the Check e-cabinet e-box communication test (10006). See
● Check e-cabinet to engine adaptor PCA communication, running the Engine adaptor PCA comm. test (01007). See
● Check e-cabinet to e-box connectivity, running the Engine adaptor PCA comm. test (01007). See Table 5-21 E-box
on page 585.
Test Motor calibration (41014)
Description This test is used to calibrate the Media Floor motor (Roll-to-free-fall motor). It makes a series of movements to ensure
that substrate movement accuracy is OK, and performs a statistical analysis (it takes some time to complete). The
printer can also be started in diagnostic mode and run this test with the motor detached, in case you are not sure
whether the problem comes from motor or gearbox. This test takes about 8 minutes.
Pass criteria Automatically provided.
Fail criteria The test will inform about any error found.
Table 5-7 Printhead primers

Test Primer check (46002)

Table 5-7 Printhead primers (continued)

Description This test checks the primer components. It can be executed when experiencing issues with the primer (such as leakage
system errors, current errors for valves/solenoids, etc.), in order to reproduce the issue or to check if it has been solved
after a repair. User can select which printhead to test.
NOTE: This diagnostic will waste some ink and some Printhead cleaning roll cloth.
Pass criteria The diagnostic finishes correctly and no system errors appear in the IPS while executing the test.
Fail criteria During the test, some system error has appeared in the IPS. Some system errors that might appear are:
● 46.03.00:40 Carriage Interconnect PCA current out of range.
● 46.04.0X:40 Primer solenoid valves X current out of range.
● 46.05.0X:40 Primer pump X current out of range.
● 46.05.0X:06 Primer X leakage detected.
To solve the issue, follow the troubleshooting in the related system error.
Table 5-8 Substrate-advance sensor (OMAS)

Test Enable advance sensor (50001)
Description This test enables the substrate-advance sensor for diagnostic purposes. The purpose of this utility is to enable or
disable the substrate-advance sensor, to be able to measure and troubleshoot the influence of the sensor on print-
quality problems. Sometimes, disabling the sensor is recommended for best print quality.
NOTE: It is possible to disable or enable the OMAS from the Internal Print Server, using the Printing adjustment
command or the Printing Adj. button.
Pass criteria None, it just tells you whether the action was done or not.
Test Disable advance sensor (50002)
Description This test disables the substrate-advance sensor for diagnostic purposes. The purpose of this utility is to enable or
disable the substrate-advance sensor, to be able to measure and troubleshoot the influence of the sensor on print-
quality problems. Sometimes, disabling the sensor is recommended for best print quality.
NOTE: It is possible to disable or enable the OMAS from the Internal Print Server, using the Printing adjustment
command or the Printing Adj. button.
Pass criteria None, it just tells you whether the action was done or not.
Test Cleanliness check (50003)
Description This test checks whether the substrate-advance sensor optics are clean or not. If not, clean the sensor window.
Pass criteria The sensor window is clean.
Test Sensor calibration (50004)
Description This test enables the subtrate-advance sensor for diagnostic purposes. The calibration prints interference patterns that
should be visually inspected.

Table 5-8 Substrate-advance sensor (OMAS) (continued)

Instructions ● Run this calibration only after replacing the substrate-advance sensor.
● Before calibrating the sensor, use the cleanliness check and clean it if necessary.
● Printheads must be aligned for accurate calibration.
● If the printer has been printing, allow it to cool down for at least an hour before running this calibration.
● Not all substrate types are suitable for this calibration. Preferably use self-adhesive vinyls of around 78 in width,
such as Avery MPI3000 and HP Permanent Gloss Self-Adhesive, or papers like HP Photorealistic. Do not use any
backlit, PP, PE/PET, or PVC substrates. Ensure that the substrate is correctly loaded and aligned, and that you
have at least 5 meters of substrate available for the calibration.
Follow the instructions on the screen. The calibration takes about 30 minutes.
Pass/fail criteria Provided in Print Care depending on test results.
Test Show sensor status (50005)
Description This test shows the substrate-advance sensor (OMAS) status: enabled or disabled. If enabled, it is being used to monitor
the substrate advance.
A numeric code will also be displayed. The meanings of these codes are shown below.
OMAS navigation status Code Meaning
ENABLED_BY_DEFAULT 0 Navigability has not been checked yet, but OMAS navigation is enabled (can
happen after printer start or after fast substrate load).
ENABLED_AFTER_CHECK 1 OMAS navigating. Navigability has been checked and the OMAS is navigating.
ENABLED_BY_USER 2 OMAS navigation has been forced by user (through Print Care Diagnostic Enable
OMAS).
ENABLED_BY_FORCE 3 OMAS navigation is forced by product.ist constant FORCE_NAVIGATION.
DISABLED_BY_DEFAULT 4 Navigability has not been checked, but OMAS navigation is disabled (can happen
after printer start or after fast substrate load).
DISABLED_BY_FIDUCIALS 6 OMAS navigation has been disabled because fiducials are not detected.
DISABLED_BY_ILLUMINATIO 7 OMAS navigation has been disabled because illumination calibration failed.
N
DISABLED_BY_SAND_REM 8 OMAS navigation has been disabled because sand removal calibration failed.
OVAL
DISABLED_BY_AFTER_SAN 9 OMAS navigation has been disabled because after-sand removal calibration
D failed.
DISABLED_BY_MISNAVIGATI 10 OMAS navigation has been disabled because it was below threshold during
ON check.
DISABLED_BY_MEDIA_TYP 11 OMAS navigation has been disabled because the preset of the loaded substrate
E specifies that it is not navigable.
DISABLED_BY_USER 12 OMAS has been forcefully disabled by user (through Print Care Diagnostic
Disable OMAS).
Pass criteria None.
Test Read PixelSizeOffset value from Nvm (50006)


Description This test shows the current stored value for the sensor calibration (PixelSizeOffset). This value is saved after executing
Sensor calibration (50004) or Write PixelSizeOffset (decimicrons/pixel) value to Nvm (50007). Note that this test only
shows you the current stored value, it does not allow to change that value.
NOTE: This is a temporary diagnostic that may disappear in the future. It is designed to be able to read the parameter
value in case sensor calibration (50004) is not working properly.
Pass criteria The test shows correctly the stored value for PixelSizeOffset.
Fail criteria The test is not able to show the stored value for PixelSizeOffset.
Test Write PixelSizeOffset (decimicrons/pixel) value to Nvm (50007)
Description This test allows user to manually calibrate the substrate-advance sensor. The purpose of this diagnostic is the same as
Sensor calibration (50004) but in this test user can directly modify the parameter PixelSizeOffset, while with sensor
calibration the printer uses a plot to calibrate the value.
Note: this is a temporary diagnostic that may disappear in the future. It is designed to be able to write the parameter
value in case sensor calibration (50004) is not working properly.
NOTE: This is a temporary diagnostic that may disappear in the future. It is designed to be able to write the parameter
value in case that Sensor calibration (50004) is not working properly.
Instructions Run this calibration only after replacing the substrate-advance sensor.
Pass criteria The value PixelSizeOffset is correctly stored in the Nvm.
Fail criteria The value PixelSizeOffset is not correctly stored in the Nvm.
Test Media navigability test (50008)
Description Use this test to verify the recommended Advance compensation configuration for the loaded media.
NOTE: This test can also be used as a troubleshooting step for the OMAS sensor:
1. Load a well known navigable media, like a self-adhesive vinyl such as Avery MPI3000 or HP Permanent Gloss Self-
Adhesive, or paper like HP Photorealistic.
2. Run test 50008; If it returns "automatic advance compensation," the sensor works properly. If it returns "manual
advance compensation," the current OMAS sensor could be defective.
Pass criteria Returns the recommended compensation (automatic or manual) and a code (see table below).
OMAS navigation status Code Meaning
ENABLED_BY_DEFAULT 0 Navigability has not been checked yet, but OMAS navigation is enabled (can
happen after printer start or after fast substrate load).
ENABLED_AFTER_CHECK 1 OMAS navigating. Navigability has been checked and the OMAS is navigating.
ENABLED_BY_USER 2 OMAS navigation has been forced by user (through Print Care Diagnostic Enable
OMAS or through Print Adjustments).
ENABLED_BY_FORCE 3 OMAS navigation is forced by product.ist constant FORCE_NAVIGATION.
DISABLED_BY_DEFAULT 4 Navigability has not been checked, but OMAS navigation is disabled (can happen
after printer start or after fast substrate load).
DISABLED_BY_FIDUCIALS 6 OMAS navigation has been disabled because fiducials are not detected.
DISABLED_BY_ILLUMINATIO 7 OMAS navigation has been disabled because illumination calibration failed.
N
DISABLED_BY_SAND_REM 8 OMAS navigation has been disabled because sand removal calibration failed.
OVAL


DISABLED_BY_AFTER_SAN 9 OMAS navigation has been disabled because after-sand removal calibration
D failed.
DISABLED_BY_MISNAVIGATI 10 OMAS navigation has been disabled because it was below threshold during
ON check.
DISABLED_BY_MEDIA_TYP 11 OMAS navigation has been disabled because the preset of the loaded substrate
E specifies that it is not navigable.
DISABLED_BY_USER 12 OMAS has been forcefully disabled by user (through Print Care Diagnostic
Disable OMAS or through Print Adjustments).
DISABLED_BY_DEVICE_ERR 13 THIS CODE IS NOT CURRENTLY USED.

OR
DISABLED_BY_SIDEB_JOB 14 OMAS navigation has been disabled because the current job is of Dual Side B.
DISABLED_BY_INK_COLLEC 15 OMAS navigation has been disabled because ink collector is installed.
TOR
DISABLED_BY_WATERMAR 16 OMAS navigation has been disabled because the media loaded contains
K watermarks.

Figure 5-1 Substrate-advance calibration workflow
Table 5-9 Substrate path vacuum

Test Vacuum system (43001)
Description This test checks whether the platen vacuum system is working as expected. It checks that the pressure without vacuum
and with maximum vacuum is within the expected range. Make sure there is no substrate loaded or covering the platen
during this test, otherwise its result will not be reliable.

Table 5-9 Substrate path vacuum (continued)

Pass criteria Value within margins will return a passed test.
Fail criteria 1. If the test fails, check that the vacuum pump is powered and spinning.
2. Check that the vacuum sensor is properly connected and working.
3. Reset calibration.
Test Reset vacuum pump usage (43002)
Description This test simply resets the vacuum pump life counter. It should be used only when the vacuum pump is replaced.
Pass criteria None
Fail criteria None
This test should be executed only when the vacuum pump is replaced.
Test Vacuum sensor defaults (43003)
Description This test restores a default factory calibration, in case calibration has failed or the calibration is missing.
Pass criteria None.
Fail criteria None.
This test will set default factory calibration values.
Table 5-10 Scan axis

Test Scan-axis encoder manual check (86001)
Description This test can be used to check the scan-axis encoder. User will be able to manually move the carriage while the encoder
reading (in encoder units) is shown in the screen. Test will ask user to open the window to safely access the carriage.
After that, the encoder units show in the screen. This test should be used when experiencing problems with the scan-
axis: carriage not moving or repeated scan-axis motor shutdowns in a certain part of the scan-axis. In this case, the
carriage can be moved to the area where the failures are detected to determine if the problem is related to the encoder
readings or to the motor.
Pass criteria Encoder readings change with the movement of the carriage. This ensures that the encoder signal is being read by the
printer.
NOTE: It is not checking if the encoder measures are correct, to do that perform diagnostic 86002 Scan-axis analysis.
Fail criteria The encoder readings are not changing when user manually moves the carriage. In this case, the printer is not receiving
the encoder signal. Check that the encoder cable connected to J7 in PH Interconnect 1 (OPT) is not damaged and
correctly connected. If problem persists, install a new Optical Encoder (K4T88-67014).
Test Scan-axis analysis (86002)
Description This test performs a series of movements at different speeds and saves values in a log file. It also returns the measured
scan-axis length. Use the data extraction procedure to save the data from the printer.
Pass criteria All the movements included in the test are finished and the data saved. If the measured scan-axis length does not
match the recorded value, the test passes; however, it displays a warning about the discrepancy.
Fail criteria At least one of the movements is not completed. It also fails if the scan-axis length is out of the expected range.

Table 5-10 Scan axis (continued)

Test Move to service position (86006)
Description This test uncaps the carriage and moves it to the service position. After that, the printer is shut down and you are asked
to turn off the main switch to work within a safe mode.
The test helps you to move the carriage to the service position and shut down the printer automatically. Remember
that if this operation will take a long time, you are recommended to remove the printheads and put them in the orange
caps.
Pass criteria The carriage completes the movement to the service position with no issues.
Fail criteria The test fails if the printer cannot move the carriage to the service position, perhaps because of a substrate jam.
Table 5-11 Scan-beam

Test Scan-beam EE check (48001)
Description This test is intended to check scan-beam electronic checks (PCAs, output voltages and fuses). In the test, the PSU 4
voltage (PSU that powers the PPS motors and PCAs) is shown with its range of accepted values and the scan-beam fuse
in the e-cabinet is also checked. Finally, communication with the 2 Motor Drive PCAs is checked and the result shown on
screen.
Pass criteria No error appears during the test, this ensures that the electronics of the scan beam are working correctly: the PSU
provides the correct voltage, the scan beam fuse is OK, and there is communication with both motor drive PCAs. For a
complete functional check that also ensures that the Motor Drive PCAs, the motors and encoders are working properly,
run subsystem test 48002.
Fail criteria If any of the test steps fail, the result is shown on screen.
Test Scan-beam motor and encoder check (48002)

Table 5-11 Scan-beam (continued)

Description This test moves the scan-beam motor to the different positions and makes all the possible checks in every position.
This test could be useful to make a complete functional check of the system since it moves the scan-beam to a
complete set of representative positions while checking all the error conditions. This test should be executed to better
diagnose the cause of Scan-Beam system errors (shutdowns, misalignments, Homing flag not found, engage
timeout…).
After checking the electronics (as in test 48001), this test follows these steps:
1. Scan-beam moves to PRINTING position (carriage will move to capping position for safety reasons).
2. Scan-beam motors make an ENGAGE movement if needed (only if for some reason they are disengaged).
3. Scan-beam moves to SUBSTRATE_LOADING position.
4. Scan-beam moves to CUSTOM PRINTING position.
5. Scan-beam returns to PRINTING position.
During steps 3 to 5 the test shows the PWM consumed during the movement (Min, Average, Max) and informs the user
if vibrations/EE noise were found. If any error is found during the execution (shutdown, homing flag not found,
misalignment or engage timeout) the test reports it and in some cases tries to better diagnose the issue.
Pass criteria All the movements are completed correctly. In this case, the scan-beam seems to be working correctly. If there are still
some issues, it might be an intermittent issue and you could execute the test 48003 to move the scan-beam to the
position where the issue appears and reproduce the error several times.
Fail criteria One or more of the movements have failed. The test reports the failure and possible corrective actions.


Test Scan-beam movement (48003)
Description This test allows users to move the scan-beam to any defined position in closed loop: PRINTING POSITION, SUBSTRATE
LOADING position or CUSTOM PRINTING POSITION (user can set a custom position between 2.4 and 20 mm). The test
can be useful to attempt reproduction of certain printer issues, for example, if a user is experiencing intermittent
MISALIGNMENT errors only when going to PRINTING POSITION, the service engineer can try to reproduce the error
several times. If any error is detected during the movement, the issue will be notified. The motor moves to the selected
position without problems.
Pass criteria The motor moves to the selected position without problems.
Fail criteria The motor movement is not completed as expected.

Test Scan-beam motor open-loop movement (48004)


Description This test moves the scan-beam motors in open-loop. This test can be useful if something is trapped by the scan-beam
or when a big misalignment is found, but only if the printer unable to get out of the situation by a normal procedure
(moving the scan-beam from the IPS).
48004 allows users to move each of the two scan-beam motors separately in open loop during 2s. Encoder units (1
encoder unit equals approximately 0,05mm) are displayed on screen as information, but they are not used to compute
the PWM signal of the motor.
WARNING! This test should be executed by service engineers only, misuse could lead to printer mechanical failure.
Misalignment between the 2 motors should always be under 1000 encoder units (5cm). The test does not limit
misalignment that can be introduced (so the test can be executed even if the encoders are not working properly), but
the service engineer must ensure that the actual mechanical misalignment between the two sides of the scan-beam is
under the 5cm limit.
WARNING! When you finish the test, ensure that the scan-beam is in a safe position (with misalignment under 100
encoder units) and move the scan-beam to MEDIA_LOAD position with the IPS before you continue using the printer.
WARNING! Each time the button that moves each of the motors is pressed, the selected motor will add 2 seconds of
movement. It is recommended to wait for the movement to finish (wait 2s) before pressing the move button again
because if you press the button several times quickly control of the system may be lost.
Pass criteria The motor moves without problems.
Fail criteria The motor movement is not completed as expected.

Table 5-12 Ink delivery system

Test ISS electronics (22001)
Description IDS Electronic Test Procedure. This test is intended to check IDS electronic checks (PCAs, output voltages and fuses). It
tests the PSUs related to the IDS and communication with the IDS Air PCA and IDS Ink PCA. It also checks the electrical
presence of all the connected elements in the IDS along other internal checks for the PCAs.
NOTE: This diagnostic should not be executed several times in a row since it powers the ink pumps for a small amount
of time in order to check that they are working properly. Thus, executing too much could lead to a intermediate tank
leakage.
Pass criteria The PSU outputs related to the IDS are working properly, and there is communication with the IDS Air PCA and IDS Ink
PCA. All the elements connected to the IDS PCAs are properly connected.

Table 5-12 Ink delivery system (continued)

Fail criteria The printer is not able to communicate with the IDS Air PCA, IDS Ink PCA (the PSU 2 is not providing the correct power or
communication issue with any of the PSUs) or there is some element not connected to the IDS PCAs.
Test Air pressure system (22002)
Description This test sets Air Pressure System to the normal printing air pressure level (around 4750 mpsi) for a certain period of
time. This test is useful to check that APS system is working (air pump, air relief valve, and air pressure sensor). It can
also help to detect air leakage.
Main steps:
1. To reach the right pressure value, the printer will turn on both air pumps (it will work in ‘open’ loop for 45 seconds
before raising an error in case it cannot reach the right air pressure).
2. Once it has reached the right pressure, the air pump stops. If the pressure decreases too much, one of the two air
pumps is turned on to regain the right pressure value, and then this pump is turned off. The next time the
pressure decreases too much, the other air pump is turned on.
3. At the end of the test (user can select the time to maintain the system pressurized, a recommended value is 10
minutes), the test APS is depressurized. It is important to wait the end of depressurization before going ahead.
Pass criteria The air pressure system is able to reach a pressure near to 4750 psi (range 4500-5000) and to maintain it during 10
minutes, and then printer is able to depressurize completely. In this case, all the elements in the Air Pressure System
are working properly and there is no leakage.
Fail criteria There are several points where the test can fail:
1. The APS is not able to pressurize in the first 45s to 4500-5000 mpsi -> If the pressure has started increasing but
has not been able to reach the target level, there is probably a leakage or an issue with an air pump. Check that all
air tubes are correctly connected and that there is no leakage. If the pressure is not increasing at all and there is
no leakage, check the cables powering the Air Pumps and the relief valve.
2. The APS is able to pressurize to the target level but it is not able to maintain it during the selected time. In this
case probably one air pump is not working.
3. The APS is not able to depressurize the system after the selected time. In this case there is probably an issue with
the relief valve.
Possible error messages

● Air pressure sensor failure (pressure below expected)
● Error with relief valve
Test Ink cartridge LEDs (22004)
Description Ink supply LEDs test. This test lets you select one supply LED. The selected supply LEDs will start blinking sequentially
(each LED will blink for a small amount of time, then it will remain off while the test continues with the other LEDs of the
supply) then the 3 LEDs of the supply will blink at the same time. The user can also select to test all supplies LEDs, then
the sequence explained before will be repeated for all supplies (this option might take a few minutes, but allows the
user to check all LEDs without going back to the IPS to select the next supply).
Pass criteria LEDs for selected line turn on and off in the described sequence. Each LED blinks in its turn and the 3 LEDs blink
together at the end.
Fail criteria Any of the LEDs for selected lines is not able to turn on or it is on when it should not be (for example, if red LED is on
while it is the turn for white LED to blink). In this case, check the other LEDs for the supplies connected to the same
cable. If they are also experiencing problems, check the connection with the IDS Air PCA. If they are working well, check
the connection with the LED PCA for the affected supply and change it if necessary


Test Intermediate tanks information(22005)
Description This procedure displays the number of life cycles (full refill) of the intermediate tanks and also the % of ink for each
intermediate tank.
Test Ink supplies check (22009)
Description This test displays the ink level of each supply and allows the user to verify if the ink supplies connector is correctly
detecting the supply. In order to do this, the test asks to select an ink cartridge and then to disconnect and reconnect its
connector. This test should be used when experiencing issues with the ink cartridges detection in order to reproduce the
issue or verify that the system works properly.
Pass criteria The test detects the correct disconnection and connection with the ink cartridge.
Fail criteria The test is not able to detect the correct connection with the ink cartridge.
Test Electrovalves (22010)
Description You can select which valve to test (actually, the user selects a pair of electrovalves to test, since the control signal is
common for each pair of electrovalves, they can not be controlled independently), and the amount of time before the
test begins. When the test begins the selected valves will be opened and closed several times. The user can access to
the electrovalves and verify that the state is changing. It might be difficult to determine if one of the two valves that are
changing its state at the same time is not working (because of the noise produced by the other one). If you want to
determine if a certain valve is working, it is recommended to disconnect the other one in the pair to be able to hear it
correctly. An example of a use case could be: The K valve may be failing, and the service engineer wants to use
diagnostic 22010 to determine if it is working. Since the K and the C valves are controlled with the same cable, they will
be activated and deactivated at the same time. The service engineer disconnects the C valve intermediate connector
and executes the test selecting to test C and K valves. If the engineer is able to hear the noise, then the K valve is
working properly. If he does not hear any noise, the K valve is not changing its state properly. In order to further
diagnose the issue, the service engineer could connect the intermediate connector of the K valve to the C electrovalve
and execute the test again (and remember to reconnect the intermediate connector to the correct electrovalve when
the troubleshooting has finished). If he is able to hear the noise in this case (coming from the C electrovalve), the
problem with the K valve is confirmed and a new one should be installed. If the C valve is not changing status, the
problem could be with the cable from the IDS Air PCA to the K C electrovalves.
Pass criteria The valves are opening and closing, and user can feel it by touching them.
Fail criteria The user can't hear that the valves are opening and closing.
Test IT broken bag recovery (22016)
Description Recover from a broken bag in an intermediate tank. The test checks (by reading the sensor) whether there is really a
broken bag in the intermediate tanks. If not, it clears this error on NVM. So, If there is a real broken bag, you have to
clean the contacts and ink from the air tube, then install a brand new and empty IT and later on run this test again.
NOTE: This test does not refill the empty Intermediate Tank. In order to do this, after running this test, run the
diagnostic 22018 Intermediate tanks replacement or follow the PrintCare Wizard Replace Intermediate Tank.
Test Ink system leakage (22017)
Description Recover from ink system leakage. The test checks (by reading the sensor) whether there is really a system ink leakage.
If not, it clears this error on NVM.
Pass criteria If you have an ink leakage, fix it and clean the sensor, then run this test until no leakage is detected. If a false positive is
given, replace the sensor.


Test Intermediate tanks replacement (22018)
Description This diagnostic covers the process of replacing an individual or all Intermediate Tanks. This should be used mainly in
three cases (the PrintCare wizard "Replace an Intermediate Tank" can also be used to follow a complete guided process.
In fact, if you are logged in as Operator, going through the wizard is the only way to access this diagnostic):
a. If a genuine broken bag has been detected. (22.02.0X:06)
b. When the Intermediate Tanks have reached its end of life and they should be replaced
c. If the printer reports an "Intermediate tank X empty error" (22.02.0X:74)
NOTE: Before running this test, ensure that:
● The new Intermediate Tanks must be empty, otherwise the printer might get damaged.
● The cartridges that will be used to fill the replaced Intermediate Tanks must contain at least 2L of ink.
The tests consists on the following steps:
1. User selects an individual intermediate tank to replace, or all of them.
2. User should introduce the ink cartridges (only the ones corresponding to replaced Intermediate Tanks should be
connected. The ink cartridges corresponding to non-replaced intermediate tanks should be disconnected).
Remember that the used ink cartridges should contain at least 2L.
NOTE: Ensure to start the process of refilling by pressing "Continue" just after the new empty Intermediate Tanks
are installed. The refill may not work properly if there is a time delay between the insertion of the Intermediate
Tanks and the start of the refill process.
3. User should replace the selected Intermediate tanks with new empty Intermediate tanks.
4. The printer will then refill the replaced Intermediate tank. This process could take up to 1 hour, depending on the
number of Intermediate Tanks replaced.
Pass criteria The refill of the intermediate tanks completes correctly.
Fail criteria The refill of the intermediate tanks has not been correctly completed. Printer will inform on the issue found.
Test Calibrate pressure sensor (22019)


Description This procedure displays calibration values for the seven PIP sensors. Then user can select a PIP to be able to introduce
its calibration code (included with the service part, on the label). The Ink Pressure Sensor Calibration is used any time
the PIP sensors are replaced, in order to enter the proper calibration values into the system. The label in the PIP service
part includes three values: the calibration code (marked in red in the picture below), the gain calibration and the offset
calibration. In the diagnostic user should introduce the calibration code (marked in red in the picture). When user
presses "Continue" this value will be checked and stored in the NVM, and the related gain and offset calibrations will be
computed from that code. Then user can check that these computed values (shown in the image) match the ones in the
label.
Pass criteria The Print Care screen reports whether the change of values was successful.
Fail criteria The value introduced in the diagnostic is not correct. Restart the diagnostic ensuring you introduce the code correctly.
Test Ink pressure at printhead (22020)
Description Ink pressure sensor at printhead. This test applies ink pressure and guides the user to insert a syringe on the printhead
position. The ink must refill the syringe to an estimated value according to the pressure applied.
Pass criteria The expected ink volume is achieved in the syringe.
Fail criteria The volume of ink in the syringe is not the expected one.
Test Intermediate tanks refill (22024)
Description This test allows a refill of a selected intermediate tank with ink level monitoring.
This test should not be used at every refill, only in certain situations: when there is a problem in the PIP sensors causing
the automatic refill to fail, in case the Intermediate tanks must be transported (in this way, the risk of a broken bag is
reduced), etc.
Table 5-13 Carriage aerosol

Test Aerosol extraction status(49001)

Table 5-13 Carriage aerosol (continued)

Description This test allows user to test each of the fan bars for the carriage aerosol module. User can introduce a target PWM for
each of the bars and set it. Then user can check there is actually airflow for the selected fans. In this way the fans can be
tested at different working points.
Pass criteria The fans spin correctly at the expected PWM.
Fail criteria The fans do not spin at the expected PWM. In this case, please install new fans.
Table 5-14 Carriage sensors

Test Line sensor check (55001)
Description This test checks correct internal operation and communication with the line sensor located in the sensor box of the
printer. The printer enables the red LED with different current levels and performs a couple of reads to check internal
operation.
Pass criteria The readings obtained by the red LED are higher than a functional threshold.
Fail criteria The readings obtained by the red LED are lower than a functional threshold.
● This test requires a loaded white substrate.
● It will activate vacuum, substrate advance, scan axis.
Test Line sensor counter reset (55002)
Description This test deletes usage counters for line sensor, number of cycles, and working hours.
NOTE: This test should be run only when a line sensor is replaced.
Pass criteria Not applicable
Fail criteria Not applicable
Test Line sensor calibration (55003)
Description The line sensor calibration should be performed mainly after replacing a line sensor or a sensor box. It is done in two
steps:
1. Calibration of the sensor, by measuring the white of a substrate and a dark area. During this first part, you can see
that the printer places the line sensor at the top of the substrate, taking measurements (measuring the white
area), and then it places the sensor at the top of the printhead cleaning roller, performing other measurements
(measuring a dark area). A white substrate must be loaded: the substrate cannot contain color, not even light gray.
2. Calibration of the position of the line sensor versus the black printhead. During this second step, the printer will
print 21 small squares, and will scan them back.
To perform the calibration correctly, load the substrate towards the right of the printer: the edge of the substrate
should be positioned within 4 cm (2 in) of the right-hand side.
TIP: Check that the black printhead is in very good condition, most importantly the first die of the black printhead.
Pass criteria The line sensor check (55001) succeeds.
Fail criteria The line sensor check (55001) fails.
Test LsToK calibration (55004)

Table 5-14 Carriage sensors (continued)

Description This line sensor to black calibration should be performed mainly after replacing a line sensor or a sensor box. It
calibrates the position of the line sensor with respect to the black printhead. The printer will print a calibration plot, as
seen in the image below. Then it will scan the plot in order to check the calibration.
TIP: Check that the black printhead is in very good condition, most importantly the first die of the black printhead.
Pass criteria The printer has been able to print the calibration plot, which checks the black calibration.
Fail criteria The printer has been unable to print the calibration plot.
Test Color sensor check (58001)
Description This test performs a self-calibration of the spectrophotometer. The shutter is opened, and then a measurement in a
dark zone of the printer is taken. Finally, the internal white calibration tile is measured.
Fail criteria Provided automatically.
● If two readings are similar it could be that the shutter remains open/closed all the time, so repeat the test,
observing whether light from the sensor is visible all the time
● If the dark zone measurement fails, it could be that there is a piece of substrate over the calibration position.
● If the white calibration fails, maybe the sensor is dirty and needs to be replaced.
Test Color sensor open/close (58002)
Description This test checks the opening and closing of the spectrophotometer shutter, and helps you to troubleshoot its failure,
with access to the spectrophotometer and to its shutter.

Table 5-14 Carriage sensors (continued)

Execution The spectrophotometer can be seen from below when it is in the IDS side, opening and closing the shutter.
The spectrophotometer light is turned on.
The shutter is opened and closed several times.
WARNING! Do not look directly at the spectrophotometer light: the light is powerful and could harm your eyes.
Table 5-15 Drop detector

Test Check DD electronics (52001)

Table 5-15 Drop detector (continued)

Description This test performs an electrical check of the drop-detection sensors.
It performs a fake drop detection operation (without dropping ink, but moving the system like in a real drop detection).
The test can be used to ensure that the DD station sensor is working properly and that there is no electrical noise in the
system or its surroundings that could affect the actual readings.
NOTE: In order to perform a functional test for the DD, you can use diagnostic Force drop detection (52005).
Fail criteria If the test fails, there might exist electrical noise in the system perturbing the DD readings. Check that there is no other
equipment (e.g. a motor) near the DD. Also review the connection of the DD sensor.
Pass criteria If the test passes, the DD sensors and the communication with them seems to be working properly.
Test Check DD mechanics (52002)
Description This test checks the DD bump sensor and reads the linear encoder
Test DD calibration (52003)
Description This test shows the current drop-detector calibration values and allows the user to recalibrate it if needed. It should be
performed when experiencing issues with the DD or when any part of the system is changed.
The diagnostic calibrates the Y position of the drop-detector shuttle, for the printer to perform the drop detection and
capping procedures appropriately with respect to the carriage. It also calibrates the backlash and elasticity of the drop-
detector station.
Fail criteria The test fails if the new calibration values are not acceptable or if the Drop-detector Station could not complete the
calibration movements.
If it fails, perform a visual inspection of the system and ensure it is capable to move.
Test Move drop-detector station to service position (52004)
Description The drop-detetector station can't be moved manually. This diagnostic can be used to move the drop-detector station to
its service position (near the door under the IPS). This diagnostic can be used in order to have a better access to the
elements in the drop detector station, in order to clean the drop-detector sensors or even to change some parts.
The test is also useful to verify that the station is able to do a complete movement along its path.
Pass criteria The drop-detector station is able to finish the movement to its service-position and back to homing. In this case, the
mechanical system is working properly.
Fail criteria The drop-detector station is not able to finish the movement. There might be a jam, a problem with the motor or with
the transmission.
Test Force drop detection (52005)

Table 5-15 Drop detector (continued)

Description This test executes a single drop detection for all the printhead dies. The diagnostic will show, for each printhead, its
serial number, life (liters used) and the number of nozzles out for each die.
NOTE: This test shows the number of nozzles that were not detected during the drop-detection executed on the
diagnostic. This will not coincide with the number of nozzles out stored in the nozzle health database, since the values
stored in the database record the number of nozzles that have consistently been out for an amount of drop-detection
tries (this is, a nozzle is counted as "out" in the database when it is not detected several times in a row).
Thus, take in mind that the values shown in 52005 represent a single measure while the values stored in the nozzle
health database are more representative of the nozzle status. To check the nozzle health database execute diagnostic
52010 Display printing nozzle health database content.
Test Display printing nozzle health database content (52010)
Description This test displays the current content of the printing nozzle health database. This database records the number of
nozzles that have consistently been dead for an amount of drop-detector tries (this is, a nozzle is counted as "dead" in
the database when it is not detected several times in a row during different drop-detections).
Test Reset printing nozzle health database content (52012)
Description This test resets the content of the printing nozzle health database.
Table 5-16 Printhead cleaning

Test Visual movement check (47002)
Description This test is similar to the previous one, but makes a movement large enough to be seen by a human observer. If the
previous test is passed, but you are unable to see movement in this one, perhaps there is a jam, or friction is too high,
and the motor is unable to move the axis.
Pass criteria Movement detected.
Test Manual movement check (47003)

Table 5-16 Printhead cleaning (continued)

Description 1. Select the axis to be observed.
2. Press the Start button.
3. Move the axis manually. For the Advance (MA), you need to open the latch (pull out and rotate the black knob), and
try to rotate the axis. It will only rotate a very little, but enough for the test/motor to detect the movement.
4. Press the Stop button.
5. The encoder should detect movement.
Pass criteria Delta in encoder counts reported, showing that the closed-loop feedback works.
Fail criteria The encoder does not detect movement.
Test Motor direction test (47004)
Description This test moves the selected cleaning roll axis, making a very small movement that you may not notice.
The test initializes correctly, it operates in open loop and will always report OK.
Recommended sequence is: Engage motor (Z), Source roll (MI), Advance (MA), and Output roll (MO). You need to place a
finger on the printhead cleaning roller blade for the engage motor (Z), on the axis of the input roll for the source roll
(MI), on the motor of the substrate advance motor for the advance (MA), and on the axis of the output roll for the output
roll (MO).
Pass criteria Movement detected.
Fail criteria Movement not detected.
Test Printhead cleaning Z calibration check (47005)
Description This test performs actions to show you the Z axis calibration. To execute the full process, see Height and tilt check and
calibration test on page 1132.
NOTE: If some other tests have been run (manual motor movement, visual motor movement, or motor direction test)
before running this calibration, you may need to restart the printer. Otherwise, the printer may fail to raise the printhead
cleaning roller blade.
Test Set printhead cleaning Z calibration (47006)
Description Execute this test in order to set or change the current calibration, if needed after running the printhead cleaning Z
calibration check. See Height and tilt check and calibration test on page 1132.
Table 5-17 Monitor curing temperatures

Test Monitor curing temperatures (16001)
Description This test displays the internal temperatures of the curing modules. This test is useful to see internal chamber curing
module temperatures and check whether they are uniform. Also consider that modules without substrate under them
are not powered.
Table 5-18 Curing

Test Status of the curing modules (16002)

Table 5-18 Curing (continued)

Description Displays the status of the curing modules, safety interlocks status, substrate presence under each module and
temperature of each chamber (internal).
Also with this test you can apply power to heaters and fans (only the ones with substrate under them, reproducing
printing conditions).
Options available are:
● Heaters on and fans 40%
● Heaters off and fans 40%
This test has enabled all software monitors, so you can reproduce and isolate system errors reported by the customer
for troubleshooting purposes. Recommended to be executed when the customer reports curing problems, then you can
check whether all modules have the same behavior.
The specifications to check for each test description are as follows.
Test description: Closed loop 80°C 40% (5 minutes waiting to heat up the modules)
● Temperature: 80°C ±1.5°C (both chambers)
● Rotational speed: 3300 ±300 rpm
● 24 V line voltage: 24 V ±10%
Test description: Open loop 400 W 95%
● Temperature: Will increase gradually. After 5 minutes should be around 90°C ±10°C.
NOTE: Extreme environmental conditions may affect the temperature response.
Test Monitor one curing module (16003)

Table 5-18 Curing (continued)

Description Monitor all the internal parameters monitored in the curing PCA in one single module.
Also with this test you can apply power to heaters and fans (only the ones with substrate under them, reproducing
printing conditions).
This test has enabled all software monitors, so you can reproduce and isolate system errors reported by the customer.
Recommended to be executed when the customer reports curing errors, to identify the module and root cause of the
problem.
problem.
Table 5-19 Monitor drying temperatures

Test Monitor drying temperatures (17001)
Description This test displays the internal temperatures of the drying modules. This test is useful to see internal chamber drying
module temperatures and check whether they are uniform.
Table 5-20 Drying

Test Status of the drying modules (17002)

Table 5-20 Drying (continued)

Description Displays the status of the drying modules, safety interlocks status, substrate presence under each module and
temperature of each chamber (internal).
Also with this test you can apply power to heaters and fans.
This test has enabled all software monitors, so you can reproduce and isolate system errors reported by the customer
for troubleshooting purposes. Recommended to be executed when the customer reports curing problems, then you can
check whether all modules have the same behavior.
Test Monitor one drying module (17003)

Table 5-20 Drying (continued)

Description Monitor all the internal parameters monitored in the drying PCA in one single module.
Also with this test you can apply power to heaters and fans.
problem.
Table 5-21 E-box

Test Engine PCAs (01005)
Description This test checks that there is an engine PCA attached to each slot of the PCI express. In the formatter PCA there are five
PCI express slots. Slots 1 to 4 must be attached to one engine PCA each, and slot 5 must be free. Any configuration
other than this is wrong.
Pass/fail criteria If the slots corresponding to PCAs 1 to 4 reply properly and slot #5 does not reply, the test result is PASS. Otherwise the
test result is FAIL.
Possible causes ● At least one of the engine PCAs is missing or assembled in slot 5.
for test failure
● The contacts of the PCI express bus in any slot are dirty (formatter or engine PCA).
● An engine PCA is broken.
● The formatter PCA is broken.

Table 5-21 E-box (continued)
Test Engine adaptor PCAs (01007)
Description This test checks that each of the engine PCAs is properly connected to its corresponding engine adaptor PCA. The
engine PCA tries to communicate with the microcontroller of the engine adaptor PCA.
Pass/fail criteria If there is a problem with the communication (missing reply, unexpected reply) between any engine PCA and its
corresponding engine adaptor PCA, the test result is FAIL.
Possible causes ● The flat cable between engine PCA and engine adaptor PCA is missing.
for test failure
● Flat cables are wrongly connected (PCA mismatch).
● Flat cables are improperly assembled (not completely inserted).
● An engine PCA is broken.
● An engine adaptor PCA is broken.
Table 5-22 E-cabinet

Test Fan (10001)
Description This test checks whether the rotation signal of the fan is detected.
Pass criteria The rotation signal of the fan is detected.
Fail criteria The rotation signal of the fan is not detected.
Action(s) Possible causes for a test failure:
● Fan not connected to the e-cabinet PCA
● Fan blocked or malfunctioning
● E-cabinet PCA malfunction
Test Power supplies (10004)
Description This test starts up all the DC power supplies, measures their output voltages, and reads their status signals (if
available).
During this test the firmware asks the user to press the rearm button.
Pass criteria All the power supplies output voltages are inside their ranges and no alarm signal is detected.
Fail criteria One or more PSUs are not supplying the adequate voltage or an alarm signal is detected.
● PSU end of life (internal fan not working or otherwise)
● PSU protection activated (be sure to leave some time for the PSU to cool down and do an OFF/ON cycle with the
main switch before repeating)
● PSU cabling: AC, DC, or control cables not connected or damaged
● PSU output voltage-sensing jumper missing

Table 5-22 E-cabinet (continued)
Test E-cabinet state (10005)
Description This test shows the state of all the analog and digital sensors on the e-cabinet PCA (voltages, currents, temperature,
switch states, and so on).
Test Communication (10006)
Description This test checks whether there is communication between the e-box and the e-cabinet PCA.
Pass criteria The e-cabinet PCA responds to a communication command.
Fail criteria The e-cabinet PCA does not respond to a communication command
● Communication cable disconnected or damaged
● PSU-2 not working (e-cabinet PCA not powered)
● E-box malfunction
Test All outputs state change (10007)
Description This test activates the DC PSUs and the selected outputs of the e-cabinet PCA.
During this test the firmware asks the user to press the rearm button.
Pass criteria The selected outputs can be activated.
Fail criteria One or more outputs cannot be activated.
● The system powered by the failing output has a problem; check that system for short-circuits
Test Watchdog (10008)
Description This test checks that the watchdog timer on the e-cabinet PCA works.
Pass criteria Watchdog timer works
Fail criteria Watchdog timer fails
Action(s) Causes for a test fail:
Test Activate/deactivate outputs (10009)
Description This test activates the DC PSUs and the activates all the outputs of the e-cabinet PCA. It also tests the state of the
fuses.
Pass criteria All outputs can be activated.
Fail criteria One or more outputs cannot be activated.

Table 5-22 E-cabinet (continued)

● The system powered by the failing output has a problem; check that system for short-circuits
● The output fuse on the failing output is blown
Test Temperature (10010)
Description This test reads the internal temperature of the e-cabinet.
Pass criteria Temperature inside range.
Fail criteria Temperature outside range.
● Insufficient ventilation:
– Fan not working
– Ventilation grille blocked by an external item (a box, a table…)
– Air filters clogged with dust
● Room temperature above machine specifications
Table 5-23 Printer installation and purge

Test Set input voltage (10100)
Description This test allows to set the input voltage configuration for the printer. Please follow the instructions in the installation
guide to use it.
Test Force normal boot (22511)
Description The execution of this test forces the printer to start in normal mode at the next restart.
Test IDS Purge (22515)
Description With this diagnostic the printer will execute the purge process. It should be used only when the printer is not purged (for
example, at installation). The purge process consists of a series of automatic steps, mainly: filling the ink tubes up to the
electrovalves, partially refilling the intermediate tanks, filling the ink tubes up to the printheads, and making a complete
refill of the intermediate tanks. User intervention is needed during this test to perform several steps (installing
cartridges, intermediate tanks, purgers, etc.). The diagnostic will guide you along the steps.
Pass criteria The diagnostic finishes without errors, the ink tubes are filled with ink and the intermediate tanks are also refilled. In
this case the TRS and the ISM will be set as purged, and the printer will be ready to print.
Fail criteria There has been some error in the process, causing that the ink tubes are not filled with ink until the printheads or that
the intermediate tanks are not refilled. In this case the printer should inform about the failure, and the ISM and TRS will
remain as NOT purged. In this case the printer won't be ready to print.

Table 5-23 Printer installation and purge (continued)

Test Set printer as purged (22516)
Description This test sets the IDS (ISM and TRS) as purged (filled with ink).
This should only be used if the purge process has physically been completed (there is ink in the tubes arriving at the
printhead, and the Intermediate Tanks are already refilled).
NOTE: If the purge process has been completed with the diagnostic IDS Purge (22515) and this test finished correctly,
the IDS will be automatically set as purged. In this case the diagnostic Set printer as purged (22516) is not needed.
Test IDS Purge process status reset (22517)
Description This test can be used to start the purge process from scratch, in case the diagnostic IDS Purge (22515) has not been
completed correctly.
If during the IDS purge (22515) any issue appears, the process may be stopped. If the user restarts the process by
running diagnostic 22515 again, the test will start from the last step that was correctly completed before. In most cases
this is a useful feature, but it is possible that sometimes it is preferable to start from scratch. In this case, by running the
diagnostic IDS Purge process status reset (22517) the purge will start from the first step the next time diagnostic IDS
Purge 22515 is executed.
Table 5-24 Printer reshipment preparation

Test Set ISM as not purged (22603)
Description This test sets the ISM as not purged (empty), so that the next time the printer is powered up it will ask to be filled with
ink. In order for the IDS to be set as not purged, this test and 22604 Set TRS as not purged should be executed.
Test Set TSR as not purged (22604)
Description This test sets the TRS as not purged (empty), so that the next time the printer is powered up it will be ask to be filled
with ink. In order for the IDS to be set as not purged, this test and 22603 Set ISM as not purged should be executed.
Test Move carriage (22605)
Description This test moves the carriage to the service position, allowing you to insert the syringes into the ink lines to empty them.
Table 5-25 Utilities

Test Set date and time (99001)
Description This utility changes the actual date and time of the internal electronics system in the printer, this date and time are
different from the data displayed by the IPS PC of the printer. Correct setup of the time and date in the printer is
especially important when saving and tracking the error logs used for escalations. Performing this utility is
recommended when installing the printer in order to align the time with the local time.
Test Report firmware version (99002)

Table 5-25 Utilities (continued)

Description This utility shows the version number of the firmware installed in the printer. It also reports the setting of the PPS screw
installed in the printer. Here is an example:
Test Save NVM (99003)
Description This utility creates a backup copy of all the NVM values of the printer (including calibration values, part numbers, and so
on) in the tmp directory of the hard drive of the printer (where the printer.log is stored). Only for escalations. Since this
diagnostic is only available in diagnostic mode, you should reboot the printer in normal mode after running the
diagnostic to be able to retrieve the file (the file, inside the tmp folder, is called NVMcontent.tar).
Test Restore NVM (99004)
Description This utility recovers a previous copy of all the NVM values of the printer (including calibration values, part numbers, and
so on). Only for escalations.
Test Force boot mode (99006)
Description This utility sets the printer to start always in diagnostic mode. This is useful if you intend to perform multiple tests in
diagnostic mode.
Test Enable advanced logging (99007)
Description This utility activates advanced logging for escalations. This advanced logs will be saved in the printer.log file in the tmp
directory of the printer. Select the subsystem where the issues are being experienced to enable its advanced logging,
and repeat the operations which are causing the issues. When the issue is repeated with the advanced logging
activated, the printer.log file contains the additional information needed for escalations. When the printer is restarted
the advanced logging is automatically deactivated.
NOTE: This diagnostic does not create any other new file apart from the printer.log file in the tmp directory. All the new
data activated by this diagnostic is included in the printer.log file.
WARNING! After troubleshooting the printer, remember to reboot it to deactivate the advanced logging. It is not
recommended to have advanced logging active during normal operation, unless it is being used to diagnose an issue as
it may cause the printer to hang.
Test Get printer logs (99009)
Description This utility displays a URL that takes you where the Printer.log file is stored. The URL can be copied: select it with the
mouse, and press Ctrl-Insert. To paste it, press Shift-Insert.
Test Set IP address (99010)
Description This utility guides you to change the IP addresses of the computer and printer.
Test Recover 01_60_03_03 SE SN mismatch (99012)

Table 5-25 Utilities (continued)

Description When reusing an e-box hard disk or an EEPROM (ISM board) from another printer, you may see system error
01.60.03:03 about an SN mismatch. This utility rewrites either the hard disk or the EEPROM with the correct information
and calibrations.
How to run utility 99012: Recover 01_06_03_03 SE SN mismatch
1. Log in as ServiceEngineer and start the printer in diagnostic mode.
2. Run the utility. If you do not see it in the list of utilities, restart the built-in computer and try again.
3. When the utility starts, you should see the following screen:
4. After a few seconds, the utility asks you to rearm the printer.

5. Select the serial number of the hard disk drive or the EEPROM (ISM board) and press Continue. This is the
most important step as it is required to choose the proper component. Select the component that is not
being replaced.
For example, if the hard disk drive is being replaced, update it with the printer information, which is stored
in the EEPROM; so you should select the EEPROM.
6. Press Continue to perform the operation.

7. Press Next to continue.
8. Press Next to see the report.

9. Press Finish to exit the utility.
10. Select Printer tools ►Power options ►Restart to restart the printer.
Table 5-26 Carriage rail cleanliness

Test Friction analysis (86003)
Description This maintenance script moves the carriage along the scan axis, reading and displaying friction values and limit
thresholds. It recommends a cleaning process if needed.
Table 5-27 Double-sided Day and Night Kit

Double-sided Day Night Kit checks and Installation
This group of diagnostics is designed to be executed either by operators or service engineers, with the goal of diagnosing the system in
case there a some problem.
NOTE: Diagnostics 90001, 90002, 90003 and 90004 will FAIL if the Double-sided Day and Night Kit is not properly installed (using
diagnostics 90011 to 90016).
Description This test is intended to check Double-sided Day and Night electronics. In the test, the printer checks if the kit is set as
installed in the NVM, then, the communication with the Motor Drive PCA is checked and the result is shown on screen.
NOTE: This test does not check the Double-sided Day and Night Kit E-cabinet.

Table 5-27 Double-sided Day and Night Kit (continued)

Pass criteria The Double-sided Day Night Kit Motor Drive PCA is properly communicating with the printer.
Fail criteria The printer is not able to communicate with the Double-sided Day and Night Kit Motor Drive PCA or the Double-sided
Day and Night Kit is not installed in the printer.
If the printer is not able to communicate with the Double-sided Day and Night kit, follow the troubleshooting until the
problem is solved:
1. Check the power cable going from the Double-sided Day and Night E-cabinet to the Motor drive PCA (24V).
2. Check the buttons cable and connector (J4 in Motor drive PCA). Address should be correctly configured.
3. Check the data cable connected to J1 in the Motor drive PCA.
4. Check that the bus terminates at the P2 connector.
5. Check that the Double-sided Day Night E-cabinet is working properly.
6. Install a new Motor drive PCA (SVC Part: CZ056-67190).
Test Lights check (90002)
Description This test is intended to check Double-sided Day and Night lights. In the test, the printer allows to switch the lights on
and off (for print-zone front light and all output lights) and also to adjust the light intensity (only for print-zone back
light).
Pass criteria If all the lights are able to switch on/off correctly and the feedback shown on the screen is also correct, the LED Bars are
working properly.
Fail criteria a. Some lights are not switching on/off:
1. Check the power and data lines for the affected LED Bar, see Figure 2-14 Printzone + Day and Night LEDs
and Beacon Subsystems on page 88.
2. a. If all the Output lights are failing, review especially its connections with the Double-sided Day and
Night E-cabinet. Check the power cable going from the Double-sided Day and Night E-cabinet to the
output lights (24V). If the output is not working properly (24V not detected), install a new Double-sided
Day and Night E-cabinet. If 24V are present in the output, but output lights are not working, or only
one is not working, install a new LED Bar.
b. If the Print-zone front light is failing and it is correctly connected, install a new LED Bar. If this does not
solve the issue, install a new Motor drive PCA (Illumination and buttons).
c. If the print-zone back light is failing and it is correctly connected, reboot the printer. If the problem
persists, install a new LED Bar. If this does not solve the issue, install a new Motor drive PCA (Double-
sided Day and Night Kit).
b. There are some LEDs not working in a certain LED Bar: Install a new LED Bar.
Test Buttons check (90003)
Description This test is intended to check Double-sided Day and Night button. It should be executed when having problems with the
LED Bars (for example, LED Bars don’t power on. With this test the user can distinguish if the problem comes from the
button or from the LEDs/PSU). In the test the status of the button is shown. The user should press the button and the
status on the screen should change while it is pressed.
NOTE: To ease troubleshooting of LED Bars, the Print-zone LEDs button (installed in the printer by default, not with
the Double-sided Day and Night Kit) is also shown in this diagnostic. To diagnose this button and also the PPS Media
Load button, also access diagnostic 89001 Buttons check in the Illumination and buttons section.
Pass criteria The status on the screen for the buttons changes when pressed, this ensures that there is no problem with the buttons
themselves.


Fail criteria The status on the screen for the buttons does not change when pressed, or changes randomly. In this case, the affected
buttons should be examined looking for a faulty cable or changed in case cabling is working.
Test Scanning check (90004)
Description This test is to check the scanning system of Double-sided Day and Night. It should be executed when repeatedly having
issues detecting light (90.02.0X:01), reading Double-sided Day and Night Line sensor (90.06.00:01) or reading fiducials.
The diagnostic will scan the system first with the print-zone back light off and then with the print-zone back light on in
order to determine if the measures are correct and if the elements in the system are working properly.
NOTE: For this diagnostic to be able to determine if the lights and the line sensor are working properly, it is necessary
to have the Scan Beam in printing position and no substrate loaded. If there is substrate loaded, a Fail in the diagnostic
could be caused by the media.
NOTE: When this diagnostic is executed, two files will be created in the tmp folder containing the results of the test
(ScanDataCalib_0.txt and ScanDataCalib_20.txt). These files could be required in case of remote support.
Pass criteria The measures with print-zone back light off/on are inside the defined ranges. If this is the case, the print-zone back
lights and the line sensor seem to work properly. In this case, if you have been experiencing issues, they could be
related to the media used.
Fail criteria The measures with print-zone back light off/on are outside the defined ranges. If the measures with print-zone back
light off are outside the range, there is probably an issue with the Double-sided Day and Night Line sensor or its
connections. If the measures with print-zone back light on are outside range, both Double-sided Day Night Line Sensor
and print-zone back lights should be checked.
The following group of diagnostics is designed to be executed only by service engineers in order to install the Double-sided Day Night Kit.
They should be run sequentially, and the kit will be installed only when the last diagnostic (90015 Double-sided Day and Night Install Kit) is
executed. The previous diagnostics (90011 to 90014) are designed to ensure that the system is properly installed and working before
setting the kit as installed.
NOTE: Diagnostics 90011 to 90014 are similar to diagnostics 90001 to 90004. However, 90001 to 90004 check if the Double-sided Day
and Night Kit is installed before starting the test, while 90011 to 90014 don’t make that check. Thus, before setting the Double-sided Day
and Night Kit as installed only diagnostics 90011 to 90015 can be used.
Description See Electronic check (90001). 90011 only differs from 90001 in that it does not check if Double-sided Day and Night Kit
is installed before starting the diagnostic.
Test Buttons check (90012)
Description See Buttons check (90003). 90012 only differs from 90002 in that it does not check if Double-sided Day and Night Kit is
installed before starting the diagnostic.
Test Lights check (90013)
Description See Lights check (90002). 90013 only differs from 90003 in that it does not check if Double-sided Day and Night Kit is
installed before starting the diagnostic.
Test Scanning check (90014)
Description See Scanning check (90004). 90014 only differs from 90004 in that it does not check if Double-sided Day and Night Kit
is installed before starting the diagnostic.
Test Install Kit (90015)


Description This diagnostic sets the Double-sided Day and Night Kit as installed in the NVM. In order to be able to print Double-sided
Day and Night jobs the kit should be set as installed by using this diagnostic. This diagnostic is to be executed once all
the hardware upgrades have been done and all the previous checks (90011 to 90014) pass successfully. After
execution, it required to reboot the printer to finish the installation and calibrate the system using diagnostic 90016
Offsets calibration. It is also possible to uninstall the kit with this diagnostic.
Pass criteria The kit is properly set as installed.
Fail criteria The printer is not able to set the kit as installed.
Test Offsets calibration (90016)
Description This diagnostic should be executed after installing Double-sided Day and Night Kit (with diagnostic 90015) in order to
calibrate the system before starting to print Double-sided Day and Night jobs. Follow the instructions in the Installation
guide for DSDN Calibration while running this test
Pass criteria The calibration values are correctly stored in the NVM.
Fail criteria The printer is not able to store the calibration values in the NVM.
Double-sided Day Night Kit calibrations
This group of diagnostics is designed to be executed either by operators or service engineers in order to change the different calibrations
for the Double-sided Day and Night Kit.
NOTE: Diagnostics 90021 and 90022 will FAIL if the Double-sided Day and Night Kit is not properly installed (using diagnostics 90011 to
90016).
Test Offsets calibration (90021)
Description See diagnostic 90016. This test has the same functionality than 90016. After the installation of the Kit, offset values
should not be changed unless a constant and repeatable deviation in registration is observed. In this case, it is
recommended to complete an offset calibration as explained in the Installation guide.
NOTE: When this diagnostic is executed, the file DSDN_Calibrations.log in the tmp folder will be updated with the new
introduced values. This can be used to keep traceability of changes in the offsets or in the media edge to fiducial
distance.
Test Media Edge to fiducial distance configuration (90022)
Description This diagnostic allows user to change the distance between the media edge and the printed fiducials. It should only be
executed before starting to print side A. It is not recommended to change this value except in very specific conditions
(for example, if a print is almost the same width than the media used and the default media edge to fiducial distance is
too big to be able to print fiducials, this distance could be reduced). The default value for media edge to fiducial distance
is 3cm.
NOTE: Changing this value after side A is already printed might result in issues printing side B (printer will not be able
to detect fiducials).
NOTE: Ensure that the new introduced value for Media Edge to fiducial distance is a valid one before printing side A:
estimate the place where the fiducials will be printed and ensure there will be no interference with media edge holders.
NOTE: When this diagnostic is executed the file DSDN_Calibrations.log in the tmp folder will be updated with the new
introduced values. This can be used to keep traceability of changes in the offsets or in the media edge to fiducial
distance.
Pass criteria The new Media Edge to fiducial distance is correctly stored in the NVM.
Fail criteria The printer is not able to store the new value for Media Edge to fiducial distance.

Table 5-28 Vapor removal

Test Vapor removal electronics check (30001)
Description Check communication with the vapor removal electronics:
● Vapor removal PCA
Test Vapor removal blower check (30002)
Description ● The test applies duty cycles of 0% and 100%.
● In each case, the printer will inform whether the speed readings are correct or not.
Test Heat exchanger fan array check (30003)
Description Check heat exchanger fan arrays for the following conditions:
● Fault signal
● Current too low
Table 5-29 Beacon

Test Beacon status check
Description This test checks the status of the LED units in the printer beacon.
Execution Reset the printer and wait for the status beacon LED units to light up simultaneously during the start-up process.
Fail criteria If one of the LED units does not light up, it might be fused or wrongly assembled to the beacon.
If all the LED units do not light up, then:
● One or more LED units might not be correctly assembled to the beacon.
● The beacon might not be correctly connected to the USB port in the IPS.
● The USB port in the IPS might not be supplying energy to the beacon.
Ask for a status beacon service kit (K4T88-67262) if some replacement is needed.

6 Parts and diagrams
● Rear left covers
● Front left covers
● Front center covers
● Front right covers
● Rear right covers
● Window covers
● Structure covers
● Vapor removal (1)
● Drying
● Aerosol
● E-cabinet (general)
● Left e-cabinet
● Inside-left e-cabinet
● Center bottom e-cabinet
● Center-top e-cabinet
● Right e-cabinet
● E-box
● Printhead cleaning system (1)
● Printhead cleaning system (2)
● TRS
● PPS
● Ink system module (1)
ENWW 599
● Impelling
● Service station (1)
● Service station (2)
● Substrate path (1)
● Curing (1)
● Curing (2)
● Old Carriage (1)
● New Carriage (1)
● Carriage (2)
● Human machine interface
● LEDs
● Double sided day and night kit (accessory)
● Forklift (accessory)
● Dual roll kit (accessory)
● R2FF (accessory)
● Ink collector (accessory)
600 Chapter 6 Parts and diagrams ENWW

Rear left covers

Part number Description
1 K4T88-67173 Left perforated metal sheet corner (K4T88-67173) on page 989
2 K4T88-67169 Left side cover (K4T88-67169) on page 983
3 K4T88-67164 Back left corner (K4T88-67164) on page 979
4 K4T88-67165 Back left door (K4T88-67165) on page 980
5 K4T88-67166 Back left top cover (K4T88-67166) on page 981
6 K4T88-67174 Front left perforated metal sheet (K4T88-67174) on page 989
7 K4T88-67156 Stop button (K4T88-67156) on page 958
8 K4T88-67154 Rear left cover (K4T88-67154) on page 954
9 K4T88-67234 eStop kit cables (K4T88-67234) on page 1003
ENWW Rear left covers 601

Front left covers

1 K4T88-67175 Top left perforated metal sheet (K4T88-67175) on page 990
2 K4T88-67171 Left rotomolding (K4T88-67171) on page 985
4 K4T88-67167 Front left cover (K4T88-67167) on page 982
5 K4T88-67168 Front left corner (K4T88-67168) on page 982
8 K4T88-67172 Left lateral perforated sheet metal (K4T88-67172) on page 988

ENWW Front left covers 603

Front center covers

1 K4T88-67195 ID buttons and switches (K4T88-67195) on page 1002
2 K4T88-67153 Front right cover (K4T88-67153) on page 948
3 K4T88-67152 Front left cover (K4T88-67152) on page 944

Front right covers

1 K4T88-67172 Left lateral perforated sheet metal (K4T88-67172) on page 988
3 K4T88-67184 Back right perforated metal sheet (K4T88-67184) on page 998
4 K4T88-67180 Front right cover (K4T88-67153) on page 948
5 K4T88-67179 Back left top cover (K4T88-67166) on page 981
7 K4T88-67181 Front right door (K4T88-67181) on page 995
9 K4T88-67186 Right rotomolding (K4T88-67186) on page 1000
10 K4T88-67185 Rear left cover (K4T88-67154) on page 954
ENWW Front right covers 605


Rear right covers

1 K4T88-67262 Beacon lights (K4T88-67262) on page 906
2 K4T88-67184 Back right perforated metal sheet (K4T88-67184) on page 998
3 K4T88-67155 Rear right cover (K4T88-67155) on page 956
5 K4T88-67177 Back right cover (K4T88-67177) on page 992
6 K4T88-67178 Back right corner (K4T88-67178) on page 992
7 K4T88-67176 Right side top cover (K4T88-67176) on page 991
ENWW Rear right covers 607


Window covers
1 K4T88-67158 Top center window (K4T88-67158) on page 965
2 K4T88-67159 Top center right window (K4T88-67159) on page 966
3 K4T88-67307 Top center ID accessories (K4T88-67307) on page 971
4 K4T88-67163 Front window structure (K4T88-67163) on page 976
5 K4T88-67308 Front Window arcs (K4T88-67308) on page 977
6 K4T88-67294 Safety interlock window (K4T88-67294) on page 1004
7 K4T88-67301 Window hinges (K4T88-67301) on page 968
8 K4T88-67160 Top center rear cover (K4T88-67160) on page 970
9 K4T88-67157 Top center left window (K4T88-67157) on page 964
K4T88-67317 Grommet SVC
ENWW Window covers 609

Structure covers
1 K4T88-67183 Right structure (K4T88-67183) on page 998
2 K4T88-67170 Left structure (K4T88-67170) on page 984
3 K4T88-67162 Top center structure (K4T88-67162) on page 975

Vapor removal (1)

1 K4T88-67100 Vapor removal silencer box (K4T88-67100) on page 1306
2 K4T88-67069 Vapor removal PCA (K4T88-67069) on page 1304
3 K4T88-67106 Vapor removal dirt collector (K4T88-67106) on page 1298
4 K4T88-67093 Vapor removal link pipe (K4T88-67093) on page 1323
5 K4T88-67099 Vapor removal waste container (K4T88-67099) on page 1312
6 K4T88-67096 Vapor removal pump (K4T88-67096) on page 1324
ENWW Vapor removal (1) 611

Vapor removal (2)

1 K4T88-67104 Vapor removal inlet collector (K4T88-67104) on page 1294
2 K4T88-67249 Vapor removal interconnect kit (K4T88-67249) on page 1318 (includes the cables:
K4T88-50125, K4T88-50153 , K4T88-50286 and K4T88-50287)
3 K4T88-67250 Vapor removal cable kit (K4T88-67250) on page 1318 (includes the cables: K4T88-50071 ,
K4T88-50073 , K4T88-50075 , K4T88-50159 , K4T88-50182)
4 K4T88-67098 Vapor removal drain tubes parts (K4T88-67098) on page 1299
5 K4T88-67105 Vapor removal outlet collector (K4T88-67105) on page 1313
6 K4T88-67102 Vapor removal counterflow heat exchanger (K4T88-67102) on page 1287
7 K4T88-67103 Vapor removal fan collector (K4T88-67103) on page 1290
8 CZ056-67379 Vapor removal fan (CZ056-67379) on page 1285

Vapor removal (3)

1 K4T88-67092 Vapor removal inlet pipe (K4T88-67092) on page 1320
2 K4T88-67097 Vapor removal output box w foams (K4T88-67097) on page 1301
3 K4T88-67091 Vapor removal exit pipe (K4T88-67091) on page 1318
ENWW Vapor removal (3) 613

Drying
1 K4T88-67265 Drying PCA cooling fan filter (K4T88-67265) on page 789
2 K4T88-67110 Drying fan PCA (K4T88-67110) on page 787
3 K4T88-67070 Drying PCA (K4T88-67070) on page 784
4 K4T88-67109 Drying diffuser (K4T88-67109) on page 782
5 K4T88-67107 Drying heater and fan (K4T88-67107) on page 790
— K4T88-67108 Drying chamber (K4T88-67108) on page 781
— K4T88-67228 Drying data cable kit (K4T88-67228) on page 794
— K4T88-67229 Drying PCA cables kit (K4T88-67229) on page 794
— K4T88-67230 Drying power cables Kit (K4T88-67230) on page 794

Aerosol
1 K4T88-67012 Aerosol Frame (K4T88-67012) on page 665
2 K4T88-67017 Aerosol PCA (K4T88-67017) on page 667 (Includes: K0Q45-60057 CARRIAGE _IDS VEGA Power
management PCA)
3 K4T88-67001 Aerosol box (K4T88-67001) on page 663
4 K4T88-67003 Aerosol top case (K4T88-67003) on page 670
ENWW Aerosol 615

E-cabinet (general)
1 CZ056-67128 E-cabinet fan (CZ056-67128) on page 870
2 CZ056-67137 E-cabinet fan filter (CZ056-67137) on page 871
3 K4T88-67201 E-cabinet lock (K4T88-67201) on page 877
4 K4T88-67198 E-cabinet door (K4T88-67198) on page 866
5 K4T88-67199 E-cabinet fan (K4T88-67199) on page 873
6 K4T88-67217 E-cabinet user interaction label (K4T88-67217) on page 865
— K4T88-67274 E-cabinet AC-12AWG cables (K4T88-67274) on page 893
— K4T88-67275 E-cabinet AC-6AWG cables (K4T88-67275) on page 893
— K4T88-67276 E-cabinet bundle cables (K4T88-67276) on page 894
— K4T88-67236 PCA interlocks cables kit (K4T88-67236) on page 894

Left e-cabinet
1 K4T88-67291 Automatic circuit-breaker 10A (K4T88-67291) on page 884
2 K4T88-67213 E-cabinet circuit-breaker II (K4T88-67213) on page 856
3 K4T88-67216 E-cabinet AC-12AWG cables
4 K4T88-67214 E-cabinet lamps kit (K4T88-67214) on page 859
5 K4T88-67292 Residual current dev RCD 40A/3 (K4T88-67292) on page 887
6 K4T88-67293 Automatic circuit-breaker ACB (K4T88-67293) on page 890
7 K4T88-67212 E-cabinet circuit-breaker I (K4T88-67212) on page 853
ENWW Left e-cabinet 617

Inside-left e-cabinet
1 K4T88-67211 E-cabinet contactor (K4T88-67211) on page 851

Center bottom e-cabinet

1 K4T88-67210 E-cabinet PCA glass fuses (K4T88-67210) on page 848
3 K4T88-67211 E-cabinet contactor (K4T88-67211) on page 851
4 K4T88-67206 E-cabinet PSU 24V 100W (K4T88-67206) on page 834
5 K4T88-67207 E-cabinet PCU 36V-600W (K4T88-67207) on page 837
6 K4T88-67208 E-cabinet PCU 48V-600W (K4T88-67208) on page 841 (only 1 unit)
7 K4T88-67205 E-cabinet PSU 24V-600W COSEL (K4T88-67205) on page 828 (only 1 unit)
ENWW Center bottom e-cabinet 619

Center-top e-cabinet
2 K4T88-67203 E-cabinet vapor removal (K4T88-67203) on page 824
3 K4T88-67277 E-cabinet power jumpers (K4T88-67277) on page 879
4 K4T88-67204 E-cabinet vacuum pump (K4T88-67204) on page 826
5 CZ056-67129 E-cabinet safety relay (CZ056-67129) on page 820
6 K4T88-67210 E-cabinet PCA glass fuses (K4T88-67210) on page 848

Right e-cabinet
1 K4T88-60419 E-cabinet installation kit (K4T88-60419) on page 894
2 K4T88-67209 E-cabinet PCA fuse (K4T88-67209) on page 846
3 K4T88-67288 E-cabinet PCA (K4T88-67288) on page 880
ENWW Right e-cabinet 621

E-box
1 CZ056-67386 E-box fan and filter (CZ056-67386) on page 795
2 K4T88-67067 Engine PCA (K4T88-67067) on page 805
3 CZ056-67389 Fiber-optics PCA (CZ056-67389) on page 808
4 K4T88-67271 E-box PSU (K4T88-67271) on page 814
5 K4T88-67272 E-box LAN cable to IPS kit (K4T88-67272) on page 819
6 CZ056-67189 E-box interconnect PCA (CZ056-67189) on page 801
7 CZ056-67188 Engine adaptor PCA (CZ056-67188) on page 802
8 K4T88-67231 E-box cable kit (K4T88-67231) on page 818
9 CZ056-67186 Formatter PCA (CZ056-67186) on page 809
10 K4T88-67268 E-box hard disk drive (K4T88-67268) on page 797
11 K4T88-67068 Encryption PCA (K4T88-67068) on page 811

ENWW E-box 623

Printhead cleaning system (1)

1 K4T88-67117 Web wipe printhead cleaning roller up-down pair (K4T88-67117) on page 1099
2 K4T88-67113 Printhead cleaning drive roller (K4T88-67113) on page 1097
3 CZ056-67050 Web wipe roll-free hub (CZ056-67050) on page 1093
4 CZ056-67049 Printhead cleaning rubber hub (CZ056-67049) on page 1089
5 K4T88-67123 Web wipe waste management parts (K4T88-67123) on page 1112
6 Q6702-60685 Printhead cleaner waste bottle (Q6702-60685) on page 1142
7 K4T88-67122 Web wipe engage motor (K4T88-67122) on page 1141
8 K4T88-67121 Web wipe lifter parts (K4T88-67121) on page 1109
9 CZ056-67045 Web wipe transmission box (CZ056-67045) on page 1085
10 CZ056-67190 Printhead cleaning system motor drive PCA (CZ056-67190) on page 1131
11 K4T88-67114 Web wipe central cage top cover (K4T88-67114) on page 1114
12 K4T88-67115 Printhead cleaning roll pinch assembly (K4T88-67115) on page 1094
13 K4T88-67116 Web wipe printhead cleaning blade (K4T88-67116) on page 1095

ENWW Printhead cleaning system (1) 625

Printhead cleaning system (2)

1 1HA07-67050 Web wipe gear kit (1HA07-67050) on page 1117
2 K4T88-67111 Web Wipe printhead cleaning module (K4T88-67111) on page 1127
3 K4T88-67112 Web wipe printhead cleaning roll axis with structure (K4T88-67112) on page 1087
4 K4T88-67119 Web wipe roller parts (K4T88-67119) on page 1103
5 K4T88-67120 Web wipe output diverter parts (K4T88-67120) on page 1107
6 K4T88-67118 Web wipe extraction module kit (K4T88-67118) on page 1122
7 K4T88-67218 Web wipe extraction guide (K4T88-67218) on page 1124
K4T88-67251 Web Wipe cables kit (K4T88-67251) on page 1142

TRS
1 K4T88-67058 TRS eChain (K4T88-67058) on page 1274
2 K4T88-67054 TRS barnacle (K4T88-67054) on page 1274
3 K4T88-67055 TRS tubes repair (K4T88-67055) on page 1284
4 K4T88-67057 TRS Tube shelf (K4T88-67057) on page 1284
5 K4T88-67311 TRS FI tower assembly with holders (K4T88-67311) on page 1276
6 K4T88-67056 TRS Fiber-optics trailing cable (K4T88-67056) on page 1278
7 K4T88-67066 TRS Power cable 42V (K4T88-67066) on page 1282
ENWW TRS 627

PPS
1 K4T88-67060 PPS Actuator assy (K4T88-67060) on page 1059 (only 1 unit)
2 K4T88-67061 PPS Column assy (K4T88-67061) on page 1076 (only 1 unit)
3 K4T88-67063 PPS Safety PCA (K4T88-67063) on page 1082
4 K4T88-67062 PPS Encoder assy (K4T88-67062) on page 1079
K4T88-67065 PPS Cables (K4T88-67065) on page 1076
— CZ056-67190 Stand motor drive PCA (CZ056-67190) on page 1083

Ink system module (1)

1 K4T88-67026 IDS Ink pump (K4T88-67026) on page 1032
2 K4T88-67036 IDS Ink PCA (K4T88-67036) on page 1029
3 K4T88-67037 IDS Air PCA (K4T88-67037) on page 1016
4 K4T88-67025 IDS Air pump and relief valve (K4T88-67025) on page 1017
5 K4T88-67038 IDS Ink leakage detector (K4T88-67038) on page 1027
6 K4T88-67040 ISM 7x intermediate tank (K4T88-67040) on page 1056
7 K4T88-67189 Side structures wheels (K4T88-67189) on page 1051
8 K4T88-67024 IDS Ink circuit (K4T88-67024) on page 1035
9 K4T88-67018 IDS PIP assy (K4T88-67018) on page 1044
10 CZ056-67073 ISM intermediate tank (CZ056-67073) on page 1055
K4T88-67022 IDS cable (K4T88-67022) on page 1058
K4T88-67235 Interlocks sensors kit cables (K4T88-67235) on page 1058
ENWW Ink system module (1) 629



1 K4T88-67030 IDS M Cartridge connector (K4T88-67030) on page 1058 with Inkbag dry 3L and Syringe
2 K4T88-67032 IDS LM Cartridge connector (K4T88-67032) on page 1058 with Inkbag dry 3L and Syringe
3 K4T88-67041 IDS Moby support (K4T88-67041) on page 1040 (only 1 unit) with 7 labels
4 K4T88-67033 IDS PT Cartridge connector (K4T88-67033) on page 1058 with Inkbag dry 3L and Syringe
5 K4T88-67059 IDS Ink Cartridge PCA (K4T88-67059) on page 1054
6 K4T88-67031 IDS LC Cartridge connector with (K4T88-67031) on page 1058 with Inkbag dry 3L and Syringe
7 K4T88-67028 IDS Y Cartridge connector (K4T88-67028) on page 1058 with Inkbag dry 3L and Syringe
8 K4T88-67027 IDS K Cartridge connector(K4T88-67027) on page 1057with Inkbag dry 3L and Syringe
9 K4T88-67029 IDS C Cartridge connector (K4T88-67029) on page 1052 with Inkbag dry 3L and Syringe
ENWW Ink system module (2) 631


1 K4T88-67023 IDS Air circuit (K4T88-67023) on page 1012
2 K4T88-67042 IDS eValves (K4T88-67042) on page 1024 (only 1 unit) with Inkbag dry 3L and Syringe
3 K4T88-67289 IDS purge (K4T88-67289) on page 1058
4 CZ056-67308 ISM quick connector M&F assembly (CZ056-67308) on page 1050

Impelling
1 K4T88-67044 Impelling encoder strip (K4T88-67044) on page 916
2 K4T88-67306 Impelling carriage belt assembly (K4T88-67306) on page 909
3 K4T88-67051 Scan axis bump (K4T88-67051) on page 928 (only 1 unit)
4 K4T88-67050 Scan axis 3rd motor support S (K4T88-67050) on page 922
5 K4T88-67043 Impelling motor (K4T88-67043) on page 919
6 K4T88-67048 Scan axis slider rods (K4T88-67048) on page 930
7 K4T88-67052 SOL shutter (K4T88-67052) on page 939
8 K4T88-67049 Scan axis belt tensioner (K4T88-67049) on page 923
Dampener for Lyra SAX tensioner SVC (K4T88-67324) must also be purchased when purchasing
this part.
9 K4T88-67021 Belt installation tool (K4T88-67021) on page 940
10 K4T88-67302 Mid Encoder Strip Support (K4T88-67302) on page 940
11 K4T88-67324 Dampener for Lyra SAX tensioner SVC (K4T88-67324) on page 942. must be purchased when
purchasing K4T88-67049
K4T88-67046 SAX motor power cables kit (K4T88-67046) on page 940
K4T88-67047 SAX motor data cable (K4T88-67047) on page 940
ENWW Impelling 633


Service station (1)

1 K4T88-67073 Service station cap (K4T88-67073) on page 1150
2 K4T88-67076 Service station position spring (K4T88-67076) on page 1145
3 K4T88-67075 Service Station Capping Structure
4 K4T88-67074 Service station caps kit (K4T88-67074) on page 1147
K4T88-67226 Drop detector PCA cables kit (K4T88-67226) on page 1172
K4T88-67227 Drop detector system motor kit (K4T88-67227) on page 1172
ENWW Service station (1) 635

Service station (2)

1 K4T88-67082 Drop-detector sensors (K4T88-67082) on page 1166
2 K4T88-67081 Drop-detector shuttle with sensor (K4T88-67081) on page 1162
3 K4T88-67219 ODD encoder strip (K4T88-67219) on page 1172
4 CZ056-67388 Drop-detector Mux PCA (CZ056-67388) on page 1171
5 K4T88-67083 Drop-detector PCA (K4T88-67083) on page 1168
6 K4T88-67078 Drop-detector positioner (K4T88-67078) on page 1155
7 K4T88-67080 Drop-detector transmission parts (K4T88-67080) on page 1159
8 K4T88-67079 Drop-detector transmission engine (K4T88-67079) on page 1156
9 K4T88-67077 Drop-detector station (K4T88-67077) on page 1152
10 K4T88-67287 Drop-detector belt (K4T88-67287) on page 1170
— CZ056-67190 Service station Motor drive PCA (CZ056-67190) on page 1174

ENWW Service station (2) 637

Substrate path (1)

1 CZ056-67462 Hdrs Single roll spindle (CZ056-67462) on page 1005
2 CZ056-67239 Spindle ruler label
3 CZ056-67238 Left spindle journal (CZ056-67238) on page 1179
4 K4G10-67094 Spindle air valve (K4G10-67094) on page 1181
5 Q6702-60464 Pneumatic gun

Substrate path (2)

1 CZ056-67471 Drive roller worm gear (CZ056-67471) on page 1196
2 CZ056-67374 Drive roller encoder disc and PCA (CZ056-67374) on page 1185
3 CZ056-67228 Substrate drive roller transmission assembly (CZ056-67228) on page 1187
4 CZ056-67269 Drive roller encoder disc and PCA (CZ056-67374) on page 1185
5 Q6702-60478 Drive roller motor coupling (Q6702-60478) on page 1194
6 Q6702-60477 Drive roller support bearings (Q6702-60477) on page 1197
7 Q6703-67020 Substrate drive roller assembly (Q6703-67020) on page 1191
CZ056-67446 Substrate advance worm gear grease (CZ056-67446) on page 1197
CZ056-67094 MA motor encoder cable (CZ056-67094) on page 1187
K4T88-67239 MA motor data cable (K4T88-67239) on page 1187
K4T88-67240 MA motor power cable (K4T88-67240) on page 1187
K4T88-67241 MI motor encoder cable (K4T88-67241) on page 1187
ENWW Substrate path (2) 639


Substrate path (3)

1 K4T88-67136 Platen extra assembly (K4T88-67136) on page 1203
2 K4T88-67140 MEH sliders (K4T88-67140) on page 1207
3 CZ056-67321 OMAS and vacuum PCA (CZ056-67321) on page 1260
4 K4T88-67138 Media edge holder (K4T88-67138) on page 1207
5 K4T88-67220 Left spittoon (K4T88-67220) on page 1143
6 K4T88-67139 Platen assembly (K4T88-67139) on page 1205
7 K4T88-67237 OMAS and vacuum cables kit (K4T88-67237) on page 1200
8 K4T88-67137 OMAS platen assembly (K4T88-67137) on page 1200

Substrate path (4)

1 K4T88-67086 Front left pinch cover (K4T88-67086) on page 1210
2 K4T88-67194 Middle pinch protector bracket (K4T88-67194) on page 1223 (x6)
3 K4T88-67089 Pinch switch assembly (K4T88-67089) on page 1216
4 K4G10-67106 Pinch clamp (K4G10-67106) on page 1207
5 K4T88-67088 Pinch assembly (K4T88-67088) on page 1214
6 K4T88-67294 LY safety interlock pinch (K4T88-67294) on page 1235
7 K4T88-67085 Front right pinch cover (K4T88-67085) on page 1208
8 K4T88-67087 Front center pinch cover (K4T88-67087) on page 1212

Substrate path (5)

1 K4T88-67192 Right pinch protector plate (K4T88-67192) on page 1221
2 K4T88-67193 Pinch protector handle (K4T88-67193) on page 1222
3 K4T88-67261 Pinch torsion springs (K4T88-67261) on page 1226
4 K4T88-67300 Loading table shock absorber (K4T88-67300) on page 1234
5 K4T88-67254 Pinch complete assembly (K4T88-67254) on page 1230
6 K4T88-67191 Left pinch protector plate (K4T88-67191) on page 1220
7 K4T88-67190 Center pinch protector plate (K4T88-67190) on page 1219

Substrate path (6)

1 K4T88-67143 Vacuum support (K4T88-67143) on page 1268
2 K4T88-67238 Vacuum pump cable kit (K4T88-67238) on page 1269
3 K4T88-67142 Vacuum pipe (K4T88-67142) on page 1266
4 K4T88-67141 Vacuum pump and pipe (K4T88-67141) on page 1262

Substrate path (7)

1 K4T88-67135 Diverter assembly (K4T88-67135) on page 1272
2 K4T88-67134 Diverter wheel parts (K4T88-67134) on page 1273
3 CZ056-67433 Diverter module (CZ056-67433) on page 1269


Substrate path (8)

1 K4T88-67146 Left MI side plate (K4T88-67146) on page 1244
2 Q6702-60469 Spindle latch type B (Q6702-60469) on page 1175
3 K4T88-67144 MI/MO motor (K4T88-67144) on page 1237 (only 1 unit)
4 K4T88-67150 MO transmission box (K4T88-67150) on page 1248
5 K4T88-67148 Motorized MO side plate (K4T88-67148) on page 1245
6 K4T88-67151 MI MO gears upgrade and spindles (K4T88-67151) on page 1249
7 Q6702-60468 Spindle latch type A (Q6702-60468) on page 1256
8 K4T88-67145 Motorized MI side plate (K4T88-67145) on page 1242
9 K4T88-67149 Left MO side plate (K4T88-67149) on page 1247
K4T88-67242 MI motor data cable (K4T88-67242) on page 1256
K4T88-67243 MI motor power cable kit (K4T88-67243) on page 1256
K4T88-67244 MO motor encoder cable (K4T88-67244) on page 1256
K4T88-67245 MO motor data cable (K4T88-67245) on page 1256
K4T88-67246 MO motor power cable kit (K4T88-67246) on page 1256
K4T88-67247 MI resistors power cable (K4T88-67247) on page 1256
K4T88-67248 MO resistors power cable (K4T88-67248) on page 1256


Curing (1)
1 CZ056-67061 Curing bracket pin support (CZ056-67061) on page 761
2 K4T88-67126 Curing bracket pin support (CZ056-67061) on page 761
3 K4T88-67127 Curing central module (K4T88-67127) on page 758
4 K4G10-67122 Curing Side Foams (K4G10-67122) on page 767
5 K4T88-67128 Curing left module (K4T88-67128) on page 759
6 CZ056-67060 Curing linear guide kit (CZ056-67060) on page 761
7 K4T88-67129 Curing latch (K4T88-67129) on page 760
8 K4T88-67130 Curing bottom plate w Ribs (K4T88-67130) on page 766
9 K4G10-67083 RH BP diverter adaptor (K4G10-67083) on page 765
10 K4G10-67073 RH bottom plate diverter barrier (K4G10-67073) on page 764
K4T88-67222 Curing LAN cables kit (K4T88-67222) on page 763
K4T88-67223 Curing PCA cables kit (K4T88-67223) on page 763
K4T88-67224 Curing grounding cables kit S (K4T88-67224) on page 763
K4T88-67225 Curing power cables kit (K4T88-67225) on page 763
K4G10-67118 Lower curing beam EPDM foam (K4G10-67118) on page 775
ENWW Curing (1) 649


Curing (2)
1 CZ056-67384/1HA07-670 Curing and Vapor removal PCA (CZ056-67384/1HA07-67015) on page 772

15
2 K4T88-67304 Curing PCA cooling fan (K4T88-67304) on page 768
3 1HA07-67038 Curing heater and fan module (1HA07-67038) on page 750
4 CZ056-67055 Curing temperature sensor kit (CZ056-67055) on page 753
ENWW Curing (2) 651

Old Carriage (1)

1 K4T88-67013 Primer and latch. Not available anymore. Ask for Service kit Pen pocket color (K4T88-67310)
on page 704 (x1) and Pen pocket optimizer (K4T88-67313) on page 706 (x1)
2 K4T88-67006 Pen pocket. Not available anymore. Ask for Service kit Pen pocket color (K4T88-67310)
3 K4T88-67002 Pen pocket base. Not available anymore. Ask for Service kit Pen pocket color (K4T88-67310)
4 K4G10-67091 Printhead interconnect color PCA. Not available anymore. Ask for Service kit Pen pocket color
(K4T88-67310) on page 704 (x1) and Pen pocket optimizer (K4T88-67313) on page 706 (x1)
5 K4T88-67004 Line sensor (K4T88-67004) on page 695 (only 1 unit)
6 K4T88-67010 Carriage assembly (K4T88-67010) on page 672
7 K4T88-67016 Undercarriage protector (K4T88-67016) on page 721
8 K4G10-67092 Printhead interconnect optimizer PCA. Not available anymore. Ask for Service kit Pen pocket color
(K4T88-67310) on page 704 (x1) and Pen pocket optimizer (K4T88-67313) on page 706 (x1)
9 K4T88-67009 Carriage tower (K4T88-67009) on page 731

New Carriage (1)

1 1HA07-67018 Primer and latch (1HA07-67018) on page 708 New configuration required to replace this part
2 K4T88-67310 and Service kit to upgrade the color/optimizer pen pocket to the new configuration. See Pen pocket
K4T88-67313 color (K4T88-67310) on page 704 (x1) and Pen pocket optimizer (K4T88-67313)
on page 706 (x1)
3 K4T88-67309 Service kit to upgrade the 4 pen pockets to the new configuration. See Pen pockets (4x)
(K4T88-67309) on page 703
4 1HA06-67002 Printhead interconnect color PCA (1HA06-67002) on page 713 New configuration required to
replace this part
5 K4T88-67004 Line sensor (K4T88-67004) on page 695 (only 1 unit)
6 K4T88-67010 Carriage assembly (K4T88-67010) on page 672
7 K4T88-67016 Undercarriage protector (K4T88-67016) on page 721
8 1HA06-67003 Printhead interconnect optimizer PCA (1HA06-67003) on page 717 New configuration required
to replace this part
9 K4T88-67009 Carriage tower (K4T88-67009) on page 731
ENWW New Carriage (1) 653

Carriage (2)
1 CZ056-67373 Carriage interconnect PCA (CZ056-67373) on page 728
2 K4T88-67015 Carriage fan (K4T88-67015) on page 691
3 K4T88-67011 Carriage oiling felts (K4T88-67011) on page 736
4 K4T88-67008 Carriage bearings (K4T88-67008) on page 685
5 K4T88-67005 Online spectrophotometer (SOL) (K4T88-67005) on page 732
6 K4T88-67014 Carriage encoder reader (K4T88-67014) on page 687
— K4T88-67007 Carriage cables (K4T88-67007) on page 728
— K4T88-67252 SOL PCA cables kit (K4T88-67252) on page 736

Human machine interface

1 K4T88-67267 Screen (K4T88-67267) on page 897
2 K4T88-67295 IPS monitor (K4T88-67295) on page 895
3 K4T88-67269 Keyboard (K4T88-67269) on page 898
4 K4T88-67270 Internal Print Server (K4T88-67270) on page 896
5 K4T88-67290 Forklift (K4T88-67290) – (Accessory) on page 1363
6 K4T88-67188 Screen mount bracket (K4T88-67188) on page 898
7 K4T88-67187 Screen mount (K4T88-67187) on page 901
ENWW Human machine interface 655

LEDs
1 K4T88-67196 Pz LED lights (K4T88-67196) on page 1326

Double sided day and night kit (accessory)

1 K4T88-67004 Line sensor (K4T88-67004) on page 1336
2 CZ056-67190 Motor DRV PCA (CZ056-67190) on page 1356
3 P4P91-67002 D&N e-cabinet (P4P91-67002) on page 1342
4 K4T88-67195 D&N button (K4T88-67195) on page 1358
5 K4G10-67048 Back light assy (K4G10-67048) on page 1334
6 K4G10-67047 Front light assy (K4G10-67047) on page 1331
7 P4P91-67004 D&N protector (P4P91-67004) on page 1352
8 P4P91-67003 Platen lights (P4P91-67003) & D&N ramp (P4P91-67007) on page 1345
9 P4P91-67006 MEH standard and D&N sliders (P4P91-67006) on page 1354
P4P91-67001 Dsp cables kit
ENWW Double sided day and night kit (accessory) 657

Forklift (accessory)

Dual roll kit (accessory)

1 CZ056-67243 Spindle ruler labels (CZ056-67243) on page 1367
2 K4T88-67298 Center support & shims (K4T88-67298) on page 1370
3 K4G10-67094 Spindle spring air valve (K4G10-67094) on page 1370
4 CZ056-67238 Spindle journal (CZ056-67238) on page 1366
5 CZ056-67461 Dual roll spindle Hrds (CZ056-67461) on page 1369
6 CZ056-67244 Spindle differential cover (CZ056-67244) on page 1368
7 CZ056-67459 Spindle gear Hrds (CZ056-67459) on page 1369
ENWW Dual roll kit (accessory) 659

R2FF (accessory)
1 W3U61-67004 R2FF substrate collector assy (W3U61-67004) on page 1380
2 CZ056-67175 R2FF switch cable assy (CZ056-67175) on page 1381
3 CZ056-67173 Pinch lever kit (CZ056-67173) on page 1378
4 W3U61-67003 RTFF brushless motor assy (W3U61-67003) on page 1384
5 CZ056-67178 Inner pinch hinge (CZ056-67178) on page 1375
6 CZ056-67176 Outer pinch hinge (CZ056-67176) on page 1376
7 W3U61-67001 R2FF side plates (W3U61-67001) on page 1382
8 CZ056-67174 R2FF damper (CZ056-67174) on page 1380
9 CZ056-67465 R2FF hardened gears & extraction tool (CZ056-67465) on page 1386
10 CZ056-67468 R2FF roller (CZ056-67468) on page 1385
11 W3U61-67002 R2FF cable kit (W3U61-67002) on page 1395

Ink collector (accessory)

1 P4P92-67001 Ink collector edge holder (P4P92-67001) on page 1396
2 P4P92-67002 Ink collector module (P4P92-67002) on page 1396
3 P4P92-67004 Ink collector protector (P4P92-67004) on page 1397
ENWW Ink collector (accessory) 661

7 Removal and installation
● Aerosol
● Carriage
● Curing
● Drying
● E-box
● E-cabinet
● Human-Machine interface
● Impelling
● Industrial design covers
● Ink system module
● Print to Paper Space (PPS)
● Service station: capping and drop detector
● Substrate path
● Tube Routing System (TRS)
● Vapor removal
● Platen lights
● Uptime and maintenance kits
● Double sided day and night kit (P4P91A) – (Accessory)
● Forklift (K4T88-67290) – (Accessory)
● Dual roll kit (T0F91A) – (Accessory)
● R2FF (Accessory)
● Ink collector (Accessory)
662 Chapter 7 Removal and installation ENWW

Aerosol
Aerosol box (K4T88-67001)
Removal
1. Move the carriage to the service position.
2. Turn off the printer and the power enable switch.
3. Open the window.
4. Open the Aerosol fan cover.
5. Remove the old filter frame.
ENWW Aerosol 663

6. Remove the filter.
7. Disconnect the cables from the Aerosol box.

8. Remove the 4 screws that attach the box to the carriage.
9. Remove the Aerosol box.
Installation
▲ Reverse the process.
Aerosol Frame (K4T88-67012)

Removal
ENWW Aerosol 665

3. Open the window.
4. Open the Aerosol fan cover.
5. Remove the old filter frame.

Installation
1. Add the filter.
2. Insert the new filter frame.
3. Close the Aerosol fan cover.
4. Close the window.
Aerosol PCA (K4T88-67017)

Removal
2. Turn off the printer in the correct way for maintenance operations.
3. Open the window.
4. Remove the right Aerosol box. See Aerosol box (K4T88-67001) on page 663.
ENWW Aerosol 667

5. Disconnect the SOL cable.
6. Loosen 9 screws from the electrical cover.
7. Remove the electrical cover.

8. Disconnect all the cables from the Carriage power management PCA.
9. Remove the 5 PCA screws.
10. Remove the PCA.
Installation
ENWW Aerosol 669

Aerosol top case (K4T88-67003)

Removal
3. Open the window.
4. Disconnect the cables from the Aerosol box.

5. Remove the hinges that attach the Aerosol lid and the Aerosol container.
6. Open the top case latch.
7. Remove the top case.
Installation
ENWW Aerosol 671

Carriage
Carriage 1
● Carriage assembly (K4T88-67010)
● Carriage bearings (K4T88-67008)
● Carriage encoder reader (K4T88-67014)
● Carriage fan (K4T88-67015)
● Line sensor (K4T88-67004)
● Pen pockets (4x) (K4T88-67309)
● Pen pocket color (K4T88-67310)
● Pen pocket optimizer (K4T88-67313)
● Primer and latch (1HA07-67018)
● Printhead interconnect color PCA (1HA06-67002)
● Printhead interconnect optimizer PCA (1HA06-67003)
● Undercarriage protector (K4T88-67016)
Carriage assembly (K4T88-67010)
Removal
1. Move the Carriage to the service position.
3. Open the window.
4. Remove the rear cover (the one behind the Carriage intervention position). See Top center rear cover
(K4T88-67160) on page 970.
5. Remove the Carriage belt. See Impelling carriage belt assembly (K4T88-67306) on page 909.

6. Remove the 2 Carriage oiling felts placed on the top rod by removing the 2 Allen screws (Allen 3 wrench).
ENWW Carriage 673

7. Repeat the same operation on the other side of the Carriage.
8. Untighten 6 tube guide screws.

9. Remove the tube guide.
10. Untighten 3 tube cover screws.
11. Remove the tube cover.
ENWW Carriage 675

12. Cut the tubes ties.
13. Remove the Optimizer pen interconnect electronics. See Printhead interconnect optimizer PCA
(1HA06-67003) on page 717.
14. Remove the printheads.
15. Untighten the 4 interconnect towers screws.

16. Disassemble the Fluid Interconnect Towers for each Pen Pocket slot.
17. Disconnect SOL cable.
18. Untighten the 9 electronic cover screws.
ENWW Carriage 677

19. Remove the electronic cover.
20. Disconnect the power cable from the electronics PCA.
21. Cut the cables ties.
22. Remove the Fiber optics PCA (CZ056-67389). See Fiber-optics PCA (CZ056-67389) on page 739.

23. Untighten the 2 Allen screws from the carriage tower.
24. Remove the Tube routing system and place it over the tray.
25. Untighten the rear bearing screw from the input side.
ENWW Carriage 679

26. Remove the bearing by pulling it out. At that point, the Carriage will rotate over the platen. To prevent any
damage on it, place some cloth between them.
27. From the output side, pull up the Carriage and remove it from the printer.
Installation
1. Untighten the rear bearing screw. Once the screw is fully untighten, remove the bearing by pulling it out. (in
case of a new Service Part).

2. From the output side, introduce the Carriage into the Scan Axis rods
3. From the Input side of the printer and through the SAX beam reparation window insert the rear bearing
removed on step 1 and tighten the rear bearing screw
ENWW Carriage 681

4. Place properly and carefully with the fingers the Encoder strip inside the Encoder sensor.
NOTE: Be careful when doing this operation as the encoder strip could cut.
5. Connect the Fiber-optics cable to the Slinky PCA and after that tighten the PCA to the Carriage Tower.
6. Assemble the Tube Routing System by tightening 2x screws

7. In case the Carriage’s ink tubes need to be replaced also, cut the tube and reconnect it with the new ones.
In the case of no need to replace the ink tubes, remove the tubes that already come with the carriage.
8. Place the tube cover by tightening 3x screws
Place the tube guide by tightening 6x screws
9. Connect power cable to the PCA in case of New Carriage, it is need to remove the cover first.
ENWW Carriage 683

10. Close the Electronics cover by tightening 9x screws
11. Install the Fluid Interconnect Towers on the Carriage (in case of New Carriage, disassemble the Optimizer
Electronics)
Tighten the screw.
12. Install the 2x Carriage Oiling felts placed on the top rod by tightening 2x allen screws (allen 3 wrench).
Repeat the same operation on the other side of the Carriage.
13. Install the Carriage belt.
14. Install the Left cover.
15. Install the Rear cover.

Carriage bearings (K4T88-67008)
Removal
3. Open the window.
4. Remove the Carriage Oiling Felts. See Carriage oiling felts (K4T88-67011) on page 736.
5. Untighten the 4 Allen screws of the bearing housing from the right side.
6. Remove the bearing housing from the right side
ENWW Carriage 685

7. Untighten the 4 screws of the bearing housing from the left side.
8. Remove the bearing housing from the left side.
9. Move the Carriage to the intervention position on the SAX.
10. Unscrew 7 screws.

11. Remove the back cover.
13. Remove the bearing by pulling it out.
Carriage encoder reader (K4T88-67014)
Removal
ENWW Carriage 687

3. Open the window.
4. Disconnect the cable from the Optimizer PCA.
NOTE: Cut the cable ties needed to release the Encoder cable.
5. Loosen the Allen screw from the side of the Carriage.

6. Remove the Encoder sensor holder.
7. Unscrew the two Encoder sensor screws.
8. Cut the cable tie.
ENWW Carriage 689

9. Remove the Encoder sensor reader.
Installation
1. Install the new Encoder Sensor on the Encoder holder.
2. Install the Encoder Sensor holder.

3. Tighten the Allen screw from the lateral of the Carriage.
4. Connect the cable to the Optimizer PCA.
5. Ensure the cable to the electronics cover with a cable tie in order to secure the cable.
Carriage fan (K4T88-67015)
Removal
ENWW Carriage 691

3. Open the window.
5. Loosen 9 screws from the Electrical cover.

6. Remove the Electrical cover.
7. Disconnect the Carriage fan cable from the Electronics PCA.
8. Loosen the 4 T-15 Carriage fan screws.
ENWW Carriage 693

9. Remove the Carriage fan and unroute the cable.
Installation
1. Route the cable through the fan guard.
2. Tighten the 4x T-15 screws.

3. Connect the cable to the PCA.
4. Place the Electronics cover back on making sure that the cables are not kinked by the cover.
Tighten 9x screws.
Line sensor (K4T88-67004)
Removal
3. Open the window.
ENWW Carriage 695

4. Unscrew the 3 Line sensor cable clip screws.
5. Unplug the line sensor cable from the PCA.
6. Unroute the cable ferrite from the ferrite holder and pull away the Line sensor cable.

7. Unscrew the 2 remaining Line sensor cable clip screws.
8. Pull away the cables and remove the sensor cable clip.
9. Unscrew the 2 line sensor enclosure screws.
ENWW Carriage 697

10. Unplug the cable from the SOL PCA.
11. Remove the left Aerosol box. See Aerosol box (K4T88-67001) on page 663.
12. Unplug the Line sensor cable from the Printhead interconnect color PCA.
13. Unroute the cable ferrite from the ferrite holder.

14. Detach cables from the enclosure.
15. Remove the Line sensor enclosure.
NOTE: To remove the Line sensor follow the next steps. Otherwise go to step18 to remove the Day and
Night Line sensor.
16. Loosen the screw from the lateral side of the carriage.
ENWW Carriage 699

17. Remove the Line sensor from the top of the carriage.
18. Loosen the screw from the lateral side of the carriage.
19. Remove the Day and Night Line sensor from the top of the carriage.
Installation
1. Take the Line sensor and introduce it to the lateral side of the Carriage ensuring the pins are well placed.

Tighten the screw from the lateral side of the Carriage.
2. Connect the cable while routing it through the Line sensor enclosure.
ENWW Carriage 701

3. Tighten 2x T-15 Line sensor enclosure screws.
4. Place the Line sensor cable clip on top of the other one.

5. Tighten the 5x screws.
Pen pockets (4x) (K4T88-67309)

For this kit you should have the old Printhead pockets configuration in order to make the upgrade to the new
set-up.
Check the differences in the image below:
This kit contains 3 whole new set-ups for colors and 1 for optimizer.
Each set-up affects the Printhead pockets, the PCA cover, the FI tower cover and the Primer and latch.
Removal and installation
▲ Follow the steps in Pen pocket color (K4T88-67310) on page 704 for the color Printhead pockets and in
Pen pocket optimizer (K4T88-67313) on page 706 for the optimizer.
ENWW Carriage 703

Pen pocket color (K4T88-67310)

Check the set-up that you have in your machine. You can differentiate them looking at the latch, see the image
below:
This kit contains a whole new set-up for 1 color.
This set-up affects the Printhead pockets, the PCA cover, the FI tower cover and the Primer and latch.
This kit is not valid for the optimizer. Service Kit K4T88-67313 contains the new set-up for the optimizer.
Removal
3. Remove RH Printhead interconnect color PCA. See Printhead interconnect color PCA (1HA06-67002)
on page 713.
4. Unscrew the 3 tube cover screws.

5. Remove tube cover.
6. Remove the screw that secures the TRS FI tower.
NOTE: There are 2 screws in the new pen pocket configuration.
7. Pull out the TRS FI tower.
ENWW Carriage 705

8. Disconnect the primer cable from the printhead interconnect PCA.
NOTE: There are 2 cables.
9. Remove the 4 screws that secure the printhead pocket base.
10. Remove the printhead pocket from the carriage.
Installation
▲ Reverse the removal process.
Pen pocket optimizer (K4T88-67313)

Check the set-up that you have in your machine. You can differentiate them looking at the latch, see the image
below:

This kit contains a whole new set-up for the optimizer.
This set-up affects the Printhead pockets, the PCA cover, the FI tower cover and the Primer and latch.
This kit is not valid for colors. Service Kit K4T88-67310 contains the new set-up for colors.
Removal
3. Remove RH Printhead interconnect color PCA. See Printhead interconnect color PCA (1HA06-67002)
on page 713.
4. Remove the that secures the TRS FI tower.
NOTE: There are 2 screws in the new pen pocket configuration.
5. Pull out the TRS FI tower.
ENWW Carriage 707

6. Disconnect the primer cable from the printhead interconnect PCA.
NOTE: There are 2 cables.
7. Remove the 4 screws that secure the printhead pocket base.
8. Remove the printhead pocket from the carriage.
Installation
Primer and latch (1HA07-67018)

Check if you have the new or the old Pen pocket configuration. You can check this looking at the latches.

Follow the removal process according to the configuration you have (old or new):
Removal (old configuration)
3. Open the window.
4. Disconnect the primer cable.
NOTE: There are 2 cables for each primer.
ENWW Carriage 709

5. Open the latch.
6. Remove the latch and the primer.

Removal (new configuration)
3. Open the window.
4. Disconnect the primer cable.
NOTE: There are 2 cables for each primer.
ENWW Carriage 711

5. Open the latch.
6. Remove the screw and the latch retainer.

7. Remove the latch and the primer.
Installation
▲ Reverse the removal steps.
Printhead interconnect color PCA (1HA06-67002)
Removal
3. Open the window.
ENWW Carriage 713

4. Open the printhead latch.
6. Protect the printhead with their orange sealing cap.

7. Close the latch.
8. Disconnect all the cables from the printhead interconnect color PCA.
9. Open the latch and unscrew two M3 screws.
ENWW Carriage 715

10. Remove 4 screws (only for the new configuration).
11. Remove the X-Spring (only for the new configuration).
12. Open the left latch to avoid interaction.

13. Remove the printhead interconnect PCA.
Installation
Printhead interconnect optimizer PCA (1HA06-67003)
Removal
3. Open the window.
ENWW Carriage 717

4. Open the printhead latch.
6. Protect the printhead with its orange sealing cap.

7. Disconnect all the cables from the printhead interconnect optimizer PCA (the data trailing cable, the power
cable from the printhead interconnect optimizer PCA and the two spray-to-spray cables—one connects to
the drying PCA down and the other connects to the printhead interconnect color PCA 2).
8. Unroute the cable ferrite from the ferrite holder.
9. Remove 4 screws (only for the new configuration).
ENWW Carriage 719

10. Remove the X-Spring (only for the new configuration).
11. Remove the printhead interconnect optimizer PCA assembly from the carriage.
12. Remove the 2 ferrite holder screws.

13. Remove the ferrite holder.
Installation
1. Install the ferrite holder on the new PH interconnect optimizer.
2. Reverse the removal steps.
Undercarriage protector (K4T88-67016)
Removal
1. Move the Carriage to the service position and the PPS up.
ENWW Carriage 721

3. Open the window.
4. Unscrew the 3 Line sensor cable clip screws.
5. Unplug the Line sensor cable from the PCA.

6. Unroute the cable ferrite from the ferrite holder and pull away the line sensor cable.
7. Unscrew the 2 remaining line sensor cable clip screws.
8. Pull away the cables and remove the sensor cable clip.
ENWW Carriage 723

9. Unscrew the 2 line sensor enclosure screws.
10. Unplug the cable from the SOL PCA.
11. Detach the cables from the enclosure.

12. Remove the Line sensor enclosure.
13. From below, remove 2 screws and 3 screws from the Undercarriage protector.
14. Remove the left Aerosol box (K4T88-67001). See Aerosol box (K4T88-67001) on page 663.
15. From the top of the Carriage, remove 8 T-15 screws and 4 Allen screws.
ENWW Carriage 725

16. Remove the Color under carriage protector from the Carriage.
17. From the top of the Carriage, remove 4 T-15 screws.
18. Remove the Optimizer under carriage protector from the Carriage.
Installation
1. Place the Undercarriage protector optimizer below the carriage ensuring 2 pins are entering inside the
Carriage slot datums.

2. Tighten the 4 screws from the top of the Carriage following the sequence in the image.
3. Place the colored Undercarriage protector below the Carriage ensuring 2 pins are entering inside the
Carriage slot datums.
ENWW Carriage 727

4. Tighten the 12 screws from the top of the Carriage following the sequence in the image.
5. Finally, from the bottom side, tighten 2 T-15 screws for the UCP optimizer and 3 screws for the colored
UCP.
Carriage 2
● Carriage cables (K4T88-67007)
● Carriage interconnect PCA (CZ056-67373)
● Carriage tower (K4T88-67009)
● Online spectrophotometer (SOL) (K4T88-67005)
● SOL PCA cables kit (K4T88-67252)
● Carriage oiling felts (K4T88-67011)
● Fiber-optics PCA (CZ056-67389)
Carriage cables (K4T88-67007)

See Cables on page 1469.
Carriage interconnect PCA (CZ056-67373)
Removal

3. Open the window.
5. Untighten 9 screws from the Electrical cover.
ENWW Carriage 729

6. Remove the Electrical cover.
7. Remove the right Aerosol box. See Aerosol box (K4T88-67001) on page 663.
8. Disconnect all the cables from the Carriage interconnect PCA.
9. Untighten 7 screws from the Carriage interconnect PCA.

10. Remove the Carriage interconnect PCA.
Carriage tower (K4T88-67009)
Removal
2. Switch off the printer.
3. Remove the top cover.
4. Disconnect the cables from the FO PCA.
5. Untighten the tree screws from the top and remove the carriage tower.
Installation
ENWW Carriage 731

2. Reassemble the Fiber-optics support with the separators into the new Carriage tower.
3. Assemble the Carriage tower into the Carriage by tightening the 3 screws from the top.
Online spectrophotometer (SOL) (K4T88-67005)
Removal
3. Open the window.

4. Unplug the SOL cable.
5. Untighten the 8 SOL cover screws.
6. Remove the SOL cover.
ENWW Carriage 733

7. Loosen the 3 SOL PCA screws.
8. Remove the SOL PCA.
9. Disconnect the SOL data cable from the PCA opening the connector.

10. Untighten the two SOL screws .
11. Remove the SOL shutter.
12. Remove the 4 SOL cover support screws.
ENWW Carriage 735

13. Remove the SOL cover support.
SOL PCA cables kit (K4T88-67252)

Carriage oiling felts (K4T88-67011)
Removal
2. Open the window.
3. Manually move the Carriage to the center of the platen.

4. Locate the lower and upper carriage oiler felts from the left side.
5. Remove 3 screws.
6. Remove the lower carriage oiler felt.
ENWW Carriage 737

7. Remove 2 screws and the metal part covering the upper carriage oiler felt.
8. Remove the upper carriage oiler felt.
9. Locate the lower and upper carriage olier felt from the right side.
Installation
1. Be careful, the carriage oiler felts have pins that help to mount them.

2. Make sure that, once installed, the blue plastic part in the oiler felt is outwards (not inwards).
Fiber-optics PCA (CZ056-67389)
Removal
3. Remove the rear cover (the one behind the Carriage intervention position). See Top center rear cover
(K4T88-67160) on page 970.
4. Disconnect all cables.
ENWW Carriage 739

5. Remove the seven PCA screws.
6. Disconnect the fiber optics cable and remove the fiber optics PCA.

Curing
Curing service position
The service position of the curing module assembly is used frequently in the curing procedures as well as other
subsystems related to it. For that reason, we offer the below explanatory procedure.
Removal
2. Open the front door.
ENWW Curing 741

3. Open both curing module assembly latches.
4. Pull the curing module to the load position.

5. Through the rear space, unscrew the right Philips screw blocker.
NOTE: If it is not possible to reach the blocker screw through the rear space, then raise the Right button
cover (four screws) in order to access the two screws of the cable bundler cover to ease access.
ENWW Curing 743

6. Loosen the 4 cable ties that attach the curing cables to the structure.
Curing module assembly

Removal
2. Open the front door and pull the curing module to the service position. See Curing service position
on page 741.

3. For the right module, remove the two T-25 screws and open the cable covers.
4. Disconnect the LAN cable from the curing PCA at LAN connector (J12). Disconnect all the cable air
connections on module 1, as well as the grounding cable.
ENWW Curing 745

5. On the left side of the printer, remove the three screws that secure the front module curing to the side
plate.

6. On the right side of the printer, remove the three screws that secure the cables Right buttons cover to side
plate so that it can be withdrawn.
ENWW Curing 747

7. Cut the ties that hold the routing curing cables along the cable bundler cover, and unroute them. Remove
the screw limiting the curing guide and remove the Right button cover.

8. On the left side, remove the three screws shown in the figure, which fix the support guide to the side plate.
9. Carefully open the curing module assembly and remove the three screws that hold the upper curing slide
support to the right side plate. On other side, remove the remaining screws.
IMPORTANT: The following operations require at least two people. Holding and removing the curing
module assembly must be done with caution, as it is too large and heavy for one person.
10. Open both clamps, and hold the curing module assembly on both sides by holding the upper beam and the
clamp.
11. Carefully slide the module out, holding it by the clamp and the upper position on both sides.
12. Leave the curing module assembly on the table.
Installation
▲ Follow the removal process in reverse order.
ENWW Curing 749

Curing heater and fan module (1HA07-67038)

Removal
2. Use a screwdriver to remove the screws of the curing module.
3. Raise the PCA module in order to reach the interior of the module.

4. Disconnect the two cables shown in the picture. You have to press the retention clip on each of the two
connectors, and gently pull the cable. The black one is for the DC fans supply and the white one is for AC
power to the curing heaters.
5. Use a screwdriver to remove the screws of the fan-resistor module.
ENWW Curing 751

6. Remove the fan-resistor module.

7. Put the new fan-resistor module into position. Screw in the screw and connect the two cables to each fan-
resistor module.
8. Close the curing module and replace the screws to secure it.
Installation
Curing temperature sensor kit (CZ056-67055)

Removal
ENWW Curing 753

3. Use a screwdriver to remove the two curing module screws in to raise it in order to ease the next step.
4. Remove the four pointed T-20 screws and open the curing PCA cover.
5. Disconnect the temperature sensor cable from the curing PCA.

6. Open the Curing service cover.
7. Remove the curing fan heater assembly.
ENWW Curing 755

8. Disconnect the temperature sensor extension to temperature sensor cable.
9. Unroute the temperature sensor cable from its supports, looping through both covers.
Installation
1. Be careful when replacing the temperature sensor: it is important to leave the sensor free on air, but also
to route the temperature sensor cable correctly, looping along the temperature sensor support.
CAUTION: The temperature sensor must be placed at a distance of 3.5 ± 1 mm from the curing impinging
plate surface. Otherwise, the curing module fans will not work properly.

2. Connect the temperature sensor to temperature extension cable and route it in the opposite way.
Curing right module (K4T88-67126)

Removal (preliminary)
1. Pull the curing module to the service position.
2. Remove the two T-25 screws and open the cable covers.
3. Remove the four T-20 screws and the curing PCA cover.
4. Disconnect the LAN cable from the curing PCA at LAN connector (J12).
5. Disconnect all the cable air connections on module 1 and unroute for module 1 those cables that keep on
routing to module 2.
6. Cut the flanges that hold the routing curing cables along the cable bundler cover, and unroute those cables.
7. Remove the four pointed T-20 screws and the vapor removal mobile collector.
8. Remove the six pointed screws and the vapor removal motion curing box.
9. Push back the curing module to the carpet position and close both clamps.
NOTE: It is recommended to screw back both the cable cover and the curing PCA cover before removing
the curing module assembly, in order to make the removal of the curing module easier to handle.
10. Carefully open the curing module assembly and remove the three screws that hold the left upper curing
slide support to the sideplate.
11. Move the curing module assembly back to the carpet position and remove the two remaining screws from
the left upper curing slide support.
12. Loosen the right upper curing slide support (T-20 screws).
13. Slide a flange through the left upper curing slide support and the left curing side plate and tighten it in
order to disable linear guide movement.
ENWW Curing 757

14. Repeat the same operation to tighten the right linear guide with a flange.
NOTE: The following operations require at least two people. Holding and removing the curing module
assembly must be done with caution, as it is too large and heavy for one person.
15. Open both clamps and hold the curing module assembly on both sides, by holding the upper beam and the
clamp.
16. Pull the curing module slightly to the left in order to free the right side from the T-20 screws.
17. Carefully slide the module out, holding it by the clamp and the upper position on both sides.
18. Leave the curing module assembly on a flat surface.
Removal
2. Remove the curing module assembly. See Curing module assembly on page 744.
3. Remove the three HEX screws, and the six screws that hold the lower beam to the right curing external
sideplate.
4. Remove the right curing external sideplate from the curing module assembly.
5. Remove the two T-25 screws and open their cable covers.
6. Remove the four T-20 screws and the curing PCA cover.
7. Disconnect and unroute all the cables routed along the right curing module (the cables that go from the
right module to the central top right module 2) in order to be able to remove the module separately.
8. Remove the ground short.
9. Remove the right module by pulling it to the right.
IMPORTANT: Do not touch or remove the pins from their location when replacing any module, in order not
to modify the calibration along the guides during the replacement procedure.
Installation
1. To install the side plate back it is important to close the vapor removal guide properly with silicone in order
not to have any air leakage.
TIP: It is strongly recommended to use Dow Corning 732 Multi-Purpose Sealant.
2. Check the status of the curing modules. See Table 5-18 Curing on page 581.
NOTE: You can check all the curing modules, or one particular module.
Curing central module (K4T88-67127)

Removal

3. Remove the three HEX screws, and the six screws that hold the lower beam to the right curing external
sideplate.
5. For each module, from the right to the required module, remove the two T-25 screws and open their cable
covers.
6. For each module, from the right to the required module, remove the four T-20 screws and the curing PCA
cover.
7. Disconnect and unroute all the cables routed along the curing modules in order to be able to remove the
modules separately.
8. For each module, from the right to the required module, remove the ground short cable.
10. Remove the subsequent modules by sliding them to the right.
Installation
1. When reinstalling the side plate, it is important to close the vapor removal guide properly with silicone in
order not to have any air leakage.
Curing left module (K4T88-67128)

Removal
3. Remove the three HEX screws, and the six screws that hold the lower beam from both the right curing
external sideplate.
5. For all the modules, going from right to left, remove the two T-25 screws and open their cable covers.
6. For all the modules, going from right to left, remove the four T-20 screws and the curing PCA cover.
7. Disconnect and unroute all the cables routed along the curing modules (which means removing the entire
cable routing) in order to be able to remove all the modules separately.
8. For all modules, remove the ground short cable.
10. Remove the subsequent modules by sliding them to the right.
ENWW Curing 759

Installation
1. When reinstalling the side plate, it is important to close the vapor removal guide properly with silicone in
order not to have any air leakage.
Curing latch (K4T88-67129)

Removal
3. Open both curing latches.
5. Remove the two pointed T-20 screws and replace the latch.

Installation
Curing linear guide kit (CZ056-67060)

Removal
3. Remove the screws that hold the linear guide to the external sideplate and the curing slide support.
4. Replace the linear guide.
Installation
Curing bracket pin support (CZ056-67061)

Removal – Preliminary steps
ENWW Curing 761

Removal – Upper pin
1. Remove the two T-25 screws and open the cable covers of the module you are working on.
2. Remove the pin support screws with an HEX key.
IMPORTANT: Do not touch or remove the modules when replacing any pin support, in order not to modify
the calibration along the guides during the replacement procedure.
IMPORTANT: Do not remove more than one pin at a time, in order not to affect the calibration along the
curing beams.
Removal – Lower pin
1. Remove the pointed screws using a flat screwdriver in order open the Curing service inner cover and reach
the lower pins of the module you are working on.

2. Remove the pin support screws with an HEX key.
IMPORTANT: Do not touch or remove the modules when replacing any pin support, in order not to modify
the calibration along the guides during the replacement procedure.
IMPORTANT: Do not remove more than one pin at a time, in order not to affect the calibration along the
curing beams.
Installation
Curing LAN cables kit (K4T88-67222)

Curing PCA cables kit (K4T88-67223)

Curing grounding cables kit S (K4T88-67224)

Curing power cables kit (K4T88-67225)

ENWW Curing 763

RH bottom plate diverter barrier (K4G10-67073)

Removal
2. Remove any substrate.
6. To remove any top barrier, remove the 3 screws that hold it to the diverter.
7. To remove any bottom barrier, remove only the top diverter wheels and remove the screws.

Installation
▲ Follow the removal process in reverse. Verify that the removed and installed diverter wheels are working
properly.
RH BP diverter adaptor (K4G10-67083)

Removal
1. Unload the substrate.
3. Protect the OMAS sensor covering it with paperboard.
4. Pull the curing module to the service position. See Curing service position on page 741.
5. Remove only the top wheels on the bottom diverter (36 wheels) in order to unscrew the bottom plates.
6. Remove the bottom plate base screws.
ENWW Curing 765

7. Remove the 3 modules of the bottom plate starting from the leftmost module.
8. Remove the bottom plate diverter adaptors.
Installation
1. Follow the removal process in reverse. Be careful to start to mount the bottom plate from the right side of
the printer to the left side.
2. Verify the flatness of the bottom plate assembly. The distance between 2 ribs belonging to different
bottom plates should be less than 1 mm. Check this specification in the 4 junctions circled in the image.
Curing bottom plate w Ribs (K4T88-67130)

Removal
4. Pull the curing module to the substrate load position and remove any substrate.
5. Push the curing module assembly back to the closed position and remove the flat Phillips M6 screw from
each dolly (left and right).
7. Remove the Torx M3 screws that fix the bottom plates to the upper and lower diverter modules.
8. Remove the bottom plate assembly.

NOTE: When removing the bottom plate, you are recommended to remove the three panels from the ISM
side to the e-cabinet side (from left to right). When installing, follow the reverse order, from right to left,
from the e-cabinet side to the ISM side.
NOTE: To replace any rib of the curing bottom plate assembly, it is necessary to remove the entire curing
bottom plate, so that the screws hidden backwards, that attach the ribs to the curing bottom plate, are
accessible.
Installation
▲ Perform the opposite procedure to install the curing bottom plate assembly.
CAUTION: Ensure that both Torx M6 screws are replaced at the ends of the curing linear guides;
otherwise, the guide lines can break easily.
Curing Side Foams (K4G10-67122)

Removal
4. Pull the curing module to the substrate load position and remove any substrate.
5. Push the curing module assembly back to the closed position and remove the flat Phillips M6 screw from
each dolly (left and right).
ENWW Curing 767

7. Locate the side foams.
8. Remove the curing bottom plate side foam.
Installation
1. Clean the whole surface of the metal sheet with alcohol so that there is no glue left.
2. Position the new side foam correctly and press it carefully against the metal sheet so that it is correctly
glued.
3. Close the curing module assembly.
Curing PCA cooling fan (K4T88-67304)

Removal

5. Remove the two screws and raise the curing PCA module.
ENWW Curing 769

6. Remove the four T-20 screws and open the curing PCA cover.
7. Remove the PCA cover.

8. Disconnect the PCA fan cable from the Curing PCA.
9. Remove the four pointed nuts that hold the PCA fan.
10. Remove the curing PCA fan.
Installation
▲ Place the new fan in the correct position (see below picture), and screw it to the AC safety cover sheet.
ENWW Curing 771

Curing and Vapor removal PCA (CZ056-67384/1HA07-67015)

When a system error occurs, its code indicates which PCA must be changed, check the following diagram to
identify them.
Removal

5. Remove the two screws and raise the curing PCA module.
6. Remove the four T-20 screws and open the curing PCA cover.
ENWW Curing 773

7. Remove the PCA cover.
8. Disconnect all the cables located at the left side of the PCA, including the PCA fan cable.
9. Remove the pointed T-20 screws that hold the AC safety cover sheet, then, while sliding the cover along
the AC cables; disconnect the cables from the curing PCA.

10. Remove the T-8 pointed screws.
11. Remove the curing PCA.
Installation
1. Install the new curing PCA and secure it with screws.
2. Reconnect the AC cables, sliding them through the AC safety cover sheet.
3. Install the AC safety cover sheet.
4. Connect all the left cables to the curing PCA, including the PCA fan cable.
5. Install the curing PCA cover.
Lower curing beam EPDM foam (K4G10-67118)

Follow the instructions included with the service part box.
IMPORTANT: There is an area of the Bottom curing beam where it is difficult to remove the foam. It is
recommended not to remove the old foam on this area (indicated in the image below).
The new foams included in this Service Kit must be cut to a reduced size during installation.
ENWW Curing 775

Removal & Installation
1. Prepare the access to the Bottom curing beam. Remove media and turn off the printer.
a. Disassemble the LED mounting beam by unscrewing ten Torx-20 screws and both Curing handles by
unscrewing four Allen-4 mm screws.
b. Lift the Front door bottom covers. Unscrew twelve PH-2 screws and lift the Curing module service
covers.

c. Use a screwdriver or other tool to keep the covers lifted.
2. Mask and protect the printer against the 3M™ Industrial Cleaner used to remove the foam adhesive. It is
extremely important that these products do not reach any undesired parts of the printer.
Recommended: vinyl duct tape, width 50 mm.
a. Disassemble the spindle. Use vinyl media to mask the printer. Use masking tape to hold the media
and seal the desired areas against the adhesive remover.
ENWW Curing 777

b. Masking of the upper side of the beam (protect the Curing modules) and of the lower side of the
beam (protect the Diverter).
3. Remove the black foam layer of the Curing beam by using the scraper included in the kit. Alternatively, an
Oscillating multi-tool with a scraper blade could be used for this process.
● Required tool: scraper included in the kit.
● Optional tool: oscillating multi-tool with a scraper blade.
● Required personal protection: particulate respirator.
a. Scrape the foam.

b. The following image shows the beam surface condition after scraping the foam layer:
4. Apply the recommended 3M™ Industrial Cleaner Citrus Based spray over the remaining layer of adhesive
and paper. Let it rest for a few minutes
WARNING! Required personal protection:
Gas and vapor respirator Impermeable NBR gloves Safety glasses with side shields
Required product
Use a 3M™ industrial cleaner (citrus based). Different 3M™ products are available depending on the
country:
● 3M™ Adhesive Remover Citrus Based 6040/6041 spray.
● 3M™ Scotch-Weld™ 50098 Citrus Based Cleaner spray.
CAUTION: Avoid applying the 3M™ cleaner on any undesired parts of the printer to prevent any damage.
a. Apply the 3M™ cleaner. After a few minutes, remove the adhesive and paper layer by using the
scraper. Clean and wipe the Curing beam with the 3M™ cleaner until it is free of adhesive.
ENWW Curing 779

b. Next, remove the masking of the printer and use a cloth to completely wipe any remaining 3M™
cleaner from the printer.
5. Stick the new foams to the Curing beam.
a. Stick the new foam starting from the bottom and working towards the top of the beam (see above
image, new foam in red).
b. Cut the new foam to the size needed on the upper side of the beam using a cutter.
c. Once all the foams are replaced, reassemble the LED mounting beam and the Curing handles.

Drying
Drying chamber (K4T88-67108)
Removal
1. Set up the PPS.
3. Remove the Right rotomolding. See Right rotomolding (K4T88-67186) on page 1000.
4. Remove the Drying heater and fan. See Drying heater and fan (K4T88-67107) on page 790.
5. Remove the bar from the right structure.
ENWW Drying 781

6. Remove the grounding cable for this task (service staff only).
7. Remove the Drying diffuser. See Drying diffuser (K4T88-67109) on page 782.
8. Remove the impelling motor. See Impelling motor (K4T88-67043) on page 919.
9. Remove the right sideplate K0Q45-00004.
10. Remove the screws between the scan beam and the chamber.
11. Remove the chamber 1 or 2 sliding out to the right.
Drying diffuser (K4T88-67109)

Removal
1. Set up the PPS.

3. Open the pinch.
ENWW Drying 783

5. Remove diffuser.
Installation
1. Put the diffuser in place with the pin.
2. Reverse removal instructions.
Drying PCA (K4T88-67070)

PCA/Module/Chamber number correlation.

Removal – Right side (PC, monitor etc.)
1. Remove the Back right cover. See Back right cover (K4T88-67177) on page 992.
2. Disconnect the cables. Do not remove the yellow cable.
4. Remove the metal part.
ENWW Drying 785

5. Disconnect the Fan cable.
6. Disconnect the PCA cables.
7. Unscrew the PCA support screw.

8. Remove the PCA support.
9. Unscrew 5 PCA screws.
10. Remove the PCA.
Removal – Left side (Ink cartridges, Vapor removal etc.)
1. Remove the left rotomolding. See Left rotomolding (K4T88-67171) on page 985.
2. Follow the same process as above (for right side).
Installation
Drying fan PCA (K4T88-67110)

Removal – Right side (PC, monitor etc.)
ENWW Drying 787

2. Disconnect the cables. Do not remove the yellow cable.
5. Disconnect the fan cable.

6. Unscrew the 4 fan screws.
7. Remove the fan PCA.
Removal – Left side (Ink cartridges, Vapor removal etc.)
2. Follow the same process as with the right side.
Installation
▲ Reverse removal instructions.
Drying PCA cooling fan filter (K4T88-67265)

Removal – Right side (PC, monitor...)
ENWW Drying 789

2. Remove the part by hand.
Removal – Left side (Ink cartridges, Vapor removal...)
2. Remove the part by hand.
Installation
Drying heater and fan (K4T88-67107)

Removal
1. Set up the PPS.

3. Open the pinch.
4. Unscrew the 7 cover screws.
ENWW Drying 791

5. Remove the cover.
NOTE: If the fan is located on the right side follow steps 6 and 7, if not go to step 8.
6. Open the window.
7. Move carriage to the left.
8. Disconnect and unroute the cables (from the MR cable tie where marked).
NOTE: The red cable goes through the left cable tie and is connected in the left connector. The colored
cable passes through the right cable tie and is connected in the middle connector. The thinnest cable goes
through the right cable tie and is connected in the right connector.

9. Unscrew 1 screw.
10. Remove fan.
11. Remove heater.
Installation
1. Put the heater in place with its pins.
ENWW Drying 793

2. Put the fan in place with its pin.
IMPORTANT: The Fan cable connector MUST go with the "hook" looking to the left.
IMPORTANT: Order of the cables from left to right: red cable, colored cable, black cable
3. When installing the back cover again, be careful to put the lip of the rear back cover on top of the lip from
the pinch protector cover. If not, the pinch covers will not open.
Drying data cable kit (K4T88-67228)

Drying PCA cables kit (K4T88-67229)

Drying power cables Kit (K4T88-67230)


E-box
E-box fan and filter (CZ056-67386)
Removal
2. Remove the back right cover. See Back right cover (K4T88-67177) on page 992.
3. Remove the two T-20 screws from the e-box support and pull it out carefully.
4. Remove the seven T-20 screws and remove the e-box cover.
5. Disconnect the fan cable from the formatter PCA.
6. Remove the fan filter.
ENWW E-box 795

7. Remove the four crossed screws that hold the fan.
8. Remove the screw that holds the coated lanyard.

9. Remove the fan.
Installation
1. Insert and connect the new fan.
2. Screw back the e-box cover.
3. Remove the plastic cover and replace the filter.
E-box hard disk drive (K4T88-67268)

Removal
ENWW E-box 797


5. Disconnect the hard disk data cable from the formatter PCA (SATA 1 connector) and the power cable from
the HDD.
ENWW E-box 799

6. Remove the four screws that hold the hard disk drive sheet cover.
7. Remove the four T-10 screws and remove the hard disk drive from its sheet cover.

Installation
1. Insert the new hard disk drive.
2. Reconnect the hard disk data cable to the formatter PCA (SATA 1 connector).
Replacing E-box HDDs

Background
The E-Box hard disk contains most of the printer’s data, including the firmware. However, key data, such as the
product number, serial number, and calibration values, is also replicated in the internal memory of the ISS PCA 1,
so that there is a backup to protect against data loss. This means that if the hard disk drive fails, it can be
replaced by a new one, and the key data will automatically be copied from the ISS PCA 1 to the new hard disk.
Similarly, if the ISS PCA 1 breaks, it can be replaced, and the key data will be automatically copied from the hard
disk onto the new part. It is important to understand what this means in practical terms: the hard disk and ISS
PCA 1 cannot be replaced simultaneously, and can only be replaced by new parts. If either the hard disk or the
ISS PCA is not new (e.g. they come from another printer), then the printer will trigger a system error preventing
the replacement parts from being used.
Considerations
If the E-Box Hard Disk Drive (HDD) on an HP Latex 1500 printer needs to be replaced, there are several factors
that must be taken into consideration. The most important of these is that a previously used HDD from a
different printer cannot be installed under any circumstances. Installing a used drive on another printer will
cause an error:
E-box interconnect PCA (CZ056-67189)

Removal
1. Remove the four engine adaptor PCAs. See Engine adaptor PCA (CZ056-67188) on page 802.
2. Disconnect all the cables from the E-box interconnect PCA.
NOTE: You are strongly recommended to ensure that all cables are labeled, to avoid confusion when
replacing the e-box interconnect PCA and reconnecting all the cables.
ENWW E-box 801

3. Remove the 16 T-10 screws.
4. Remove the e-box interconnect PCA.
Installation
1. Insert the new e-box interconnect PCA.
2. Screw the e-box interconnect PCA into position.
3. Reinstall and reconnect the four engine PCAs.
4. Reinstall the engine adaptor PCAs.
NOTE: Be careful while reconnecting the engine adaptor PCAs to the e-box interconnect PCA. It can be
hard to connect both PCAs correctly, and the connector pins are delicate: they can easily break.
5. Reconnect all the cables to the e-box interconnect PCA, taking care to connect each cable to the
corresponding e-box interconnect PCA connector. See Figure 2-17 E-box on page 91.
Engine adaptor PCA (CZ056-67188)

Removal

5. Disconnect the engine adaptor PCA from all cables. See Subsystem block diagrams on page 79.
ENWW E-box 803

6. Remove the four T-20 screws from the support that holds the four engine adaptor PCAs and pull it slightly
out. The four engine adaptor PCAs remain connected to the e-box interconnect PCA.
7. Carefully remove the engine adaptor PCA.
Installation
1. Insert the new engine adaptor PCA, making sure to connect it properly to the e-box interconnect PCA.
NOTE: Be careful while reconnecting the engine adaptor PCAs to the e-box interconnect PCA. It can be
hard to connect both PCAs correctly, and the connector pins are delicate: they can easily break.
2. Locate the engine adaptor PCA’s metal sheet support and push it slightly to match it with the four engine
adaptor PCA supports.

3. Screw back the four screws that hold the metal sheet support, ensuring that the four PCAs are properly
connected to the e-box interconnect PCA.
4. Reconnect the engine adaptor PCA cables.
Engine PCA (K4T88-67067)

Removal
ENWW E-box 805

5. Disconnect the engine PCA from all the cables that you can reach. See Subsystem block diagrams
on page 79.
6. Remove the T-10 screw that holds the engine PCA.

7. Remove the engine PCA.
8. Disconnect any remaining cables.
Installation
1. Insert the new engine PCA. Ensure that it is well placed between its plastic supports, so that it is correctly
connected to the formatter PCA. Otherwise the printer will return an error.
2. Secure the Engine PCA with a T10 screw.
3. Take note that the encrypted PCA is placed on the 4th slot.
4. Reconnect the engine PCA cables.
ENWW E-box 807

Fiber-optics PCA (CZ056-67389)

Removal
4. Remove the seven T-20 screws and the e-box cover.
5. Disconnect all cables from the fiber-optics PCA. See Subsystem block diagrams on page 79.

6. Remove the seven T-10 screws that attach the fiber-optics PCA.
7. Remove the PCA.
Installation
1. Insert the new fiber-optics PCA.
2. Use the seven T-10 screws to fix the PCA.
Formatter PCA (CZ056-67186)

Removal
5. Remove the four engine PCAs. See Engine PCA (K4T88-67067) on page 805.
ENWW E-box 809

6. Disconnect all the cables from the formatter PCA connectors.
7. Remove the two pointed T10 screws and carefully remove the light pipe.

8. Remove the nine T-10 screws that hold the formatter PCA.
9. Remove the formatter PCA.
Installation
1. Insert the new formatter PCA.
2. Connect the cables to the formatter PCA.
3. Reinstall the light pipe.
4. Reinstall and reconnect the four engine PCAs.
Encryption PCA (K4T88-67068)

Removal
1. Turn off printer: Automatic Circuit Breaker 50A (Labeled: “PRINTER”) and the Automatic Circuit Breaker 10A
(Labeled: “IPS”).
ENWW E-box 811

2. Remove back right cover. See Back right cover (K4T88-67177) on page 992.
3. Remove 1 screw.
4. Carefully rotate the e-box.

5. Remove 10 screws.
6. Taking special care not to damage the attached fan cable, rotate the e-box cover to lay it on the floor.
7. Location of encryption PCA:
ENWW E-box 813

8. Remove encryption PCA from the fourth engine PCA:
Installation
E-box PSU (K4T88-67271)

Removal
3. Disconnect the power cord from the e-box.

4. Loosen the four crossed screws that hold the PSU (do not remove them, so that the PSU will not be freed
inside the e-box while pulling it out).
ENWW E-box 815


7. Disconnect both the PSU cables from the formatter PCA and the air connector.
ENWW E-box 817

8. Remove the four loosened screws that hold the PSU (they are located outside the e-box).
9. Remove the PSU.
Installation
1. Insert the new PSU.
2. Screw the PSU to the e-box.
3. Reconnect the PSU to the formatter PCA and the air connector.
4. Screw the e-box cover and push it back to its vertical position.
5. Reconnect the power cord to the PSU connector.
E-box cable kit (K4T88-67231)

See Cables on page 1469
E-box cable kit (K4T88-67273)

E-box LAN cable to IPS (K4T88-67232)


E-box LAN cable to IPS kit (K4T88-67272)

ENWW E-box 819

E-cabinet
E-cabinet safety relay (CZ056-67129)
Removal
1. Turn off the printer and its built-in computer, then turn off the main switch and the computer power switch.
2. Open the e-cabinet doors.
3. Disconnect the e-cabinet safety relay from all cables.
4. Remove the e-cabinet safety relay fixed to the DIN rail.
TIP: You are recommended to use a flat screwdriver to pull the plastic tab, so that the part can be easily
removed from the DIN rail.
Installation
1. Insert the new safety relay.

2. Reconnect all cables to the safety relay.
3. Close the e-cabinet doors.
4. Reconnect and turn on the printer.
E-cabinet terminal block kit (K4T88-67202)

See Electrical system: E-cabinet on page 5 and Figure 2-8 PS e-cabinet terminal blocks installation on page 82
for more information about the e-cabinet functionality and the terminal blocks installation.
The cross connectors are inserted into the terminal block in close proximity to each other, and are fitted with
yellow (plastic) insulators. They are labeled 1-7.
Several original terminal blocks are included in the kit, they have to be cut using a cutter to fit the needed type.
NOTE: Be careful when cutting them, if they are not correctly cut, it can happen that two adjacent connectors
are not insulated from each other and a short circuit can occur.
ENWW E-cabinet 821

Removal
1. Turn off the printer: Automatic Circuit Breaker 50A (Labeled: “PRINTER”) and the Automatic Circuit Breaker
10A (Labeled: “IPS”).
2. Open the e-cabinet door with the special key supplied with the installation kit.
3. Location of the e-cabinet terminal block:

4. Loosen the screws in order to pull out the cables.
5. Pull out the cables.
6. Loosen the screws in order to pull out the cables.
ENWW E-cabinet 823

8. Unclip the e-cabinet terminal block, use a flat screwdriver to pull the plastic tab.
9. Remove the e-cabinet terminal block.
Installation
E-cabinet vapor removal (K4T88-67203)

Removal

3. Location of the e-cabinet vapor removal:
ENWW E-cabinet 825

4. Loosen the 6 screws and pull out the cables.
5. Remove the grounding cable screw.
6. Remove 4 screws and then remove the e-cabinet vapor removal.
Installation
E-cabinet vacuum pump (K4T88-67204)

Removal

3. Location of e-cabinet vacuum pump:
ENWW E-cabinet 827

4. Loosen the screws and pull out the cables.
5. Remove 4 screws and then remove the e-cabinet vacuum pump.
Installation
E-cabinet PSU 24V-600W COSEL (K4T88-67205)

Check PSU configuration on page 14 and DC power supplies on page 13 for information on each PSU, and Safety
circuit, power transformer, and PCA on page 13 for the PSU 8.
Removal

3. Location of the PSU-2, PSU-4, PSU-6 and PSU-7:
ENWW E-cabinet 829

4. Remove the plastic protector.
5. Loosen 2 screws to pull out the cables.

7. Disconnect one connector.
8. Remove 2 screws and washers.
9. Leave the PSU module on the plastic rail for better access to loosen the screws.
ENWW E-cabinet 831

11. Loosen 3 screws and pull out the cables.
12. Remove the PSU module.

13. Remove 4 screws and remove the plate support.
14. Some of the power supplies are adjusted to a voltage that is not the factory default. The voltage is adjusted
during the manufacture of the e-cabinet and before a service part is sent, however, it is highly
recommended for both the user and printer security to always check the voltage adjustment before
installing a new PSU. The e-cabinet PCA has a voltage meter for each PSU to measure the voltage and the
firmware will raise a warning if it is not properly adjusted.
Installation
NOTE: Pay special attention to placing the ferrite in the same position as it was and check the grounding
connection.
ENWW E-cabinet 833

E-cabinet PSU 24V 100W (K4T88-67206)

Removal

3. Location of the PSU-8:
4. Loosen 2 screws in order and pull out the cables.
ENWW E-cabinet 835

5. Loosen 2 screws in order and pull out the cables.
6. Remove the PSU-8 module from the rail.
installing a new PSU. The e-cabinet PCA has a voltage meter for each PSU to measure the voltage and the
Installation
connection.

E-cabinet PCU 36V-600W (K4T88-67207)

Removal
ENWW E-cabinet 837

3. Location of the PSU-3:

7. Remove the PSU-3 module.
ENWW E-cabinet 839

8. Remove 2 screws and washers and remove the plate support.
installing a new PSU. The e-cabinet PCA has a voltage meter for each PSU to measure the voltage and
The PSU-3, as it is from a different supplier, has a different process of verification and adjustment.
It is highly recommended to check the correct position of the bridges, as shown in the figure below.
Installation

connection.
E-cabinet PCU 48V-600W (K4T88-67208)

Removal
ENWW E-cabinet 841

3. Location of the PSU-1 and PSU-5:
4. Remove the plastic protector.

5. Loosen 2 screws to pull out the cables.
ENWW E-cabinet 843


12. Remove the PSU module.
13. Remove 4 screws and remove the plate support.
ENWW E-cabinet 845

installing a new PSU. The e-cabinet PCA has a voltage meter for each PSU to measure the voltage and
Installation
connection.
E-cabinet PCA fuse (K4T88-67209)

Removal

3. Locate the failing fuse identified by the Print Care error message logs. (See also Figure 2-4 E-box side
on page 20 and PSU configuration on page 14.)
4. Remove the defective e-cabinet PCA fuse.
Installation
ENWW E-cabinet 847

E-cabinet PCA glass fuses (K4T88-67210)

Removal
3. All e-cabinet fuses are located in two terminal blocks: TB5 (power supplies fuses), and TB7 (vacuum pump
fuses). Check below the list of all fuses.

4. Open the e-cabinet fuse holder by pulling the plastic tab out from the top so the fuse slot rotates exposing
the e-cabinet fuse.
5. Unclip the e-cabinet glass fuse from the hole of the holder using a flat-screwdriver.
6. Remove the e-cabinet glass fuse.
Installation
e-Cabinet fuses
● TB5 – Power supplies fuses
ENWW E-cabinet 849

● TB7 – Vacuum pump fuses

E-cabinet contactor (K4T88-67211)

Removal
ENWW E-cabinet 851

3. Location of the e-cabinet contactor:
4. Loosen 1 screw and remove e-cabinet contactor retainer.

6. Remove 2 screws.
7. Pull out the metallic rail and slide out the e-cabinet contactor.
Installation
E-cabinet circuit-breaker I (K4T88-67212)

Removal
ENWW E-cabinet 853

3. Remove the front right bottom cover. See Front right bottom cover (K4T88-67179) on page 993.
5. Remove the front metal cover.

6. Location of e-cabinet circuit-breaker I:
8. Remove 2 screws.
ENWW E-cabinet 855

9. Pull out the two metal rails to access the circuit-breaker I.
10. Slide out the metal rail and remove the e-cabinet circuit-breaker I.
Installation
E-cabinet circuit-breaker II (K4T88-67213)

Removal

ENWW E-cabinet 857

6. Location of the e-cabinet circuit-breaker II:
8. Remove 2 screws.

9. Pull out the two metal rails to access the circuit-breaker II.
10. Slide out the metal rail and remove the e-cabinet circuit-breaker II.
Installation
E-cabinet lamps kit (K4T88-67214)

Power enable
Removal
ENWW E-cabinet 859

3. Location of the e-cabinet lamp (Power Enable):

4. Loosen 1 screw.
5. Using the screwdriver, and taking special care not to damage any cables, gently pull up the L-shaped lever
to detach the main body from the lens cap.
6. Pull out the main body with the cables.
ENWW E-cabinet 861

8. Remove the lens cap from the exterior.
Installation
Rearm
Removal

3. Location of the e-cabinet lamp (Rearm):
4. Loosen 1 screw.
ENWW E-cabinet 863

5. Using the screwdriver, and taking special care not to damage any cables, gently pull up the L-shaped lever
to detach the main body from the lens cap.
6. Pull out the main body with the cables, loosen the screws, and pull out the cables.
7. Remove the lens cap from the exterior.
Installation

E-cabinet user interaction label (K4T88-67217)

Removal
ENWW E-cabinet 865

5. Remove the label.
Installation
E-cabinet door (K4T88-67198)

Removal
1. Turn off the printer: Automatic Circuit Breaker 50A (Labeled: “PRINTER”) and Automatic Circuit Breaker 10A
(Labeled: “IPS”).
2. Locate the 4 fan filters:

3. Pull off plastic cover and remove fan filter.
4. Open e-cabinet door with special key supplied in installation kit.
5. Disconnect the connectors from the two fans located in the upper part of the e-cabinet door.
ENWW E-cabinet 867

6. Open the 3 ties.
7. Hold the fan by hand and unscrew the 4 screws and nuts from one fan located in the upper part of the e-
cabinet door.
8. Hold the fan by hand and remove the rear guard fan.

9. Remove the fan (follow steps 7 to 9 for the other fan).
10. Remove the 2 e-cabinet locks to be reused. See E-cabinet lock (K4T88-67201) on page 877.
11. Remove the nut and disconnect the grounding cable from the e-cabinet door assembly.
12. Remove the 2 bobby pins from the e-cabinet door hinges.
ENWW E-cabinet 869

13. Remove the e-cabinet door.
Installation
1. At this point, if you see a requirement, you can change the fan filter. Be careful to locate it correctly: it must
cover the fan’s square surface.
E-cabinet fan (CZ056-67128)

Removal
1. Turn off the printer and its built-in computer, then turn off the main switch and the computer power switch.
2. Open the e-cabinet doors.
3. Disconnect the fan cable from its air connector.
4. Remove the four crossed screws that hold the fan and remove the fan.
Installation
1. Insert the new fan and attach with the four screws.
2. Reconnect the fan cable.
3. Close the e-cabinet doors.

4. Remove the plastic cover and replace the filter with the new one.
5. Reconnect and turn on the printer.
E-cabinet fan filter (CZ056-67137)

Removal
1. Locate the fan filters on the printer.
2. Pull off the plastic fan filter cover and remove the fan filter from each fan.
3. Open the e-cabinet door with the special key supplied with the Installation kit.
ENWW E-cabinet 871

4. Unscrew the four screws and nuts from one fan (hold the fan by hand).
5. Remove the rear guard fan (hold the fan by hand).
Installation
1. For each fan, change the fan filter for the new one provided. Be careful to locate it correctly: it must cover
the fan’s square surface.

2. Reverse the removal instructions.
E-cabinet fan (K4T88-67199)

Removal
2. Locate the 2 fans located in the upper part of e-cabinet door.
ENWW E-cabinet 873

3. Pull off the plastic cover and remove the defective fan filter (fan 1 or 2).
4. Open the e-cabinet door with the special key supplied in installation kit.
5. Disconnect the fan connector.

6. Open the tie.
7. Hold the fan by hand and unscrew the 4 screws and nuts from one fan located in the upper part of the e-
cabinet door.
8. Hold the fan by hand and remove the rear guard fan.
ENWW E-cabinet 875

9. Remove the fan.
10. Remove the 4 screws and nuts, then remove the grid.
Installation
1. Replace the grid removed from the damaged fan.

2. Be careful with the position of the label.
3. At this point, if you see a requirement, you can change the fan filter. Be careful to locate it correctly: it must
cover the fan’s square surface.
E-cabinet lock (K4T88-67201)

Removal
1. Open the e-cabinet door with the special key supplied in installation kit.
ENWW E-cabinet 877

2. Remove 1 screw.
3. Remove the metal plate.
4. Remove the special washers.

5. Use a spanner to remove the special nut.
6. Remove the e-cabinet lock.
Installation
E-cabinet power jumpers (K4T88-67277)

Removal
ENWW E-cabinet 879

3. Location of the e-cabinet power jumper:
4. Remove the e-cabinet power jumper.
Installation
E-cabinet PCA (K4T88-67288)

Removal

3. Location of the e-cabinet PCA:
ENWW E-cabinet 881

4. Disconnect all the cables from the inside e-cabinet PCA. Before disconnecting any cable, ensure that it is
labeled to avoid any mismatch when reconnecting.

6. Disconnect all cables from outside the e-cabinet PCA.
7. Remove 10 cross screws.
ENWW E-cabinet 883

8. Remove the e-cabinet PCA lid.
9. Remove the 13 T10 screws that hold e-cabinet PCA to its lid and then remove e-cabinet PCA.
Installation
Automatic circuit-breaker 10A (K4T88-67291)

Removal

ENWW E-cabinet 885

6. Location of the automatic circuit-breaker 10A:
8. Remove 2 screws.

9. Pull out the two metal rails to access the circuit-breaker 10A.
10. Slide out the automatic circuit breaker 10A from the metal rail.
Installation
Residual current dev RCD 40A/3 (K4T88-67292)

Removal
ENWW E-cabinet 887


6. Location of the residual current dev RCD 40A/3:
8. Remove 2 screws.
ENWW E-cabinet 889

9. Pull out the two metal rails to access the residual current dev RCD 40A/3.
10. Slide out the residual current dev RCD 40A/3 from the metal rail.
Installation
Automatic circuit-breaker ACB (K4T88-67293)

Removal
1. Turn off the the printer: Automatic Circuit Breaker 50A (Labeled: “PRINTER”) and the Automatic Circuit
Breaker 10A (Labeled: “IPS”).

ENWW E-cabinet 891

6. Location of the automatic circuit-breaker ACB:
8. Remove 2 screws.

9. Pull out the two metal rails to access the circuit-breaker ACB.
10. Slide out the automatic circuit breaker ABC from the metal rail.
Installation
E-cabinet AC-12AWG cables (K4T88-67274)

E-cabinet AC-6AWG cables (K4T88-67275)

ENWW E-cabinet 893

E-cabinet bundle cables (K4T88-67276)

PCA interlocks cables kit (K4T88-67236)

E-cabinet installation kit (K4T88-60419)

See the Installation guide.

Human-Machine interface
IPS monitor (K4T88-67295)
Removal
2. Disconnect the 2 screen cables.
3. Unscrew the 2 support screen screws.
4. Remove the monitor.
ENWW Human-Machine interface 895

Internal Print Server (K4T88-67270)

Removal
2. Unscrew the e-box screw.
3. Rotate the e-box.
4. Disconnect all the cables.

5. Remove IPS.
Screen (K4T88-67267)
Removal
2. Remove the IPS monitor. See IPS monitor (K4T88-67295) on page 895.
3. Unscrew the 4 screen screws.
4. Remove the Screen.

Screen mount bracket (K4T88-67188)

Removal
1. Remove the Front right top. See Front right top (K4T88-67182) on page 996.
3. Remove the Screen mount bracket.
Keyboard (K4T88-67269)
Removal

2. Unscrew the e-box screw.
3. Rotate the e-box.
4. Disconnect the keyboard and mouse cables.

5. Remove the keyboard and mouse. Unroute cables.
6. Unscrew the 5 keyboard bottom cover screws.
7. Remove the keyboard bottom cover.

8. Unscrew the 4 keyboard surface screws.
9. Remove the keyboard surface.
Screen mount (K4T88-67187)

Removal
2. Disconnect 2 screen cables.

3. Unscrew 2 screen screws.
4. Remove the screen.
6. Unscrew the E-box screw.

7. Rotate the E-box.
8. Disconnect the keyboard and mouse cables.
9. Remove the keyboard and mouse and unroute thecables.

10. Unscrew the 5 keyboard bottom cover screws.
11. Remove the keyboard bottom cover.
12. Remove the 4 keyboard surface screws.

13. Remove the keyboard surface.
14. Unscrew the 4 brace plate support screws.
15. Remove the brace plate and unroute cables.

16. Unscrew the 4 brace plate support screws.
17. Remove the brace support.
Installation
Beacon lights (K4T88-67262)

Removal
2. Disconect USB from beacon and unroute it.

3. Remove front left perforated metal sheet. See Front left perforated metal sheet (K4T88-67174)
on page 989.
4. Unscrew 3 screws that attach beacon to right rotomolding.
5. Disconnect lights.
6. Pull out beacon.

7. Cut cable tie.
8. Disconnect USB.
9. Remove USB cables.
Installation
▲ Reverse the removal instructions.

Impelling
Impelling carriage belt assembly (K4T88-67306)
Removal
2. Open the window and move the carriage to the center position.
3. Remove the Left side cover. See Left side cover (K4T88-67169) on page 983.
4. Loosen the screw (1) and remove the bridge from the Vapor removal´s tube (2).
5. Move the tube.
ENWW Impelling 909

6. Remove the right stopper.
7. Install the Belt installation tool.
8. Remove the left stopper.

9. Install the Belt installation tool
10. Tighten the Belt installation tool till fully compress the springs, and release all the tension of the belt.
NOTE: Tighten them little by little, at the same time.
11. Remove 1 Allen screw, and the washer, that secures the belt to the carriage.
ENWW Impelling 911

13. Remove the bearing from the left side.
14. Remove the belt from the left side.

15. Stretch the belt to the other side of the carriage.
16. Remove the belt from the right side.
17. Remove 1 screw, and the washer, from the carriage.
ENWW Impelling 913

19. Remove the belt from the carriage.
20. Remove the belt.
Installation
1. Replace the belt, routing it through the impelling and the carriage, and ensure that the last tooth of the belt
is engaging the latest slot of the metal part.

2. Install the metal plate and tighten the screw.
3. Remove the Right side top cover. See Right side top cover (K4T88-67176) on page 991.
4. Replace the belt on the right side and ensure it is well routed and does not overlap on the motor pinion's
flange.
5. Untighten the belt installation tools little by little and both tools at the same time. Remove the belt
installation tool and replace the security stopper. (In both sides.)
ENWW Impelling 915

6. Once the process is finished, it is important to ensure that the tension of the belt is the correct one, check
that the slot in the shaft is centered on the pulley holder.
Impelling encoder strip (K4T88-67044)

Removal
1. Remove the Left rotomolding. See Left rotomolding (K4T88-67171) on page 985.
2. Remove the 10 metal plates by untightening 2 screws for each support.
3. Untighten the screw that secures the Encoder to the encoder tensioner.

4. Remove the Encoder strip from the printer.
Installation
1. Install the right side of the Encoder strip and tighten the Encoder strip support.
2. Install the left side of the Encoder strip in the Encoder tensioner by tightening the screw that holds the
Encoder.
ENWW Impelling 917

3. Insert the Encoder strip inside the Encoder sensor of the carriage, ensuring they are not touching each
other.
4. Install the remaining 9 metal Encoder supports ensuring that the screw is not tightened to the end.
NOTE: It is important to ensure that the Encoder strip is not trapped between the Encoder support and
the metal plate. There has to be some play between both parts.
5. To ensure there is some play between the Encoder support and the Encoder, pull a little bit the Encoder
strip ensuring that it is free.

Impelling motor (K4T88-67043)

Removal
2. Remove the IDS cover. See Left side cover (K4T88-67169) on page 983.
3. Loosen the screw (1) and remove the Vapor removal’s tube exhaust (2).
4. Move the tube.
ENWW Impelling 919


10. Remove the Scan Axis 3rd motor support. See Scan axis 3rd motor support S (K4T88-67050)
on page 922.
11. Disconnect the data and power cables from the Impelling motor from behind the printer.
12. Once the belt is loose, untighten the 3 screws from the front of the Scan axis.
ENWW Impelling 921

13. Loosen the screw until you can remove the motor.
14. Remove the Impelling motor from behind of the printer.
Installation
▲ Undo the steps of the removal process.
Scan axis 3rd motor support S (K4T88-67050)

Removal
2. Remove the 2 support screws.

3. Remove the third Motor support.
Scan axis belt tensioner (K4T88-67049)

Removal
2. Open the window and move the carriage to the center position.
4. Loosen the screw (1) and remove the bridge from the Vapor removal’s tube (2).
ENWW Impelling 923

5. Move the tube.

9. Install the Belt installation tool
ENWW Impelling 925

11. Remove 1 Allen screw, and the washer, that secures the belt to the carriage.
13. Remove the Belt from the metal plate that holds the Belt.

14. Remove the Scan axis pulley from the assembly.
15. Untighten the belt installation tools little by little and both tools at the same time. Remove the belt
installation tool.
16. Remove the Pulley holder.
ENWW Impelling 927

17. Remove the springs.
18. Remove both shafts if needed by untightening the nuts.
Scan axis bump (K4T88-67051)

Removal (right)
2. Remove the screw that secures the bump in its position.

3. Remove the axis bump.
Removal (left)
2. Remove the screw that secures the bump in its position.
3. Remove the axis bump.
ENWW Impelling 929

Scan axis slider rods (K4T88-67048)

Removal
1. Move the Drop detector shuttle to service position from Print Care.
2. Rise up the SAX beam to the serviceability position.
3. Remove the Drying diffusers. See Drying diffuser (K4T88-67109) on page 782.
6. Remove the top cover. See Top center rear cover (K4T88-67160) on page 970.
7. Remove the Web Wipe. Follow steps 1 to 7 of the Web Wipe Extraction Guide (K4T88-67218). See Web
wipe extraction guide (K4T88-67218) on page 1124.
8. Remove the Capping station. See Service station caps kit (K4T88-67074) on page 1147
9. Remove all the printheads.

11. Remove the bearing by pulling it out.
12. Move the carriage to the left.
ENWW Impelling 931

14. Install the right Belt installation tool.
16. Install the left Belt installation tool.

ENWW Impelling 933

18. Remove the two Carriage Oiling felts placed on the top rod by removing 2 Allen screws.

19. Repeat the same operation on the other side of the carriage.
20. Remove the Carriage and place it over the platen.
ENWW Impelling 935

21. Remove the cable tray cover.
22. Unroute the cables that are travelling along the cable tray.
23. Unscrew the cable tray screws.

24. Remove the cable tray to have access to the Rod slider screws.
25. Untighten all the screws (36) from the top of the printer.
26. Remove the top rod slider from the right side.
ENWW Impelling 937

27. Untighten all the screws (36) from the bottom of the printer.
28. Remove the bottom rod slider from the right side.
Installation
▲ When installing the Slider rods, it is very important to first tighten the middle screw of the Scan axis and
then tighten the other ones from the center to the ends.
Note that the central screw is different from the other ones and does not have washer neither spring nor
sealing.

SOL shutter (K4T88-67052)

Removal
1. Remove the Front left cover. See Front left cover (K4T88-67167) on page 982.
2. Unplug the power cable.
3. Remove 1 screw.
4. Remove the SOL shutter.
Installation
▲ Undo all the previous steps.
ENWW Impelling 939

Belt installation tool (K4T88-67021)

Used to release tension in the carriage belt springs for any purpose needed.
SAX motor data cable (K4T88-67047)

SAX motor power cables kit (K4T88-67046)

Mid Encoder Strip Support (K4T88-67302)

Removal
2. Open window.
3. Remove the 2 screws pictured below.
4. Remove the part.
Installation
NOTE: Remember to put pins through encoder strip and into position,
NOTE: The first encoder strip support goes like this:

NOTE: To ensure that there is some “play” between the Encoder support and the Encoder, pull the
Encoder Strip a little bit to ensure it is free.
ENWW Impelling 941

Dampener for Lyra SAX tensioner SVC (K4T88-67324)

The following steps carefully describe the process to assemble the dampener SVC kit ( K4T88-90526) on the
Lyra SAX tensioner.
The goal of this SVC kit is to dampen the tensioner vibrations.
Tools needed
● M3 Allen wrench provided by the service engineer.
WARNING!
2. Follow the instructions step by step without altering the order.
3. Whenever the removal of any screw is indicated, it is implied that small related items, such as washers,
growers, nuts, and similar items are included.

Rework process
1. Install the belt tensioner following the process defined in this Service Manual. See Scan axis belt tensioner
(K4T88-67049) on page 923
2. Before installing the "Pulley Retainer" proceed to install the damper components as follows:
a. First install the two 32 x 6 NBR O-rings (K0Q46-40040) on the Tensioner Spring Shafts.
b. Then install the Damper Ring Retainer (K0Q46-00313).
c. Secure using 4 x screws 0515-5595, 4 x 0535-1120 nuts, 4 x K0Q45-20375 spacers (reused from
the curing module) and 4 x lock washers at 3-6lb·in.
ENWW Impelling 943

Industrial design covers

Buzzer and cable
Removal
2. Open the printhead cleaning door.
3. Locate the buzzer under the right front cover.
4. Disconnect the buzzer from its air connector.
5. Remove the right front cover.
6. Remove the two pointed screws that attach the buzzer to the right front structure and replace it with the
new one.
Front left cover (K4T88-67152)

Removal

3. Remove the outside front left cover (K4T88-00311) taking care with the pins.
4. Unscrew 1 screw.
5. Open window.
ENWW Industrial design covers 945

6. Open the curing.
7. Unscrew 1 screw.

8. Remove the left rotomolding center cover (K4T88-00194).
10. Remove the left lower inside front cover (K4T88-00192) taking care with the pin.

12. Remove the left upper inside front cover (K4T88-00193).
Installation
Front right cover (K4T88-67153)

Removal

3. Remove the outside front right cover (K4T88-00197).

5. Remove the right lower inside front cover (K4T88-00195) taking care with the pins.

7. Remove the right upper inside front cover (K4T88-00196) taking care with the pins.
8. Open window.

9. Open curing.

11. Unscrew the inside screw.
12. Remove the right rotomolding center cover (K4T88-40026).
Installation
1. Make sure to open the door to install the outside front right cover (K4T88-00197)

Rear left cover (K4T88-67154)

Removal
2. Remove the back left top cover. See Back left top cover (K4T88-67166) on page 981.
3. Open the back left door.
5. Pull cover out a little. Be careful with the stop button cables.

6. Loosen stop button screw.
7. Pull out clip.
8. Remove stop button.

9. Remove rear left cover.
Installation
Rear right cover (K4T88-67155)

Removal
2. Remove the back right top cover (K4T88-67177). See Back right cover (K4T88-67177) on page 992.

4. Pull the cover out a little. Be careful with the stop button cables.
5. Remove the button. See ID buttons and switches (K4T88-67195) on page 1002.
6. Loosen the stop button screw.
7. Pull out the clip.

8. Remove the stop button.
9. Remove the rear right cover.
Installation
Stop button (K4T88-67156)

Removal
2. Open window.

4. Pull the button.
5. Loosen inside screw.

6. Pull small spike upwards.
Installation
Removal – Rear left stop button
2. Remove the back left top cover. See Back left top cover (K4T88-67166) on page 981.
3. Open the back left door.

5. Pull cover out a little. Be careful with the stop button cables.
6. Loosen stop button screw.

7. Pull out clip.
Removal – Rear right stop button
2. Remove the back right top cover (K4T88-67177). See Back right cover (K4T88-67177) on page 992.

4. Pull the cover out a little. Be careful with the stop button cables.
5. Remove the button. See ID buttons and switches (K4T88-67195) on page 1002.
6. Loosen the stop button screw.
7. Pull out the clip.

8. Remove the stop button.
Top center left window (K4T88-67157)

Removal
2. Open window.
3. Remove the window grommet.

4. Unscrew 20 nuts.
5. Remove the top left center window.
Installation
Top center window (K4T88-67158)

Removal
2. Open window.

3. Remove the window grommet.
4. Unscrew 20 nuts.
5. Remove the top left center window.
Installation
Top center right window (K4T88-67159)

Removal

2. Open window.
3. Remove window grommet.
4. Unscrew 20 nuts.

5. Remove top left center window.
Installation
Window hinges (K4T88-67301)

Removal
1. Open the window.
2. Remove the bottom c-clip and screw to free the gas spring in the bottom part. Do it in both gas springs.

3. Loosen half turn the 6 screws of the support, just to give it some mobility. Do this only in the support of the
hinge to change.
4. Close the window.
5. Remove the 4 screws of the hinge.
6. Remove the hinge.
Installation
1. Tighten 4 screws. First the 2 screws to the support and then the ones to the window. Recommended
torque: 11 N/m.
2. Open the window.
3. Tighten the 6 screws of the support. Recommended torque: 3.2 N/m.
4. Reinstall the gas springs.

Top center rear cover (K4T88-67160)

Removal
3. Remove back cover.

5. Remove top cover.
Installation
2. When installing the back cover again, be careful to put the lip of the rear back cover on top of the lip from
pinch protector cover. If not, the pinch will not open.
Top center ID accessories (K4T88-67307)

Removal
IMPORTANT: The following operations require at least two people.
2. Open the window.

3. Unscrew 2 screw of each sensor safety door.
4. Remove sensor safety door.

5. Remove 2 c-clips (top and bottom).
6. Remove top clip (be careful with the washers).

7. Remove down clip.
8. Remove the gas spring.
9. Unscrew 2 screws of the corresponding hinge.

10. Remove 6 screws from the hinge support.
11. Remove the hinge support.
12. Repeat this process for the other 3 gas springs.
Top center structure (K4T88-67162)

Removal
1. Remove the Top center rear cover (K4T88-67160). See Top center rear cover (K4T88-67160) on page 970.
2. Remove the Top center ID accessories (K4T88-67307). See Top center ID accessories (K4T88-67307)
on page 971.
3. Remove the Pz LED Lights (K4T88-67196). See Pz LED lights (K4T88-67196) on page 1326.
4. Remove the Left rotomolding center cover (K4T88-40025).
5. Remove the Right rotomolding center cover (K4T88-40026).
6. Remove all the cables inside all the beams.
7. Remove the screws.
8. Remove the structure.
NOTE: When removing the shims (positioners), count them and put the same ones when installing the
new part.
Installation
▲ Reverse the removal instructions. Process consists in putting the two lateral arches, then the central and
the rear ones and, finally, the two semi-arches.
NOTE: Install the same shims removed before.
Front window structure (K4T88-67163)

Arches (1-4, from right to left).
Removal – Arch 1
1. Remove the Top center right window (K4T88-67159). See Top center right window (K4T88-67159)
on page 966.
2. Locate the spring gas.
3. Remove the screws to remove the interlock support.
5. Remove the arch 1.
Removal – Arch 2
1. Remove the Top center window (K4T88-67159 and K4T88-67158). See Top center right window
(K4T88-67159) on page 966 and Top center window (K4T88-67158) on page 965.
2. Remove the screws .

Removal – Arch 3
1. Remove the Top center window (K4T88-67157 and K4T88-67158). See Top center left window
(K4T88-67157) on page 964 and Top center window (K4T88-67158) on page 965.
Removal – Arch 4
1. Remove the Top center left window (K4T88-67157). See Top center left window (K4T88-67157)
on page 964.
2. Remove the spring gas.
3. Remove the screws to remove the interlock support.
Removal – Tube assy (once all the arches have been removed)
1. Remove Hinges.
2. Remove the Top and Bottom tubes.
Installation
Front Window arcs (K4T88-67308)

Removal
NOTE: In case of changing more than 1 arc, remove and install one by one.
1. Open the window.
2. Remove the grommet.
3. Remove the c-clip from the gas spring.

4. Press the window up a bit to be able to remove the bolt. Take the metal cylinders at both sides of the gas
spring when removing the bolt and leave the gas spring hanging from the support with the other bolt.
5. Remove 14 nuts and 14 washers.
6. Remove 8 T-20 screws.

7. Remove arc.
Installation
Back left corner (K4T88-67164)

Removal
2. Remove back left top cover. See Back left top cover (K4T88-67166) on page 981.
4. Remove the left side cover. See Left side cover (K4T88-67169) on page 983.

5. Unscrew 2 screws on the other side.
6. Remove left back corner.
Installation
Back left door (K4T88-67165)

Removal
1. Remove left back top cover. See Back left top cover (K4T88-67166) on page 981.
2. Open door approximately 45 degrees.

3. Slide back left door up and remove it.
Installation
Back left top cover (K4T88-67166)

Removal
3. Remove the back left top cover.

Installation
Front left cover (K4T88-67167)

Removal
2. Unscrew 2 cover screws.
3. Remove left front cover.
Installation
Front left corner (K4T88-67168)

Removal
2. Remove left side cover. See Left side cover (K4T88-67169) on page 983.
3. Remove front left cover. See Front left cover (K4T88-67167) on page 982.

5. Remove left front corner.
Installation
Left side cover (K4T88-67169)

Removal

3. Remove left side cover.
Installation
Left structure (K4T88-67170)
Removal
1. Remove all the covers regarding the left structure.
2. Remove the vapor removal.
3. Remove the IDS.

4. Loosen the screws.
5. Remove the left structure.
Installation
Left rotomolding (K4T88-67171)

Removal
1. Turn off printer and power-enable switch.
2. Remove left side cover. See Left side cover (K4T88-67169) on page 983.
3. Remove left front cover. See Front left cover (K4T88-67167) on page 982.
4. Remove back left top cover. See Back left top cover (K4T88-67166) on page 981.
5. Remove stop button. See Stop button (K4T88-67156) on page 958.
6. Remove left lateral perforated metal sheet. See Left lateral perforated sheet metal (K4T88-67172)
on page 988.
7. Remove two left perforated metal sheet corners. See Left perforated metal sheet corner (K4T88-67173)
on page 989.
8. Remove front and rear perforated sheet metal. See Front left perforated metal sheet (K4T88-67174)
on page 989.
9. Remove top left perforated sheet metal. See Top left perforated metal sheet (K4T88-67175)
on page 990.
10. Remove the left stop button cables.

11. Remove the 4 screws attaching the left rotomolding to the left structure.
12. Loosen pipe aerosol removal bracket.

13. Pull the pipe aerosol out.
14. With 2 people, remove the left rotomolding.

16. Remove the pipe aerosol.
Installation
Left lateral perforated sheet metal (K4T88-67172)

Removal
3. Remove left lateral perforated sheet metal.

Installation
Left perforated metal sheet corner (K4T88-67173)

Removal
3. Remove left perforated metal sheet corner.
Installation
Front left perforated metal sheet (K4T88-67174)

Removal

3. Remove left perforated metal sheet.
Installation
Top left perforated metal sheet (K4T88-67175)

Removal

3. Remove top left perforated metal sheet.
Installation
Right side top cover (K4T88-67176)

Removal
3. Remove the right side top cover.

Installation
Back right cover (K4T88-67177)

Removal
3. Remove the back right cover.
Installation
Back right corner (K4T88-67178)

Removal
2. Remove the back right covers. See Back right cover (K4T88-67177) on page 992.
3. Remove the right side top cover. See Right side top cover (K4T88-67176) on page 991.

4. Remove 5 screws from the right back corner.
5. Remove the right back corner.
Installation
Front right bottom cover (K4T88-67179)

Removal

3. Remove the front right bottom cover.
Installation
Front right corner (K4T88-67180)

Removal
3. Remove the right side top cover. See Right side top cover (K4T88-67176) on page 991.

5. Remove the front right corner.
Installation
Front right door (K4T88-67181)

Removal

2. Open the door approximately 45 degrees.
3. Slide the front right door up and remove it.
Installation
Front right top (K4T88-67182)

Removal
2. Remove screen mount. See Screen mount (K4T88-67187) on page 901.

4. Unroute cables and remove front right top.
Installation

Right structure (K4T88-67183)
Removal
1. Remove all the covers regarding the right structure.
2. Remove the Service station.
3. Remove the Human-machine interface.
4. Remove the E-box.
5. Remove the E-cabinet.
6. Remove the right structure.
Installation
Back right perforated metal sheet (K4T88-67184)

Removal

3. Remove back right perforated metal sheet.
Installation
Top right perforated metal sheet (K4T88-67185)

Removal

3. Remove top right perforated metal sheet.
Installation
Right rotomolding (K4T88-67186)

Removal
2. Remove top right perforated metal sheet. See Top right perforated metal sheet (K4T88-67185)
on page 999.
3. Remove left lateral perforated sheet metal. See Left lateral perforated sheet metal (K4T88-67172)
on page 988.
4. Remove left perforated metal sheet corner. See Left perforated metal sheet corner (K4T88-67173)
on page 989.
6. Remove right side top cover. See Right side top cover (K4T88-67176) on page 991.
7. Remove beacon. See Beacon lights (K4T88-67262) on page 906.
8. Remove right stop button. See Stop button (K4T88-67156) on page 958.
9. Unscrew 2 back screws under the right rotomolding.

10. Unroute right stop button cables.
11. Unscrew front screw under right side of the right rotomolding.
12. Open front right door.

13. Unscrew front screw from right door under right rotomolding.
14. With 2 people, remove right rotomolding.
Installation
ID buttons and switches (K4T88-67195)

Removal
2. Open rear right cover or front right cover. See Rear right cover (K4T88-67155) on page 956 or Front right
cover (K4T88-67153) on page 948.

3. Loosen nut.
4. Unplug and unroute cable.
5. Remove switch button.
InstallatIon
eStop kit cables (K4T88-67234)


Safety interlock window (K4T88-67294)

Removal
2. Remove the right rotomolding.
3. Open the window.
4. Unscrew the interlock screw.
5. Open the interlock.

6. Unroute cables.
7. Remove 2 screws with the Allen key.
8. Remove the interlock.
Hdrs Single roll spindle (CZ056-67462)

Removal
1. Open the latch lever pivot on both sides.

2. Remove the Single roll spindle.

Ink system module

How to separate the Ink System Module
2. Remove the Back left top cover. See Back left top cover (K4T88-67166) on page 981.
3. Remove two screws and the washers.
4. Remove the VR waste container. See Vapor removal waste container (K4T88-67099) on page 1312..
5. Remove 1 screw and the washer.
6. Remove the Left Front Cover (K4T88-67167). See Front left cover (K4T88-67167) on page 982.
ENWW Ink system module 1007

7. Remove two screws and the washers.
8. Remove one screw and the washer.
9. Remove the Left Stop Button (K4T88-67156). See Stop button (K4T88-67156) on page 958.
10. Unroute the left stop button cables.

11. Unplug all the cables.
12. Loosen 1 screw and remove 1 screw.
13. Make sure the grounding strip is free.

14. Disconnect the drain tube.
15. Loosen the screw from the bridge clamp.
16. Disconnect the pipe from the vapor removal.

17. Cover the pipe from the vapor removal with a plastic bag.
18. Carefully move the IDS module.
19. Protect the floor with a paper.

20. Disconnect the quick connector and then cover both ends with a plastic bag.
21. Pull the IDS module away.
Ink system module 1

IDS Air circuit (K4T88-67023)
Removal
2. Separate the IDS module. See How to separate the Ink System Module on page 1007.
4. Remove the ISM 7x intermediate tank. See ISM 7x intermediate tank (K4T88-67040) on page 1056.

5. Remove the Ink supplies.
6. Open the left back door.
7. Disconnect the Silicon tubes from the PIPs, taking care when pulling out the tube.

8. Disconnect the Main silicone tube from the APS pumps manifold connection.
9. Disconnect the small silicone tube that goes to the Air Pressure Sensor.
10. Remove the screw that secures the Air bottle to the metal sheet.

11. Remove the Air bottle.
Installation
1. Place the new Bottle into the structure and tighten the screw.
2. Carefully connect the Silicone tubes to all the PIPs.

3. Connect the Main and the Sensor tubes to the APS Air Pumps and to the Air Pressure Sensor.
4. Assemble all the covers back.
IDS Air PCA (K4T88-67037)
Removal
2. Disconnect all the cables coming out from the IDS Air PCA. Disconnect also the Silicone tube that goes to
the Air Pressure Sensor.
3. Remove 5 screws.

4. Remove the IDS Air PCA from the support.
IDS Air pump and relief valve (K4T88-67025)
Removal
2. Remove the Left side cover (K4T88-67169) on page 983.
3. Remove the ISM 7x intermediate tank (K4T88-67040) on page 1056.
4. Pull in the sliding latches.
5. Remove the 2 top screws from the metal supports.

7. Remove the 2 bottom screws from the metal supports.
8. Unhook the ISS module from the metal supports.

9. Move the metal supports to a place where they do not disturb to continue with the process.
10. Place 2 foams.
11. Unhook the ISS module from the right side (1) and move the ISS to the left side to have access to the IDS
Air pumps (2).

12. Remove 2 screws from the metal sheet.
13. Remove 3 screws from the metal sheet.
14. Move out the IDS Air pumps support carefully with the cables.

15. Carefully cut the bridle from the cables.
To remove the Top IDS Air pump follow the next steps (16, 17, 18, 19). To remove the Bottom IDS Air pump
go to step 20.
16. Unplug the cables from the Air pumps .
17. Disconnect 2 tubes.

18. Remove 1 screw.
19. Remove the IDS Air pump with the Relief valve.
20. To remove the Bottom IDS Air pump follow these steps:
Unplug the cable from the Air pumps.

21. Disconnect 1 tube.
22. Remove 1 screw.
23. Remove the IDS Air pump with the Relief valve.
Installation
▲ Undo all the steps done before.

IDS eValves (K4T88-67042)
Removal
NOTE: Remove the IDS eValve affected.
6. Disconnect the cable.

7. Remove the two screws that secure the affected ElectroValve.
8. Cut 2 ties.
9. Move the IDS eValves to have better access to cut the tubes.

10. Cut the affected tube using the cutting tool. Cut it 3-4 cm away from the ElectroValve.
NOTE: Some ink drops may fall down when cutting the ink line.
11. Remove the affected ElectroValve.
Installation
NOTE: The Service Kit comes with some tubes and also some fittings to accommodate the repair.
1. Take note of the ink flow when connecting the Electrovalve.

2. Connect two fittings to the tubes from the printer.
3. Connect the ElectroValve to the tubes from the printer.
4. Once all the ink lines are connected, purge the ink line repaired.
IDS Ink leakage detector (K4T88-67038)
Removal
1. Remove the Front left cover (K4T88-67167). See Front left cover (K4T88-67167) on page 982.
2. Remove 4 screws from the IDS Dummy cover .

3. Remove the IDS Dummy cover.
4. Disconnect the leakage sensor cable.
5. Remove the screw that secures the leakage sensor cable to the structure.

6. Remove the IDS Ink leakage detector.
Installation
IDS Ink PCA (K4T88-67036)
Removal
2. Remove the IDS Air PCA. See IDS Air PCA (K4T88-67037) on page 1016.
3. Remove two screws.

4. Remove the IDS Ink PCA cover.
5. Disconnect all the cables from the IDS Ink PCA.
6. Remove 7 screws.

7. Remove the metal cover.
8. Remove the top cover.
9. Disconnect all the cables.

11. Remove the IDS Ink PCA.
Installation
IDS Ink pump (K4T88-67026)
Removal

NOTE: Depending on the ink pump affected, you will need to attack the pump from one side or the other.
So remove the PCA support if needed.
6. Disconnect the cable..
7. Cut the inlet and outlet tubes from the ink pump affected next to the connector.

8. Loosen the screws a little bit.
9. Remove the Ink pumps upwards.
Installation
1. Connect the fittings to the tubes coming from the printer.

2. Connect the tubes to the new Ink pump.
3. Purge the ink line.
Ink system module 2

IDS Ink circuit (K4T88-67024)
Removal

6. Remove the top two screws from the metal supports.
8. Remove the two bottom screws from the metal supports.

9. Disconnect the PIP cables from each PIP sensor.
10. Disconnect the Silicone tube by pulling it carefully from the PIP Sensor.
11. Untighten the Luer connector from each PIP.
NOTE: This is recommended to avoid that some ink drops could fall from the ink line.

12. Unhook the Intermediate tanks housing from the metal supports.
13. Unhook the Intermediate tanks housing from the right side (1) and move it (1).
14. Remove the Intermediate tanks housing from the printer.
Installation
1. It is very important to take note at the very beginning about the Code for all PIPs. To do so, you will find a
label on the side of the PIP’s floater.
These values will be introduced through PrintCare (Diagnostic mode ►22019 – Calibrate pressure sensor) )
following the sequence:
K, C, M, Y, LC, LM and OP.

2. Hook the Intermediate tanks housing into the metal sheet support.

3. Connect the ink lines to each PIP ensuring the color line is the one defined on the Intermediate tank slot
color label. Connect also the air tubes ensuring there is no tube kinked or bent.
Connect the PIP cables to each PIP sensor ensuring you are connecting to the correct one.
4. Purge the ink lines from the port with the syringe and the needle.
5. Perform the PIP calibration process.
IDS Moby support (K4T88-67041)
Removal
1. Remove the Left side cover (K4T88-67169). See Left side cover (K4T88-67169) on page 983.

3. Remove the Ink supplies (from the Moby support affected).
NOTE: To fully remove the Moby support affected you may need to release also the neighbor support.
4. Remove the two screws that secure the front enclosure.
IMPORTANT: Ensure that the Ink Supplies and the Intermediate Tanks have been removed.
5. Pull the SIM connector and remove the front enclosure.

6. Remove the three screws that secure the Moby Support to the structure.
NOTE: Remember that to fully remove the Moby support affected, you may need to release the neighbor
supports.
7. Carefully move the Moby support to have access to the cables (1) and disconnect the cables from the LED
PCA (2).
8. Open the clamp and remove the tubes.

9. Remove the Moby support from the printer.
10. Remove 2 screws from the LED PCA.
11. Remove the LED PCA from the current Moby support, it will be installed on the new Moby support.
Installation

IDS PIP assy (K4T88-67018)
Removal
2. Open the left panel.
3. Remove the Intermediate tanks.
4. Disconnect the Quick Connector.
5. Separate the ISM from the printer.
6. Open the panel door and untighten the two screws shown on the image.

7. Twist the four latches at the rear of the Ink cartridge tube connector and release the complete assembly.
NOTE: Image does not correspond to actual design. TBR
8. Unlatch the Intermediate tanks housing from the support by rotating and pulling it at the same time.
9. Remove the Intermediate tanks housing from the back plate to have direct access to the PIP and the
Floater.

10. Undo the two clips that hold the Floater and PIP Assembly to the ISS.
NOTE: You only need to disassemble the Floater and the PIP Assembly that you intend to replace.
11. Disconnect the PIP cables from the affected PIP sensor.
12. Pull the air tube from the PIP.
IMPORTANT: Pull firmly taking care not to damage the tube.

13. Disconnect the ink tube from the PIP. Put a plastic cap on the replaced PIP and on the ink tube you have just
disconnected.
IMPORTANT: Ink may drip from the tube during this process. Hold the floater up to minimize ink drops,
and protect the tray under the PIP.
Installation
1. Connect the ink tube to the new PIP, and make sure the fitting is tightened. A loose fitting can cause ink
leakages.

2. Connect the air tube to the new PIP.
3. Attach the Floater and the PIP assembly to the Back plate.
4. Connect the PIP cable to the new PIP.

5. Insert the two clips that hold the Floater and the PIP Assembly to the Back plate.
NOTE: Be careful when inserting the plastic clips ensuring that the clip is placed correctly.
6. Place again the Intermediate tanks housing.

7. Twist the four latches at the rear of the Ink cartridge tube connector and secure the complete assembly.
8. Tighten the screws of the Intermediate tanks housing support once it has been clipped.
9. Purge the ink line affected from the diagnostic as explained in the Installation Guide.
10. Perform the PIP calibration process and run the diagnostic 22019.
ISM quick connector M&F assembly (CZ056-67308)
Removal
1. Turn off the printer and the power-enable switch (so the ink circuit will not be pressurized).
2. Open the front left panel door.
3. Remove the rear left cover. See Rear left cover (K4T88-67154) on page 954.
4. Remove the bottom left panel.
5. For quick connector male and female valves, label each ink line so that they will be correctly identified
when cutting the ink tubes and replacing both quick connector valves.
IMPORTANT: Do not mismatch the ink tube positions on the quick connector. Otherwise the printer will not
work properly because ink circuits could be mismatched between the ISM and the TRS assemblies. You are
strongly recommended to label the matching female and male quick connector tubes, so there will be no
confusion while replacing them.

6. Flush the printer completely.
7. Cut at least 10 cm away from the quick connector valve all the tubes.
Installation
1. Connect the tube to the new quick connector ink tube using the proper fitting from the tube repair kit.
CAUTION: When installing the tubes, never twist the tubes, this will damage them. Always push/slide the
tubes until they are completely installed onto the fitting.
2. Connect the quick connector and proceed to purge all the lines.
3. Perform the following reset diagnostics depending on the affected line. See Table 5-12 Ink delivery system
on page 571:
● Purge supply OP for optimizer ink.
● Purge supply K for black ink.
● Purge supply Y for yellow ink.
● Purge supply M for magenta ink.
● Purge supply C for cyan ink.
● Purge supply LM for light magenta ink.
● Purge supply LC for light cyan ink.
Side structures wheels (K4T88-67189)
Removal
4. Disconnect the Quick Connector.

5. Separate the ISM from the printer.
6. Lift up the IDS module by placing some separator between the floor and the structure.
7. Untighten the wheels.
Ink system module 3

IDS C Cartridge connector (K4T88-67029)
Removal

4. Remove the Moby support enclosure by removing the two screws that secure the enclosure to the Moby
Support.
5. Disconnect the Acumen cable and the presence cable from the SIM Connector.
6. Cut the tube after the fitting and replace the SIM connector by attaching the fitting provided on the Service
Kit.
NOTE: Ink may drip from the tube during this process.
Installation
1. Insert the new SIM connector and connect the Acumen and Presence Cable accordingly.

2. Cut the tube length of the part provided on the SK according with the needed length.
3. Close the Moby support enclosure.
4. Purge manually the ink line repaired using the syringe provided with the SK.
IDS Ink Cartridge PCA (K4T88-67059)
Removal
1. Remove the IDS Moby support. See IDS Moby support (K4T88-67041) on page 1040.
2. Remove the 2 screws that secure the LED PCA to the Moby support.

3. Remove the LED PCA.
ISM intermediate tank (CZ056-67073)
Removal
3. Disconnect the Ink supplies connector.
4. Pull out the sliding latch.

5. Remove the Intermediate tank from the housing.
6. Run diagnostic 22024.
ISM 7x intermediate tank (K4T88-67040)

Same removal process as ISM intermediate tank (CZ056-67073) on page 1055 but changing all the Intermediate
tanks.
Removal
3. Disconnect the Ink supplies connector.

4. Pull out the sliding latch.
5. Remove the Intermediate tank from the housing.
NOTE: Repeat the process for all the Intermediate tanks.
6. Remove all Intermediate tanks
7. Run diagnostic (22024).
IDS K Cartridge connector(K4T88-67027)
Removal
▲ Same as IDS C Cartridge connector (K4T88-67029) on page 1052.

IDS LC Cartridge connector with (K4T88-67031)
Removal
IDS LM Cartridge connector (K4T88-67032)
Removal
IDS M Cartridge connector (K4T88-67030)
Removal
IDS PT Cartridge connector (K4T88-67033)
Removal
IDS Y Cartridge connector (K4T88-67028)
Removal
IDS cable (K4T88-67022)

Interlocks sensors kit cables (K4T88-67235)

IDS purge (K4T88-67289)
Removal
▲ View Installation guide.

Print to Paper Space (PPS)

PPS Actuator assy (K4T88-67060)
Right side lower position
Removal
1. This must be done with the PPS down.
3. Open the front right door.
4. Open web wipe.
ENWW Print to Paper Space (PPS) 1059

8. Disconnect the power cable (1) and open the clamps (2).

9. Remove 4 screws.
10. Remove carefully the safety cover metal sheet.
11. Remove the lower right clip using the pliers.

12. Remove the washer (1) and slide the pin out of the two holes (2).
13. Move the lifter down and out until we have access to the upper pin.
14. Remove the top right clip using the pliers.

16. Remove the actuator.
Installation
2. Use the pliers to insert the clips into the pins.
3. Run the Scan-beam motor and encoder check (48002) diagnostic.
Left side lower position
Removal

5. Remove 4 screws.

7. Open the clamp and remove the cable.
8. Remove the lower left clip using the pliers.
9. Remove the washer (1) and slide the pin out of the two holes (2)..

11. Remove the top left clip using the pliers.

Installation
Right side upper position
Removal
1. This must be done with the PPS up.
3. Open the right front door.

4. Open web wipe.

9. Remove 4 screws.

11. Use the Jack screw (K4T88-85184) to set up the PPS until the motor does not touch it.
12. Open the window.
13. Remove the right top clip (1) and the washer (2) using the pliers.

14. Open the pinch.
15. Slide the pin out of the two holes.
16. Remove the right lower clip using the pliers.

Installation
1. Connect the cables of the motor.
2. Run the Scan-beam motor open-loop movement (48004) diagnostic (in diagnostic mode and logged in as
Engineer) to set a position similar to the broken motor.
Left side upper position
Removal
1. This must be done with the PPS up.

5. Remove 4 screws.

7. Open the clamp and disconnect the cable.
8. Use the Jack screw (K4T88-85184) to set up the PPS until the motor does not touch it.
9. Remove the lower left clip using the pliers.

12. Remove the top left clip using the pliers.

Installation
1. Connect the cables of the motor.
Engineer) to set a position similar to the broken motor.
PPS Cables (K4T88-67065)

PPS Column assy (K4T88-67061)

WARNING! This is a critical part , assistance from HP Engineering is required
Removal – right side
1. Set PPS in media load (up).
2. Open the right front door.
3. Open web wipe.

5. Open the E-box.
6. Loosen the red screws.
7. Remove the pink screws so that the column falls. Be aware to take it.
8. Remove the red screws and the green part.
9. Remove 4 screws to remove the pink part.
Removal – left side
1. Open the ISM module.
2. Follow the same process as for the right side.
Installation
Engineer).
IMPORTANT: Ensure that the Jack screw is out before performing step 3.
IMPORTANT: Ensure that nothing is blocking the Scan-beam path and that the motors are correctly
working. You can move them by using the buttons ISS Motor Down and SVS Motor Down in the 48004
diagnostic and visually check that they are moving.

3. Use the buttons ISS Motor Up and SVS Motor Up to move the motors up until they touch the scan-beam.
You can check that the motors have touched the scan-beam either visually or by checking that the encoder
units of the related motor start to increase.
NOTE: Every time you press a button, the selected motor moves for 2s (2 mm) in the selected direction.
Don’t press the buttons several times in a row, wait until each movement is finished and reported through
Print Care.
4. Press the button Reset encoders (Home). The motors will descend to their lowest position and the encoder
units will be set to 0 in that position.
5. Run the Scan-beam motor and encoder check (48002) diagnostic to verify that the system is working
properly.

PPS Encoder assy (K4T88-67062)

Removal
2. From the Internal Print Server, navigate to Carriage beam position ►Move to home position to lower the
carriage beam all the way. If you cannot start the printer in the normal way due to failure, use diagnostic
mode.
4. Open the pinch.
5. Locate the PPS Encoder Assy.

6. Remove 3 pointed screws.
7. Remove the encoder strip support (K0Q45-00019).

9. Remove 2 screws.
10. Remove the PCA.
Installation
1. Add new PCA.
2. Connect the cable.
3. Fasten 2 screws.
4. Add a new strip.
NOTE: The end of the strip has to be aligned with the end of the Strip support metal.

5. Fasten 3 screws to attach the metal support to the scan beam. Be aware of the position of the encoder
strip and the encoder reader. Strip should be inside.
6. Close the pinches.
7. Reset the encoder. Go to Print Care ►Diagnostics and make a Homing. This will reset the position of the
encoders and take the Scan beam to a known position.
PPS Safety PCA (K4T88-67063)
Removal
1. Unclip mylar.

2. Disconnect the cables.
3. Remove 4 screws.
4. Remove the PCA (K4T88-60370).
Installation
NOTE: PCA can be installed in both directions.
Stand motor drive PCA (CZ056-67190)

Removal
1. Open the Mylar cover (black plastic).
2. Locate the PCA in the Stand of the machine.

4. Loosen the 2 screws attaching the PCA to the structure.
Installation
NOTE: Lateral screws not needed in this case.

Printhead cleaning system

Web wipe transmission box (CZ056-67045)
Removal
1. Remove the printhead cleaning module assembly. See Web Wipe printhead cleaning module
(K4T88-67111) on page 1127.
2. Disconnect the DC motor from both power and encoder cables.
3. Remove the 3 T-25 screws that secure the gearbox base.
4. Remove the Web wipe transmission box with motor.

5. Remove the web wipe roll-free hub (CZ056-67050). See Web wipe roll-free hub (CZ056-67050)
on page 1093.
6. Remove the paper.
7. Unscrew 2 metal sheet screws.
8. Remove the metal sheet.

9. Separate and remove the inversor.
Installation
Web wipe printhead cleaning roll axis with structure (K4T88-67112)

Removal
1. Remove the Web wipe printhead cleaning roller up-down pair. See Web wipe printhead cleaning roller up-
down pair (K4T88-67117) on page 1099.
2. Remove the Web wipe transmission box. See Web wipe transmission box (CZ056-67045) on page 1085.
3. Unscrew the 6 screws around the extraction backplate.

4. Separate the cleaning module.
5. Unscrew the 2 motor PCA screws for each motor PCA.
6. Remove the 4 motor PCAs.
7. Remove the 4 transmission boxes.
Installation
▲ After installation, perform the printhead cleaner height calibration and check (47005).

Printhead cleaning rubber hub (CZ056-67049)

Removal
1. Follow steps 1 to 7 of the Web wipe extraction guide. See Web wipe extraction guide (K4T88-67218)
on page 1124.
2. Remove the Web wipe roll-free hub. See Web wipe roll-free hub (CZ056-67050) on page 1093.
NOTE: Remove 2 PCAs (top or bottom, depending on the gear you are changing, in order to access the
screws).
4. Disconnect the inside PCA housing cables.
5. Unscrew the 2 inside PCA housing screws.

6. Remove the inside PCA housing.
7. Disconnect the outside PCA housing cables.
8. Unscrew the 2 outside PCA housing screws.

9. Remove the outside PCA housing.
10. Unscrew the screw through the hole.

12. Remove the roll axis.
13. Remove the roll transmission hub.
14. Remove the rubber from the roll transmission hub.
Installation
2. Perform the Z calibration (47005).

Web wipe roll-free hub (CZ056-67050)

Removal
3. Pull the web wipe out.
4. Remove the roll-free hub.
Installation

Printhead cleaning roll pinch assembly (K4T88-67115)

Removal
2. Open the front right door (K4T88-67181).
3. Pull out the web wipe.
4. Open the pinch.

5. Unscrew the screw with a wrench.
NOTE: Take the washer between the central cage and the pinch with a pair of pincers.
6. Remove the pinch.
Installation
Web wipe printhead cleaning blade (K4T88-67116)

Removal

2. Open right front door (K4T88-67181).
4. Open the pinch.

5. Remove the blade by pulling up on it while separating the paper a bit.
Installation
▲ Push down on the new cleaning blade until you hear it click into place.
WARNING! Make sure the blade is properly inserted.
Printhead cleaning drive roller (K4T88-67113)

Removal
2. Remove the Web wipe printhead cleaning roller up-down pair (K4T88-67117). See Web wipe printhead
cleaning roller up-down pair (K4T88-67117) on page 1099.

3. Remove the c-clip.
4. Remove the bearing.
5. Remove the black gear.

6. Remove the c-clip and the bearing.
7. Remove the cleaning drive roller.
Installation
2. Perform diagnostic 47005.
Web wipe printhead cleaning roller up-down pair (K4T88-67117)

Removal
1. Remove the Back right cover (K4T88-67177). See Back right cover (K4T88-67177) on page 992.

2. Disconnect the power and LAN cables.

5. Remove the metal part which attaches the gas spring.
7. Lift up one plastic part on one side at the same time you pull down the one on the other side. When you
have both loose, pull out the web wipe.
8. Remove the Printhead cleaning roll pinch assembly (K4T88-67115). See Printhead cleaning roll pinch
assembly (K4T88-67115) on page 1094.
9. Remove the web wipe roll-free hub (CZ056-67050). See Web wipe roll-free hub (CZ056-67050)
on page 1093.

11. Unscrew the 7 screws.

12. Separate the web wipe cleaning roller up-down pair
Installation
2. Perform Z calibration check (47005).
Web wipe roller parts (K4T88-67119)

Removal
1. Remove the Web wipe. Follow steps 1 to 7 from Web wipe extraction guide (K4T88-67218) on page 1124.
2. Locate the two roller parts on the web wipe.
NOTE: Remove 2 PCAs (top or bottom depending on the gear we are changing, in order to have access to
the screws).



9. Remove the screw through the hole.
Installation
1. Reverse removal instructions
2. Perform diagnostic 47005.

Web wipe output diverter parts (K4T88-67120)

Removal
2. Remove the Back right cover (K4T88-67177) on page 992.

8. Lift one plastic part p on one side at the same time you pull down the one on the other side. When you

9. Remove the 4 screws.
10. Take it out from behind.
Installation
2. Run the diagnostic 47005.
Web wipe lifter parts (K4T88-67121)

Removal
2. Remove the Web wipe printhead cleaning blade. See Web wipe printhead cleaning blade (K4T88-67116)
on page 1095.
NOTE: Be careful as there are two different lifters: one on the front side and one on the back side.

4. Remove the metal part with the handle.
5. Remove the c-clip.

6. Remove the cam and the key.
7. Remove the spring.
8. Remove the c-clip and the golden ring.

9. Remove 2 c-clips, 2 golden rings and the lifter.
10. Remove the c-clip and then the PN 1410-1899 along with the spacer.
11. Perform the same action for the lifter in the other side, with the exception that there is no spacer in the
other side.
Installation
1. Grease in the contact zone of the golden rings with the lifter and the contact zone between the cam and
the roller bearing 1410-1889. PN of the grease is 6040-1299.
3. Run the Z calibration Z diagnostic (47005).
Web wipe waste management parts (K4T88-67123)

Removal

4. Loosen the two screws (no need to remove them).

5. Remove the whole waste management part.
Installation
1. Install the 2 screws that fix the bottle and the 2 screws that fix both metal parts.
2. Put in place and tighten the screws.
Web wipe central cage top cover (K4T88-67114)

Removal
1. Remove Web wipe printhead cleaning roller up-down pair. See Web wipe printhead cleaning roller up-down
pair (K4T88-67117) on page 1099.
2. Remove Web Wipe Pinch new (K4T88-67115). See Printhead cleaning roll pinch assembly (K4T88-67115)
on page 1094.
3. Unscrew the four screws.

4. Remove the metal part with the handle.
5. Loosen the 5 screws.

6. Remove the gear.
7. Unscrew the screw.
8. Unscrew the 2 bottom screws.
9. Remove the Web wipe printhead cleaning blade (K4T88-67116) on page 1095.

10. Rotate and remove the central cage top cover.
Installation
1. Before installing the central cage top cover, ensure that the pointed corners are correctly sealed with
silicone to prevent small ink leaks.
NOTE: If it is necessary to seal a corner, do not apply too much sealant, as it will overflow to the back of
the central cage (wipe clean the overflow). You are strongly recommended to let it dry for about 15
minutes before continuing the installation. Otherwise, it may escape and stain other parts of the cage.
2. Insert the new central cage and screw it to the central cage base on both sides and at the bottom, and also
to the rear cover.
3. Screw the central cage cover to the base plate structure and install it into the guide.
Web wipe gear kit (1HA07-67050)

Removal

2. Remove the black gear.
3. Unscrew the 2 metal plate screws from the structure.
4. Remove the metal plate

5. Remove the gear.
NOTE: Remove the 2 PCAs (top or bottom depending on the gear we are changing, in order to have
access to the screws).


12. Unscrew the screw through the hole.

15. Remove the roll transmission hub.
Installation
▲ Reverse the removal process. Install the gear in the correct position.
Web wipe extraction module kit (K4T88-67118)

Removal
1. Remove the Web Wipe printhead cleaning module (K4T88-67111) on page 1127.

2. Remove the 7 screws.
3. For the air spring, remove the remaining nut to remove it .

4. Remove the air spring.
5. Remove 8 screws from the part hanging from the scan axis that belong to this SK.
Removal
2. Perform the diagnostic 47005.
Web wipe extraction guide (K4T88-67218)

Removal
2. Remove the Back right cover (K4T88-67177) on page 992.
3. Disconnect and unroute the power and LAN cables.

Remove the gas spring.

7. Lift one plastic part up on one side at the same time you pull down the one on the other side. When you
8. Unscrew the 4 screws from the web wipe module (from each side, 8 screws in total).
9. Remove the guide.

10. Remove the 4 screws from the machine (from each side, 8 screws in total).
11. Remove the rest of the guide.
Installation
2. Run diagnostic 47005.
Web Wipe printhead cleaning module (K4T88-67111)

Removal


5. Remove the metal part which attaches to the gas spring.
7. One plastic part should be lifted up on one side at the same time you pull down the one on the other side.
When you have both loose, pull out the web wipe.
8. Remove the Printhead cleaning roll pinch assembly. See Printhead cleaning roll pinch assembly
(K4T88-67115) on page 1094.
9. Remove the We wipe roll-free hub (CZ056-67050). See Web wipe roll-free hub (CZ056-67050)
on page 1093.

11. Unscrew the 6 screws around the extraction backplane.
12. Separate the cleaning module.
Installation
▲ After installation, perform the printhead cleaning Z calibration and TILT adjustment height calibration and
check (47005).

Printhead cleaning system motor drive PCA (CZ056-67190)

Removal
1. Remove the Web Wipe Printhead cleaning module. See Web Wipe printhead cleaning module
(K4T88-67111) on page 1127.
NOTE: Remove the Web Wipe Printhead cleaning module, except the K0Q45-00081 (backplane cover
does not need to be removed in this process).
NOTE: Remove 1 PCA (top outside, top inside, bottom outside or bottom inside depending which PCA is
damaged).
2. Unplug the cables.
3. Remove the screws attaching the PCA to the structure.
Installation

Printhead cleaning tilt calibration

NOTE: It is important to follow the steps described in order. These are the procedures required to calibrate and
shim a printhead cleaning module assembly:
● Printhead cleaner height check
● Printhead cleaner tilt check
● Printhead cleaner calibration
● Printhead cleaner tilt adjustment
1. Check that the calibration and tilt have been correctly set. Perform both the printhead cleaner height check
and the printhead cleaner tilt check (in the list above).
2. If any of the printhead cleaner check procedures do not complete correctly, perform printhead cleaner
calibration and, if necessary, the printhead cleaner tilt adjustment (in the list above) to correct the
printhead cleaner height and tilt.
3. Repeat the printhead cleaner height and tilt check procedures.
Height and tilt check and calibration test

NOTE: The following tests are available in Print Care only when logged in as an Engineer.
Printhead cleaner height check: Printhead cleaning Z calibration check [47005]
This check is to find the operational height of the pressure roller of the printhead cleaning system. The check is
made while wiping the printheads (either servicing or dynamic printhead wipes).
Perform this check whenever the printhead cleaning system is replaced or repaired, or if you see a very fast
degradation of printhead life.
The printhead cleaner roll height check requires that you use the diagnostics tests; they are accessible through
the Print Care Diagnostics tab.
Diagnostic availability can change depending on the role logged in Print Care and printer boot mode. This test is
accessible at any user and printer boot mode login.
Printhead cleaning Z calibration check process:
1. From the Internal Print Server’s main screen, select Tools ►Print Care ►Diagnostic.

2. From the Diagnostic screen select Web Wipe.
3. From the Diagnostic Web Wipe screen, select Printhead cleaning Z calibration [47005] and click Run.

4. The printer starts up the electronics and the various subsystems involved in the calibration.
5. When all the subsystems are initialized, the IPS screen displays a message describing the process and
objectives of the test:
Follow the instructions given by Print Care.
6. Perform the printhead cleaner check procedure. See Table 5-16 Printhead cleaning on page 580.
7. Then select Continue.
While the printhead cleaner check procedure is performed, the carriage starts doing several dynamic wipes
at different heights of the rubber blade. After each dynamic wipe, the printhead cleaning subsystem makes
one controlled advance.

8. When the test is completed, pull the printhead cleaning module out of the printer and take a look at the
marks left on the cloth.
The test will have generated some marks on the cloth, similar to the following:
These marks help to perform both Height and Tilt calibration.

9. If you select Next, the test is finished. The Diagnostic tool shows the following screen:
Printhead cleaner tilt check
Besides looking at the height calibration of the module we also have to look how tilted the module is. In this case
what we will see is that the line marks do not start with all printheads touching the wipe at the same position but
starting with one single color. We consider that the tilt of a module is acceptable if the number of incomplete
marks (the ones that don’t extend the full length to cover all heads less than or equal to two. If there are 3 non-
complete lines, then we recommend to add a shim on the side where we first start to see the marks (adding a
shim on one side moves the module down on that side, thus reducing wiping interference with the printhead).
After which we can return to adjust the height.
▲ Tilt assessment:
● GOOD: 0 or 1 incomplete lines
● TILT adjustment needed: 2, 3, or 4 incomplete lines
In the next image we can see a miscalibrated module. This module requires Tilt adjustment.

Printhead cleaner calibration
This calibration is to adjust the height of the pressure roller of the printhead cleaning system. The user must
generate this calibration after having performed the Printhead cleaning Z calibration check [47005].
The printhead cleaner roll height calibration requires that you use the Diagnostics tests that are accessible
through Print Care. The process to access the printhead cleaner diagnostic screen is described under printhead
cleaner check.
1. From following screen select the tab Set printhead cleaning Z cal:

Once you select Next in the Diagnostic tool, the following screen will be displayed:
This screen shows the follow message:
Enter the number of visible single lines fully printed on the cleaning material in the printhead cleaning Z
calibration check
In this moment the user should introduce the number the lines that he can see on the wipe, after having
performed Printhead cleaner check.
The maximum number of lines is eight and the minimum is zero.
Once the number the lines is selected, the tool will amend the interference value between the roller blade
and the printheads, and it will adjust the e.u. if necessary. The correct height for the cleaning roll it
corresponds with is 4 visible lines, the printer adjusts the e.u. to reach this height automatically using the
lines selected at this point as a starting reference. This new value is loaded in the internal memory of the
printer (NVM).
The diagnostic screen shows:
“Current nominal position is (in e.u.): XXXXX”
“Setting nominal position to (in e.u.): YYYYY”
“Diagnostic finished OK”
Once the new value is loaded in the NVM, the calibration is done.

2. Select Next to leave the calibration screen.
After calibration, our recommendation is to repeat the printhead cleaner check to verify that the values
changed have been correctly modified.
Printhead cleaner tilt adjustment procedure
Tilts whole module to ensure continuous printhead contact along the blade. Performed manually with a screw:
1. Run the Print Care diagnostic Printhead cleaning Z calibration check [47005] to check if all lines are
complete or not.
NOTE: Tilt adjustment is required if lines are not complete:

2. Loosen the two lateral screws in the right side of the module to allow movement.
3. Loosen the screw on the left side of the module.
4. Adjust tilt using the front screw. The module is tilted towards front or rear depending on the screw
direction.
5. Fix into position with the lateral screws.
6. Run the PrintCare diagnostic Printhead cleaning Z calibration check [47005] to check if all lines are now
complete.

Web wipe engage motor (K4T88-67122)

Removal
1. Remove the Web wipe lifters parts. See Web wipe lifter parts (K4T88-67121) on page 1109.
2. Remove c-clip.
3. Remove bearing.
4. Remove c-clip and bearing from the other side.

5. Remove axle.
Web Wipe cables kit (K4T88-67251)

Printhead cleaner waste bottle (Q6702-60685)

Removal

4. Remove the waste bottle.
Installation
Left spittoon (K4T88-67220)

Removal
3. Remove the spittoon foam.

4. Remove 4 screws.
5. Remove 2 screws.
7. Remove the Rear left cover. See Rear left cover (K4T88-67154) on page 954.

8. Remove 4 screws.
9. Rotate the metal part 90 degrees to remove it.
Installation
Service station: capping and drop detector

Capping
Service station position spring (K4T88-67076)
Removal
ENWW Service station: capping and drop detector 1145

2. Open window.
3. Move the carriage to a different position than on top of the capping.

5. Remove the spring from the service station.
6. Move the capping module up to have better accessibility.
7. Remove the spring from the capping structure.
Service station caps kit (K4T88-67074)
Removal

2. Open window.
4. Open the right front door (K4T88-67181).

7. Unscrew the 3 screws from each support.
8. Remove the front supports.

9. Remove the service station caps kit.
Installation
Service station cap (K4T88-67073)
Removal
2. Open window.

5. Remove the cap pressing both of its sides.
Installation
1. Be careful with the direction of the holes when installing.

Drop detector
Drop-detector station (K4T88-67077)
Removal
2. Unplug the motor cable.
3. Unplug and unroute the switch cable.

5. Unplug all the PCA cables.
6. Unscrew the 2 spring screws.
7. Unscrew the 2 rear screws.

8. Unscrew the 2 top screws.
9. Remove the positioners.
10. Unclip the spring with a screwdriver to relieve impelling.

11. Move the carriage to the front to avoid damage by the scan structure.
12. Remove the drop-detector station.
Installation
2. Run the 52003 diagnostic to perform the "Y" calibration. Remember to use the same shims (positioners) in
the left and right side.
Drop-detector positioner (K4T88-67078)
Removal
1. Remove the Drop-detector station. See Drop-detector station (K4T88-67077) on page 1152.
2. Remove the Drop-detector shuttle with sensor. See Drop-detector shuttle with sensor (K4T88-67081)
on page 1162.
3. Remove the Drop-detector PCA. See Drop-detector PCA (K4T88-67083) on page 1168.

4. At this point you should have the assembly free.
Installation
2. Run the 52003 diagnostic to perform the "Y" calibration.
Drop-detector transmission engine (K4T88-67079)
Removal


7. Release the belt from the Top impelling.
8. Unscrew the 2 motor screws.
9. Remove the motor.

Installation
Drop-detector transmission parts (K4T88-67080)
Removal
2. Remove the Drop-detector station. See Drop-detector station (K4T88-67077) on page 1152.
3. Unscrew the metal sheet screw.

5. Remove the tensioner, spring, and belt.
6. Unscrew the pulley screw.

7. Remove the pulley.
8. Push the encoder.
9. Unclip the encoder from the rear.

10. Remove the encoder.
Installation
Drop-detector shuttle with sensor (K4T88-67081)
Removal
2. Unclip the spring with a screwdriver to release the impelling.

3. Unscrew the top screw.
4. Remove the upper assy.
5. Unscrew the 2 cable latch screws.

6. Remove the cable latch.
7. Remove the cable routing.
8. Disconnect the 5 cables.

9. Unscrew the 2 carriage guide screws.
10. Remove the carriage guide.
11. Remove the 2 guide screws.

12. Remove the 2 plates.
13. Remove the drop detector carriage.
Installation
Drop-detector sensors (K4T88-67082)
Removal
2. Go to diagnostics and move the drop detector to the front running the diagnostic 52004.

3. Unscrew the top screw.
4. Remove the upper holder assy.
5. Unplug the corresponding cable and unroute it.

6. Unscrew the 2 sensor screws.
7. Remove the sensors.
Installation
2. Perform the Y calibration (diagnostic 52003).
Drop-detector PCA (K4T88-67083)
Removal

4. Unscrew the 2 upper screws.

5. Remove the PCA.
Drop-detector belt (K4T88-67287)
Removal

6. Dismount the tensioner.
7. Remove the belt.
Drop-detector Mux PCA (CZ056-67388)
Removal
1. Remove the Drop-detector PCA. See Drop-detector PCA (K4T88-67083) on page 1168.
2. Unscrew the 3 plate screws.
3. Remove the plate.
4. Unscrew the 2 PCA screws.

5. Remove the drop-detector Mux PCA.
Drop detector PCA cables kit (K4T88-67226)

Drop detector system motor kit (K4T88-67227)

ODD encoder strip (K4T88-67219)
Removal

3. Push the encoder.
5. Unclip the encoder from the rear.
Installation

Service station Motor drive PCA (CZ056-67190)
Removal
2. Open the E-box.
3. Run test 52004 to place the Drop detector in service position.
5. Remove 2 screws to remove the PCA.
Installation

Substrate path
Spindle latch type B (Q6702-60469)
Initial steps
3. Follow the steps below for either the MI left spindle latch or the MO right spindle latch.
Removing the MI left spindle latch
1. Remove the MI spindle. See Hdrs Single roll spindle (CZ056-67462) on page 1005.
3. Remove the spring from the latch lever tab.

4. Remove the latch circlips from both lever pivot ends.
5. Remove the latch lever pivot sufficiently so that the latch lever can be replaced with the new one.
Installing the MI left spindle latch
1. Install the new latch.
2. Reinsert the lever pivot through the support spindle plate, the latch lever, and the bearing plate, and fix its
ends with the circlips.
3. Put back the spring on the latch lever tab.
TIP: You are recommended to use a flange through the latch lever tab hole to help to tighten the spring,
so that it is easier to place the spring end at the latch lever tab.
Removing the MO right spindle latch

2. Remove the outside Front left cover (K4T88-00197).
3. Remove the MO spindle. See Hdrs Single roll spindle (CZ056-67462) on page 1005.

6. Remove the latch lever pivot sufficiently so that the latch lever can be replaced with the new one.
Installing the MO right spindle latch
1. Install the new latch.

TIP: When installing the new latch through the pivot, you are recommended to remove the three T-25
screws and the MI transmission cover, so that the pivot can be pushed from the transmission side while
installing the latch.
end with the circlip.
Left spindle journal (CZ056-67238)

Removal
1. Remove the Hdrs Single Roll Spindle. See Hdrs Single roll spindle (CZ056-67462) on page 1005.
2. Place the Hdrs Single Roll in a safe place.
3. Remove the 4 screws that fix the left Journal to the spindle using an Allen key.

4. The left journal has a slot for placing a screwdriver to pry it open.
5. Lever with a screwdriver, preferably a flat one, until the Journal moves away from the spindle.
6. Continue until the Journal can be removed by hand, normally once the first two O-rings have been
released.

7. Remove the journal from the spindle and check the status of the O-rings. If you notice that some of them
are tweaked or damaged proceed to change them.
Installation
Spindle air valve (K4G10-67094)

Prepare to replace a spindle valve
1. Ensure that you have an 11 mm (7/16 inch) tube wrench key and the pneumatic gun.
2. Ensure that the printer is not printing.
3. Press the valve to deflate the spindle.
Replace a spindle valve
1. Remove the spindle valve with the tube wrench key.

2. Insert the new valve and tighten it. The valve must be well seated in position and firm, but do not force it
with the key.
Finish off replacing a spindle valve
▲ Test the new valve by inflating and deflating the spindle.
MA motor (CZ056-67269)
Removal
1. Unload the substrate so that it is easy to reach the MA motor.
3. Open the pinch.

4. Disconnect the MA motor cables.
5. Remove the screws that hold the MA motor and remove the motor.
NOTE: If the motor coupling spider comes away with the MA motor, remove the coupling spider from the
MA motor coupling and save it.

6. Loosen the screws that fix the motor coupling to the MA motor and remove the coupling.
Installation
1. Install the motor coupling to the new MA motor and screw it back to the shaft. Ensure that one of the
coupling screws is screwed against the flat surface of the shaft.
2. Reinstall the MA motor, ensuring that the coupling matches the transmission, and screw it to its support.
Ensure that the coupling spider is correctly located between the motor and the transmission couplings. A
gap of at least 1.5mm is required on both sides of the coupling spider.
3. Connect the MA motor cables.
4. Calibrate the analog encoder. See Table 5-5 Substrate path mechanics on page 551.

Drive roller encoder disc and PCA (CZ056-67374)

Removal
1. Move the scan axis to the substrate load position to raise the carriage beam all the way.
If you cannot start the printer in the normal way due to some failure, use diagnostic mode.
3. Open the pinch.
Removing the drive roller encoder sensor PCA
1. Disconnect the MA motor encoder cable from the drive roller encoder sensor PCA.
CAUTION: Do not disconnect an encoder cable by pulling the cable, because it will break the connector.
Hold the connector of the encoder cable when removing it.
2. Remove the two T-20 screws that hold the drive roller encoder sensor PCA support.

3. Remove the drive roller encoder sensor PCA support by pulling out the pins and carefully sliding the
encoder sensor straight down until it gets past the encoder disc.
4. Remove the drive roller encoder sensor PCA.
Installing the drive roller encoder sensor PCA
1. Reinstall the drive roller encoder sensor PCA.
3. Perform the diagnostic Drive roller calibration (41006). See Table 5-5 Substrate path mechanics
on page 551.
Removing the drive roller encoder disc
1. Remove the drive roller encoder sensor PCA.
2. Loosen the T-8 screw that fixes the encoder hub to the drive roller.
NOTE: Do not remove the codewheel cover, which shields the encoder disc from drive roller gear grease.

3. Remove the encoder disc with its hub from the drive roller.
Installing the drive roller encoder disc
1. Install the new encoder disc with its hub onto the drive roller.
2. Tighten the T-8 screw to fix the encoder disc hub to the drive roller.
3. Carefully reinstall the drive roller encoder sensor PCA.
4. Screw back the codewheel cover.
5. Calibrate the analog encoder. Perform the diagnostic Drive roller calibration (41006). See Table 5-5
MA motor data cable (K4T88-67239)

MA motor power cable (K4T88-67240)

MI motor encoder cable (K4T88-67241)

MA motor encoder cable (CZ056-67094)

Substrate drive roller transmission assembly (CZ056-67228)

Removal
3. Open the pinch.

5. Remove the MA motor. See MA motor (CZ056-67269) on page 1182.
6. Remove the drive roller encoder disc and PCA. See Drive roller encoder disc and PCA (CZ056-67374)
on page 1185.
7. Remove the two screws that hold the codewheel cover, and remove the cover.

8. Remove the three pointed screws that attach the right bearing L-shaped metal sheet support, and remove
the support.

9. Remove the pointed screws that hold the transmission mount, and remove the transmission mount.
10. Remove the drive roller (this operation requires two people; the drive roller weights 60 Kg) and store it
carefully.
Installation
1. Before installing the transmission mount, grease the drive roller worm gear. See Grease the Drive roller
worm gear on page 1462.
2. Install the new transmission mount.
3. Screw back the right bearing L-shaped metal sheet support.
4. Install the codewheel cover.
5. Install the substrate drive encoder disc and the substrate drive encoder PCA. See Drive roller encoder disc
and PCA (CZ056-67374) on page 1185.
6. Install the MA motor.

Substrate drive roller assembly (Q6703-67020)

Removal
3. Open the pinch.
5. Remove the substrate drive roller transmission assembly. See Substrate drive roller transmission assembly
(CZ056-67228) on page 1187.
on page 1185.

the support.

9. Remove the two pointed screws that attach the left bearing L-shaped metal sheet support, and remove
the support.
10. Remove the substrate drive roller assembly from the printer and save it in a secure place.
CAUTION: This part is very heavy, so you are strongly recommended to perform this operation with at
least two people.
Installation
1. Before installing the transmission mount, grease the drive roller worm gear.
2. Install the substrate drive roller assembly.
3. Screw back the right and left bearing L-shaped metal sheet supports.

(CZ056-67228) on page 1187.
and PCA (CZ056-67374) on page 1185. Run the Substrate path sensors diagnostic (41001).
7. Calibrate the drive roller assembly.
Drive roller motor coupling (Q6702-60478)

Removal
2. Remove the motor coupling spider.
3. Loosen the screws that attach the motor coupling to the MA motor.

4. Remove the MA motor coupling from the MA motor.
5. Loosen the screws that attach the drive roller transmission coupling to the drive roller transmission.
6. Remove the drive roller transmission coupling from the drive roller transmission.
Installation
1. Attach the new MA motor coupling to the MA motor. Ensure that one of the coupling screws is screwed
against the flat surface of the shaft.
2. Attach the new drive roller transmission coupling to the drive roller transmission. Ensure that one of the
coupling screws is screwed against the flat surface of the shaft.

3. Reinstall the MA motor, ensuring the three coupling parts match correctly, and screw the MA motor to its
support. Ensure that the coupling spider is correctly placed between the MA motor and the driver roller
transmission couplings. A gap of at least 1.5mm is required on both sides of the coupling spider.
4. Connect the MA motor cables.
Drive roller worm gear (CZ056-67471)

Removal
3. Open the pinch.
5. Remove the MA motor. See MA motor on page 1158..
on page 1185.
the support.
9. Remove the pointed screws that hold the transmission mount, and remove the transmission mount.
10. Remove the drive roller (this operation requires two people; the drive roller weights 60 Kg) and store it
carefully.
11. Remove the gear.
Installation
1. Before installing transmission mount, grease the drive roller worm gear. See Grease the Drive roller worm
gear on page 1462.
2. Install the new transmission mount.

3. Screw back the right bearing L-shaped metal sheet support..
and PCA (CZ056-67374) on page 1185.
6. Install the MA motor.
Substrate advance worm gear grease (CZ056-67446)

See Grease substrate drive transmission gears on page 1461.
Drive roller support bearings (Q6702-60477)

This service part includes all the drive roller support bearings (both ends and center).
Removal
3. Open the pinch.
on page 1185.

(CZ056-67228) on page 1187.

9. Remove the two pointed screws that attach the left bearing L-shaped metal sheet support, and remove
the support.
10. Remove the substrate drive roller assembly from the printer and save it in a secure place.
CAUTION: This part is very heavy, so you are strongly recommended to perform this operation with at
least two people.

11. Remove the drive roller assembly so that you can reach the six central support bearings (four at the front,
two at the rear).
12. For each bearing, remove the circlip carefully and remove the bearing.
Installation
1. At the left end of the substrate drive roller, remove the retaining ring and replace the bearing with the new
one.
2. Install the six new central bearings.
3. Reinstall the rear drive roller assembly and screw in its left end support bearing.
4. Reinstall the substrate drive transmission assembly.
Ensure that the worm screw, the worm gear, and the encoder assembly are correctly assembled.
5. Screw in the right end support bearing.
6. Reinstall the encoder disc and its cover.
7. Reinstall the encoder PCA.
8. Calibrate the analog encoder. See Table 5-5 Substrate path mechanics on page 551.Substrate drive roller
assembly
OMAS and vacuum cables kit (K4T88-67237)

OMAS platen assembly (K4T88-67137)

Removal
1. Set up PPS.

3. Open the pinch.
4. Disconnect OMAS cable to PCA (unload/cut media if necessary).
5. Open the window.

7. Remove OMAS platen and cable.
Installation
1. Put pins in place to set position.

2. Follow screw sequence.
Platen extra assembly (K4T88-67136)

Right side
Removal
2. Open window.

4. Remove platen extra assembly.
Installation
1. Put the pins in place to the set position.
2. Fix into place with 3 screws, following the sequence shown.
Left side
Removal
▲ Follow the same process as the right side. See Right side on page 1203.

Installation
▲ Fix into place with 3 screws, following the sequence shown.
Platen assembly (K4T88-67139)

Removal
2. Open the window.

4. Remove platen assembly.
Installation
1. Put pins in place to set position.
2. Screw following this sequence.

Media edge holder (K4T88-67138)

Removal
1. Open the window.
2. Unplug the device from its working position.
Installation
MEH sliders (K4T88-67140)

Removal
1. Remove the Media edge holder. See Media edge holder (K4T88-67138) on page 1207.
2. Remove strip.
Installation
Pinch clamp (K4G10-67106)

Removal
2. Open clamp.

3. Unscrew 4 clamp screws.
4. Remove clamp.
Installation
Front right pinch cover (K4T88-67085)

Removal
1. Set up the PPS.

3. Open the pinch.
4. Loosen 2 inner screws.

6. Remove the front right cover.
InstallatIon
Front left pinch cover (K4T88-67086)

Removal
1. Set up the PPS.

3. Open the pinch.
4. Loosen 2 inner screws.

6. Remove the front left cover.
InstallatIon
Front center pinch cover (K4T88-67087)

Removal
1. Set up the PPS.

3. Open the pinch
4. Loosen 2 screws.

6. Remove the front center cover.
Installation
Pinch assembly (K4T88-67088)

Removal
1. Remove the corresponding front cover:
● Front right pinch cover (K4T88-67085) on page 1208.
● Front left pinch cover (K4T88-67086) on page 1210.
● Front center pinch cover (K4T88-67087) on page 1212.

3. Remove the pinch assembly.
Installation
1. Move the pinch assembly so that it fits with the cover.

2. Place the cover on correctly.
3. Be careful with the flange.
Installation
Pinch switch assembly (K4T88-67089)

Removal

2. Open the pinch.
3. Location of the Pinch switch assembly:
NOTE: Remove 1 switch ( depending on the switch damaged).

4. Disconnect the switch cable.
6. Remove the switch with its support plate.

7. Unscrew the 2 switch screws.
8. Remove the switch from the support plate.
Installation
1. Install the new pinch switch.
2. Screw back the pinch switch assembly to the clamp retainer.
3. Route the switch cable, ensuring that it will not get pinched by the pinch assembly, but leaving enough free
(looped) to open the pinch assembly without interference.
4. Connect the switch cable and the pinch switch assembly.
5. Perform the safety interlock diagnostic. See Table 5-2 Safety interlocks on page 545.
Center pinch protector plate (K4T88-67190)

Removal

3. Remove the pinch protector handle.
Installation
1. Place pins correctly.
Left pinch protector plate (K4T88-67191)

Removal

3. Remove left pinch protector plate.
Installation
1. Place the pins correctly.
Right pinch protector plate (K4T88-67192)

Removal

3. Remove right pinch protector plate.
Installation
1. Place pins correctly.
Pinch protector handle (K4T88-67193)

Removal
1. Remove the center pinch protector plate. See Center pinch protector plate (K4T88-67190) on page 1219.

2. Unscrew 4 handle screws.
3. Remove pinch protector handle.
Installation
Middle pinch protector bracket (K4T88-67194)

Removal
1. Set PPS up.
2. Remove the corresponding pinch protector. See Right pinch protector plate (K4T88-67192) on page 1221.

3. Open the pinch.

5. Remove the middle pinch protector bracket.
Installation
1. Be careful to put the square nuts on correctly before assembling.
2. The best way is to insert the black screws into the square nuts without tightening, then set the cover in
position, and tighten the screws.

3. This is the wrong direction to enter from:
Pinch torsion springs (K4T88-67261)

Removal
1. Set PPS up.
3. Remove 2 screws from right and left retainers.

4. Open the pinch.
6. Remove the rear right cover. See Rear right cover (K4T88-67155) on page 956.
7. Unscrew the central screw that fixes the right hand shaft to the right hand sideplate using the L-Key.

8. Unscrew the 6 screws that fix the left hand shaft to the left hand bracket.
9. Unscrew the 6 screws that fix the right hand bracket to the right hand spring shaft.
10. Remove the shaft through the left hand bracket (2 people needed ).

12. Put the pinch assembly onto a plain flat surface of 4 meters.
Installation
NOTE: When installing right and left retainer, tighten the screw so that it is touching the spring.

Pinch complete assembly (K4T88-67254)

Removal
1. Set PPS up.
3. Remove 2 screws from right and left retainers.

4. Open the pinch.
5. Unscrews 3 screws and remove the interlock.
6. Remove the rear right cover. See Rear right cover (K4T88-67155) on page 956.
7. Unscrew the central screw that fixes the right hand shaft to the right hand sideplate using the L-Key.

8. Unscrew the 6 screws that fix the left hand shaft to the left hand bracket.
9. Unscrew the 6 screws that fix the right hand bracket to the right hand spring shaft.
10. Remove the shaft through the left hand bracket (2 people needed ).

12. Put the pinch assembly onto a plain flat surface of 4 meters.
Installation
NOTE: When installing right and left retainer, tighten the screw so that it is touching the spring.

Loading table shock absorber (K4T88-67300)

Right side
Removal
3. Remove the plate with absorber.
Installation
Left side
Removal

2. Unscrew 1 screw with the L-Key.
3. Remove the absorber.
Installation
LY safety interlock pinch (K4T88-67294)

Removal

2. Open the pinch.
NOTE: Only in the user side.
3. Unscrew the interlock screw.
4. Open the interlock.
5. Disconnect the cables, removing the screws.
6. Unroute the cables.

7. Unscrew the 2 interlock screws.
Installation
MI/MO motor (K4T88-67144)

MI motor
Removal

5. Open the E-box.
6. Disconnect the MI motor power, data, and encoder cables.
CAUTION: Do not disconnect the encoder cable by pulling the cable because it will break the connector.
Hold the connector of the encoder cable when removing it.

7. Remove the 4 Allen screws that hold the MI motor.
9. Remove the motor gear.
Installation

MO motor
Removal
4. Remove the outside Front left cover (K4T88-00197).

5. Disconnect the MO motor power, data, and encoder cables.
6. Remove the 4 metal part screws.
7. Disconnect the metal part.

8. Remove the 4 Allen screws from behind that hold the MO motor.
10. Remove the motor gear.
Installation
Motorized MI side plate (K4T88-67145)

Removal
1. Remove the MI motor. See MI/MO motor (K4T88-67144) on page 1237.

2. Remove 2 pointed screws.
3. Remove five Allen screws.
4. Remove the side plate.
Installation

Left MI side plate (K4T88-67146)

Removal
4. Remove the two pointed screws that hold the left MI side plate to the rear left pillar.
5. Remove the five Allen screws that hold the left MI side plate to the structure.
6. Remove the left MI side plate.

Installation
Motorized MO side plate (K4T88-67148)

Removal
1. Remove the MO motor. See MI/MO motor (K4T88-67144) on page 1237.
2. Remove the MO spindle from the MO spindle plates. See Hdrs Single roll spindle (CZ056-67462)
on page 1005.
3. Remove 2 screws.
4. Remove the inside front right down cover (K4T88-00195). Pay attention to the pins.

5. Remove 2 screws.
6. Remove the inside front right up cover (K4T88-00196). Pay attention to the pins.
7. Remove the 4 Allen screws.

8. Remove the motorized MO side plate.
Installation
Left MO side plate (K4T88-67149)

Removal
3. Remove the MO spindle from the MO spindle plates. See Hdrs Single roll spindle (CZ056-67462)
on page 1005.
4. Remove the 6 pointed screws that hold the left MO left side plate to the rear left pillar.

5. Remove the 4 Allen screws that hold the MO left support spindle plate to the structure.
6. Remove the Left MO side plate.
Installation
MO transmission box (K4T88-67150)

Removal
1. Remove the MO motor. See MI/MO motor (K4T88-67144) on page 1237.

3. Remove the four Allen screws from the front side.
4. Remove three Allen screws..
5. Remove the MO transmission box.
Installation
MI MO gears upgrade and spindles (K4T88-67151)

Kit contents:
● 2 sets for each roll spindle:

– Gear (stronger and 2 mm wider)
– End cap (2 mm less wide)
– C-clip
● Gear extraction tool for spindles
● 1 piece of sand paper
● 1 small tube of 35mm length, internal diameter ~ 35mm, thickness ~ 3mm
Procedure:
● For each spindle, replace gear + end cap
Process to dismount and mount the roll gear wheel and end cap
Tool required (provided with the corresponding support parts):
● Gear extraction tool for roll spindles
● 1 piece of sand paper
● 1 small tube of 35mm length, internal diameter ~ 35mm, thickness ~ 3mm
Dismount the end cap and gear from the spindle
1. Extract the roll spindles from the printer.
2. Place the gear wheel side in an elevated position.

3. Extract the C-clip
4. Extract the endcap. If necessary you can use the gear wheel extractor.
5. Use the gear wheel extractor to remove the gear wheel.
Mount the gear wheel
1. If necessary use sandpaper for 5 min. in order to increase the diameter and size of the key slot, in order to
help to mount the gear. The same could be done on the end cap.

One small piece of sandpaper is provided with the upgrade kit. But in case it is not enough, you can use a
similar sandpaper.
2. In case the black gear is not well positioned, (mainly when placing the end cap, and without being able to
place the C-clip), steps 3 to 8 have to be performed. If not go to step 9.
3. The reason that in some cases the gear can not be well placed:
4. The axis onto which the gear is slided can have slack. When placing the gear, it is important that there is no
slack, if there is, it is not possible to place the C-clip The picture below shows the 2 possible axis positions,
with the gear also in 2 different positions:
In the upper picture, with the finger just pushing the gear towards the right.
On the lower picture, with the finger, just pushing the gear towards the left. In some cases, there is slack
when moving this gear right and left as the axis can have slack at around 2 mm.
It is important to place the gear against the right journal, so that there is no more space, even when moving
the gear towards the right. In order to do that:

5. A small steel cylinder has been provided within the kit. Here is a sample:
6. Push the gear as much as possible towards the left against the right journal.
7. Place the cylinder as shown in the picture below, pushing with the fingers towards the right, that there is
space coming from the slack, between the gear and the right journal.
So as to not damage your fingers, do not place them between the gear space and right journal. Here are 2
examples:
Good/Bad position:

8. Once the fingers are in place, hit the other part of the cylinder with a hammer to place the gear on the axis.
In case it has not be well inserted, re-perform the step using sandpaper to increase the inner diameter of
the gear, and also the part where the key is inserted.
9. If necessary, insert the end cap following steps 10 to 11. If not, go to step 12.

10. Use sandpaper to help insert it.
11. You can also use a screwdriver to fix the shaft, and hit the end cap with a nylon hammer. Here is the correct
position of the flat screw driver:
While pushing towards the spindle with the end of the screwdriver (the side maintained by the hand), in
order to push towards the middle of the spindle, the gear, and the end caps, hit slightly around the end cap
with a nylon hammer. Below is a picture showing arrows where to hit.
Apply pressure on the screwdriver to push the end cap towards the center of the spindle.

12. Insert the C-clip.
13. Put the rolls back into the printer.
MI motor data cable (K4T88-67242)

MI motor power cable kit (K4T88-67243)

MO motor encoder cable (K4T88-67244)

MO motor data cable (K4T88-67245)

MO motor power cable kit (K4T88-67246)

MI resistors power cable (K4T88-67247)

MO resistors power cable (K4T88-67248)

Spindle latch type A (Q6702-60468)

Removal
3. Follow the steps below for either the MI right spindle latch or the MO left spindle latch.

Removing the MI right spindle latch
5. Remove the latch lever pivot sufficiently that the latch lever can be replaced with the new one.
Removing the MO left spindle latch

2. Remove the Outside front left cover (K4T88-003311). Pay attention to the pins.

6. Remove the latch lever pivot sufficiently that the latch lever can be replaced with the new one.
Installation
ends with the circlips.

OMAS and vacuum PCA (CZ056-67321)

Removal
1. Unload the substrate so that it is easy to reach the vacuum control PCA and the OMAS controller PCA.
3. Remove the three T-10 from the OMAS cable cover.
4. Remove the OMAS cable cover.
5. Disconnect the cables from the vacuum control PCA.

6. Remove 7 screws.
8. Disconnect the pipe.

9. Remove 3 screws.
10. Remove the OMAS PCA.
Installation
Vacuum pump and pipe (K4T88-67141)

Removal
2. Remove the Printhead cleaner waste bottle. See Printhead cleaner waste bottle (Q6702-60685)
on page 1142.

3. Loosen 2 screws (if necessary, remove the Printhead cleaning roll).
4. Remove the waste management parts.
5. Loosen the pipe clamp.

6. Remove the vacuum pipe.
7. Remove one spindle for a better access. See Hdrs Single roll spindle (CZ056-67462) on page 1005.
8. Remove 6 screws from the sidewall output.

10. Disconnect the 2 pump cables.
12. Open the E-box.

13. Remove the 4 pump screws (beware with the nuts and washers).
14. Remove the pump.
Installation
Vacuum pipe (K4T88-67142)

Removal
2. Remove the Printhead cleaner waste bottle. See Printhead cleaner waste bottle (Q6702-60685)
on page 1142.

5. Remove one spindle for a better access. See Hdrs Single roll spindle (CZ056-67462) on page 1005.

Installation
1. Install the new vacuum pipe.
2. Secure the blower inlet connector to the blower and the sidewall output to the beam.
Vacuum support (K4T88-67143)

Removal
2. Remove the Vacuum pump and pipe. See Vacuum pump and pipe (K4T88-67141) on page 1262.
3. Remove the two support screws at the rear.

4. Remove the two support screws at the front.
5. Remove the vacuum support.
Installation
Vacuum pump cable kit (K4T88-67238)

Diverter module (CZ056-67433)

Diverter top module
Removal

4. Open both curing-module assembly latches.
6. Locate the diverter module that needs to be replaced.
7. Remove all the diverter module wheels.
8. Remove the two T-10 screws that hold the diverter module adaptor.
TIP: If you cannot free the diverter module adaptor because there is not enough clearance, you can
remove the wheels and the two T-10 screws that hold the following diverter module.
9. Unclip and remove the diverter module adaptor from the diverter metal sheet base.
NOTE: The top diverter metal sheet base is an structural part. If you need to replace it, you must first
remove the curing bottom plate, in order to reach all the screws that hold the top diverter metal sheet
base.
Installation
1. Clip the diverter module adaptor to the diverter metal sheet base.
2. Install the diverter wheels back onto the diverter module adaptor.

3. Screw the diverter module adaptor to the diverter metal sheet base.
NOTE: The leftmost diverter adaptor is screwed only at its right upper hole. Moving on to the right, the
diverter top module adaptors are screwed alternately at the outer and inner upper holes.
Diverter bottom module
Removal
4. Open both curing-module assembly latches.

6. Locate the diverter module that needs to be replaced.
7. Remove all the diverter module wheels.
8. Remove the four T-10 screws that hold the diverter module adaptor.
TIP: If you cannot free the diverter module adaptor because there is not enough clearance, you can
remove the wheels and the four T-10 screws that hold the following diverter module.
9. Unclip and remove the diverter module adaptor from the diverter metal sheet base.
Installation
1. Clip the diverter module adaptor to the diverter metal sheet base.
2. Install the diverter wheels back onto the diverter module adaptor.
3. Screw the diverter module adaptor to the diverter metal sheet base.
NOTE: The leftmost diverter adaptor is screwed only at its right upper hole. Moving on to the right, the
diverter bottom module adaptors are screwed alternately at the outer and inner upper holes.
Diverter assembly (K4T88-67135)

Includes one unit of each diverter metal sheet base and eight units of either top or bottom diverter.

Diverter wheel parts (K4T88-67134)

Removal
2. Open the window.
3. Remove the diverter wheel using a flat screwdriver.
IMPORTANT: For the first and second lines of the platen diverter wheels, remove first the lateral right
sheet metal part and start removing the diverter wheels from the right side to the left side. In between
washers do not allow lateral movement.
Installation

Tube Routing System (TRS)

TRS barnacle (K4T88-67054)
Removal
5. Remove the Ink system module.
6. Cut the tube at the input and at the output of the valve.
7. Unclip the valve by rotating it counterclockwise.
Installation
1. Clip the new valve.
2. Connect the new barnacle ink tubes to the ink tubes that come from the Igus Chain and the ISM.
3. Install the air purgers provided and refill the tubes using the manual purging.
TRS eChain (K4T88-67058)

Removal

7. Once all the tubes are empty of ink, cut the tube (after the connector but close to it, as it is shown on the
images).
NOTE: Use the cutting tool to cut the ink tubes.
8. Disconnect the Data and Power cables from the Electronics.
9. Unroute the Data and Power cables from the printer.
10. Untighten the two screws that secure the Igus chain to the Carriage tower.
ENWW Tube Routing System (TRS) 1275

11. Untighten the two screws that secure the Igus chain to the TRS tray.
12. Remove the Igus chain with all tubes and cables from the printer.
Installation
1. Place the new TRS chain on the tray of the printer.
2. Secure the Igus chain to the tray with two screws.
3. Secure the Igus chain to the Carriage tower.
4. Connect the ink tubes ensuring all color labels are connected to each corresponding ink line.
5. Route and connect the Data and Power cables to the Electronics. Follow the routing instructions described
on Installation on page 1279.
6. Purge the ink lines using purge diagnostic.
TRS FI tower assembly with holders (K4T88-67311)

Check if you have the new or the old Pen pocket configuration. You can differentiate them looking at the latches,
see the image below:

Removal before purging
3. Remove all printheads from the carriage and store them in their caps.
4. Remove the five pointed screws and the carriage-tower cover.
NOTE: Before replacing the PT FI tower assembly, you are recommended to remove the printhead
interconnect PCA assembly, to give free access to the FI tower assembly screws.
5. Remove one T-10 screw from the FI holder.
NOTE: There are 2 screws in the new Pen pocket configuration.
6. Carefully disassemble the FI cover.

7. The FI cover has two snap-fit parts.
Installation
NOTE: If you change all 4 colors, the correct order to install is C/K, Y/M and LC/LM, in order to arrange the
tubes correctly.
TRS Fiber-optics trailing cable (K4T88-67056)

Removal
5. Remove the printheads
7. Remove the 2 screws that secure the lid of the tubes clamps to the Igus chain.

8. Remove the 2 screws that secure the Igus chain to the Carriage tower.
9. Unclip all the Igus lids.
10. Remove the Slinky PCA from the Carriage tower.
11. Disconnect the Fiber-optics cable from the Slinky PCA.
12. Remove the Fiber-optics cable from the Igus chain.
13. Unroute the Fiber-optics cable from the printer.
Installation
1. Connect the fiber-optics cable to the E-box connector (fiber-optics PCA J18).

2. Route the fiber-optics cable through the E-box sheet and face using ties.
NOTE: Check the angle movement and the cable tensions:
3. Route the fiber-optics cable through the hooks and ties in the structure.

NOTE: Fix the cable on the structure with a tie:

4. Route the fiber-optics cable through the chain.
NOTE: Test that the curvature angle of the cable is equal to or more than 30°:
5. Connect the fiber-optics cable to the Carriage connector (fiber-optics PCA J18).
TRS Power cable 42V (K4T88-67066)

Removal
5. Remove the printheads

7. Remove the 2 screws that secure the lid of the tubes clamps to the Igus chain.
8. Remove the 2 screws that secure the Igus chain to the Carriage tower.
9. Unclip all the Igus lids.
10. Place aside the Fiber-optics cable from the Igus chain to prevent any possible damage.
11. Disconnect the Power cable from the Carriage electronics PCA.
12. Lift up a little bit the tubes separators from the Igus chain to be able to remove the Power cable from there.
13. Unroute the Power cable from the printer.

TRS Tube shelf (K4T88-67057)

Removal
2. Remove the back cover of the printer.
3. If the tray that needs to be replaced is the one the Igus chain is secured to, untighten the two screws that
secure the chain to the tray. Once done, continue with the process.
4. Untighten the 4 screws of the tray that needs to be replaced.
TRS tubes repair (K4T88-67055)

This kit contains elbows, reducers and fittings. The purpose of this kit is to repair any tube needed..

Vapor removal
Vapor removal fan (CZ056-67379)
Removal
3. Disconnect the cable of the damaged fan.
4. Unhook the cable from the 2 hooks.
5. Remove the four top screws from the fan using a Phillips screwdriver.

6. Remove the fan metal grating.
7. Remove the bottom screws through the holes.
8. Remove the fan.
Installation

Vapor removal counterflow heat exchanger (K4T88-67102)

Removal
2. Separate a little bit the IDS module (only until step 19). See How to separate the Ink System Module
on page 1007.
4. Unhook the cable. Don't cut the tie, there is a clip to open it. .
5. Disconnect the cables of the four Vapor removal fans.
6. Unroute the cables of the Vapor removal fans from the hooks.

7. Remove 2 screws.
8. Remove 2 screws.
9. Remove 1 screws.

12. Remove these 3 parts together (fan collector, heat exchanger and inlet collector).

14. Remove the Counterflow heat exchanger .
Installation
Vapor removal fan collector (K4T88-67103)

Removal
on page 1007.


7. Remove 2 screws.
8. Remove 2 screws.
9. Remove 1 screws.


14. Remove the fan collector.
Installation
Vapor removal inlet collector (K4T88-67104)

Removal
on page 1007.


7. Remove 2 screws.
8. Remove 2 screws.
9. Remove 1 screws.


14. Remove the inlet collector.
Installation
Vapor removal dirt collector (K4T88-67106)

Removal
2. Remove the VR waste container. See Vapor removal waste container (K4T88-67099) on page 1312.

3. Remove 3 screws.
4. Remove the dirt collector.
Installation
Vapor removal drain tubes parts (K4T88-67098)

Removal

3. Disconnect the two tubes.
IMPORTANT: The 90 degrees tube is no longer available. It is not needed anymore.
4. Loosen the two value plastic fittings to remove them.
5. Disconnect one tube.

6. Release the drain tube from the three clamps and remove it.
7. Loosen the value plastic fitting to remove it.
Installation
Vapor removal output box w foams (K4T88-67097)

This pieces are not attached, they just go together.
Removal
2. Remove the Front left cover. See Front left cover (K4T88-67152) on page 944 (steps 9 and 10 are not
necessary).

4. Disconnect the pipe from the Vapor removal diverter box.
5. Remove 1 screw.

6. Remove 2 screws.
7. Remove the Vapor removal diverter box.
8. Remove 4 screws.

9. Remove the Vapor removal motion box curing.
Installation
Vapor removal PCA (K4T88-67069)

Removal

4. Remove 6 screws from the cover.
6. Remove 8 screws from the PCA.

7. Remove the VR PCA.
Installation
Vapor removal silencer box (K4T88-67100)

Removal
4. Remove the Back left corner. See Back left corner (K4T88-67164) on page 979.

6. Unroute the cable from the clamps.
7. Open the bridle to leave the cable free.
NOTE: Do not cut the bridle.
8. Disconnect the drain tube.

10. Disconnect the top part of the link pipe.

12. Disconnect the bottom part of the exit pipe.
13. Remove 2 screws from the metallic supports.
14. Remove 2 screws, holding the Silencer box with one hand.

15. Remove the Silencer box with the pump.
17. Remove 2 nuts.

18. Remove the pump (there are 2 pins).
19. Remove 2 screws and the metal part.
20. Remove the screws and cables of the filter.
Installation

Vapor removal waste container (K4T88-67099)

Removal
2. Unlock the Left back door (K4T88-67165).
3. Open the Left back door (K4T88-67165).
4. Remove the VR waste container.
Installation
▲ Reverse the removal process. Check that the tube is aligned with the VR waste container properly (the
bottle tap hole is looking to the inside of the machine like in the picture).

Vapor removal outlet collector (K4T88-67105)

Removal
on page 1007.

7. Remove 2 screws.
8. Remove 2 screws.

9. Remove 1 screws.

13. Remove the VR link pipe. See Vapor removal link pipe (K4T88-67093) on page 1323.
14. Remove the Back left corner. See Back left corner (K4T88-67164) on page 979.
15. Remove the Back left door. See Back left door (K4T88-67165) on page 980.
16. Disconnect the two drain tubes.

20. Remove the two metal retainers.

21. Remove the outlet collector turning it a bit to be able to pass it through the left structure.
Installation
Vapor removal interconnect kit (K4T88-67249)

Vapor removal cable kit (K4T88-67250)

Vapor removal exit pipe (K4T88-67091)

Removal
2. Remove the Left rotomolding (in order to have the back cover, the side cover and the front cover out in the
left side). See Left rotomolding (K4T88-67171) on page 985.
3. Remove 4 screws.

4. Remove the aerosol pipe.
5. Remove 6 screws.
6. Remove the 5 in hose connector.
Installation

Vapor removal inlet pipe (K4T88-67092)

Removal
2. Remove the Front left cover (K4T88–67152). See Front left cover (K4T88-67152) on page 944 (until step
07).
6. Disconnect the pipe from the vapor removal inlet collector.

8. Disconnect the pipe from the Vapor removal diverter box.
9. Remove the pipe.

10. Remove 5 screws from the hose connector.
11. Remove the hose connector.
12. Remove 5 screws from the hose connector.

13. Remove the hose connector.
Installation
Vapor removal link pipe (K4T88-67093)

Removal
1. Turn of the printer and the power-enable switch
4. Loosen the pipe bracket.

5. Remove 4 screws.
6. Do not loosen the two screws marked with a red circle.
7. Remove the VR link pipe.
Installation
Vapor removal pump (K4T88-67096)

Removal

2. Remove the VR silencer box. See Vapor removal silencer box (K4T88-67100) on page 1306.
3. Remove the pump and the filter.
Installation

Platen lights
Pz LED lights (K4T88-67196)
Removal
2. Open the window.
4. Remove the lamp manually.
5. Remove the attaching parts.
Installation

Uptime and maintenance kits

HP Latex 1500 Onsite basic uptime kit (V8L81A)
● CZ056-67050: Web wipe roll free hub SERV (x1).
● CZ056-67073: ISM intermediate tank SERV (x1).
● CZ056-67137: E-cabinet fan filter SERV (x1).
● CZ056-67433: Diverter module SERV (x1).
● 1HA07-67018: TH Primer and latch SVC (x1).
● K4T88-67052: SOL shutter SERV (x1).
● K4T88-67073: Service station cap assy (x1).
● K4T88-67116: WW Printhead cleaning blade (x1).
● K4T88-67209: E-cabinet PCA fuses SRV (x1).
● V8A82A: HP Latex 1500 edge holder kit (x1).
HP Latex 1500 Cleaning kit (K4T88-67255)

● Filter unit for 4.69 inch fan (x6).
● Lubricant-grease off-white.
● Gloves medium/large wht nat-rb (x24).
● Cleaning brush.
● Sponge/bag assy (x24).
● Blister for CAL User Maintenance.
● GW Lubricant oil bottle assy.
● Cleaner assy.
● Cleaning stick.
● Rod lubrication (x2 left + x2 right).
● PFA3145 Drying fan filter.
● Torx 8 wrench.
● Grease syringe 3 cc.
HP Latex 1500 Expert user kit (K4T88-67257)

● 1HA06-67002: PH Interconnect color PCA SVC (x1).
● 1HA06-67003: PH Interconnect optimizer PCA (x1).
● 1HA07-67038: Curing heater and fan - long_c (x1).
ENWW Uptime and maintenance kits 1327

● CZ056-67321: OMAS and Vacuum PCA SERV (x1).
● K4G10-67094: Spindle Spring Air Valve SERV (x1).
● K4G10-67122: Side Curing sealing rubber SRV (x1).
● K4T88-67005: SOL SERV (x1).
● K4T88-67011: Carriage oiling felts SERV (x1).
● K4T88-67021: Belt installation tool SERV (x1).
● K4T88-67025: IDS air pump and relief valve (x1).
● K4T88-67051: Scan axis bump SERV (x1).
● K4T88-67107: Drying heater and fan (x1).
● K4T88-67109: Drying diffuser (x1).
● K4T88-67306: Impelling belt assy SERV (x1).
● K4T88-67311: FI Holders and Towers (x1).
HP Latex 1500 Service maintenance kit (3000L) (K4T88-67260)

● 1HA07-67018: TH Primer and latch SVC (x1).
● CZ056-67190: Motor DRV PCA SERV (x1).
● CZ056-67228: Media drive roller transmission (x1).
● CZ056-67433: Diverter module SERV (x1).
● K4G10-67122: Side curing sealing rubber SRV (x1).
● K4G10-67094: Spindle spring air valve SERV (x1).
● K4G10-67122: Side curing sealing rubber.SERV (x1).
● K4T88-67008: Carriage bearings. SERV (x1).
● K4T88-67058: TRS eChain SERV (x1).
● K4T88-67073: Service station cap assy (x1).
● K4T88-67088: Pinch assembly (x3).
● K4T88-67093: VR link pipe (x1).
● K4T88-67137: OMAS platen assembly (x1).
● K4T88-67151: MI MO gears upgrade & spindles (x1).
● Q6702-60546: Machine grease & oil kit SERV (x1).

HP Latex 1500 Printer maintenance (K4T88-67259)

● CZ056-67433: Diverter module.
● K4T88-67011: Carriage oiling felts (x2 left + x2 right).
● K4T88-67040: ISM 7x intermediate tanks.
● K4T88-67116: WW Printhead cleaning blade.
● K4T88-67255: HP Latex 1500 Cleaning kit.
HP Latex 1500 Reseller kit (K4T88-67258)

● CZ056-00855: Carriage box (x1).
● CZ056-67190: Motor DRV PCA SERV (x4).
● CZ056-67373: Carriage interconnect PCA SERV (x1).
● CZ056-67384: Curing and Vapor removal PCA S (x1).
● CZ056-67389: Fiber-optics PCA SERV (x1).
● CZ056-67475: Engine PCA for AM v2 SERV (x1).
● 1HA06-67002: PH Interconnect color PCA SVC (x1).
● 1HA06-67003: PH Interconnect optimizer PCA (x1).
● K4T88-00995: PALLET_860x1010x114 (x1).
● K4T88-67007: Carriage cables SERV (x1).
● K4T88-67018: IDS PIP assy SERV (x1).
● K4T88-67036: IDS ink PCA SERV (x1).
● K4T88-67037: IDS air PCA SERV (x1).
● K4T88-67043: Impelling motor SERV (x1).
● K4T88-67044: Impelling encoder strip SERV (x1).
● K4T88-67055: TRS Tubes repair SERV (x1).
● K4T88-67082: Drop detector sensors (x1).
● K4T88-67083: Drop detector PCA (x1).
● K4T88-67137: OMAS platen assembly (x1).
● K4T88-67144: MI/MO motor SERV (x1).
● K4T88-67151: MI MO gears upgrade & spindles (x1).
● K4T88-67268: E-box HDD SERV (x1).
● K4T88-67288: E-cabinet PCA SERV (x1).
ENWW Uptime and maintenance kits 1329

● K4T88-67289: IDS purge SERV (x1).
● K4T88-67133: Fan curing PCA w/laquer SERV (x1).

Double sided day and night kit (P4P91A) – (Accessory)

Front light assy (K4G10-67047)
Removal
1. Remove the Front-light cable cover (J8J14-00009) on the right end of the universal mounting beam.
2. Disconnect the LED strip connector on the right side of the substrate output side.
3. Remove the LED modules, if you need help to open the brackets you can use pliers.
ENWW Double sided day and night kit (P4P91A) – (Accessory) 1331
4. Remove the universal mounting beam end cover, and slide off the front-light brackets (J8J14-00001).
Installation
1. Remove the cover at the end of the universal mounting beam, so that you can place the brackets on the
bottom of the beam.
2. Before placing the brackets (J8J14-00001), preinstall the clips.

3. Place the clips with screws and washers on the outer side of the universal mounting beam, as shown
below.
4. Slide them until they are aligned with the back light brackets, and fix them into place. Only the body of the
bracket should be inside the beam guides; screws and washers should remain outside.
5. Once the eight front-light brackets are installed, place the cover on the end of the universal mounting
beam.
6. Place the LED modules on the clips, and connect each two aligned. Ensure that the LED strip connectors
are on the right side of the substrate output side. Use pliers if you need to make easier the installation.
7. Assemble the Front-light cable cover (J8J14-00009) on the right end of the universal mounting beam.
Back light assy (K4G10-67048)

Removal
1. Turn off the printer and power-enable switch.
2. Disconnect the LED strip connector on the right side of the substrate output side.

3. Remove the LED modules, if you need help to open the brackets you can use pliers.
4. Remove the back-light brackets (J8J14-00002) from the printer, first the bottom screw and then the top
screw (0515-4862).
Installation
1. Attach the back-light brackets (J8J14-00002) to the printer, first with the top screws and then with the
bottom screw (0515-4862). The longest end of the bracket should be at the bottom.
2. Place the LED module. Ensure that the LED connectors are on the right of the substrate output side.
3. Connect the cables to the LED Modules
Line sensor (K4T88-67004)

Removal
1. Ensure that the carriage is in service position and remove the cover.

2. Extract the Line sensor as shown below, remove it to the left outside of the carriage.
3. Disconnect the cable end from the carriage connector as shown below.
Installation
1. Ensure that the carriage is in service position.
2. Connect the cable, K4T88-50009 (D&N) or K4T88-50162 (printer).
a. Open the clip.

b. Insert one end of the cable (it doesn’t matter which end). Ensure that the connectors are in contact
with the pins.
c. Close the clip.

4. Insert the Line sensor as shown below; only one position is allowed. Attach it from the outside left of the
carriage.
5. Take the other cable ends and connect them on the other side of the carriage, as shown below. Follow the
same process as before. Once installed, route the cable. Make sure the ferrites are inserted on the routing
clip.
6. Install the cover again.
D&N e-cabinet (P4P91-67002)

Removal
1. Unscrew the two 0515-0386 screws to remove the e-cabinet from the printer

2. On the e-cabinet right side, remove the support part and save it for the new e-cabinet.
3. Extract the e-cabinet and disconnect the power cable at the back of the e-cabinet.
Installation
1. Before placing the e-cabinet onto the structure, connect the power cable at the back of the e-cabinet and
route it between the computer and the e-cabinet to reach the power socket beside the e-cabinet.
2. Insert the e-cabinet and attach it to the structure with the 0515-0386 screws using a Torx 25 screwdriver.
3. Sort out the cables already connected to the printer.
4. On the e-cabinet right side, remove the two existing screws and use them to attach the support part.

5. Attach the e-cabinet to the printer with two 0515-0386 screws as shown below
Platen lights (P4P91-67003) & D&N ramp (P4P91-67007)

Removal
1. Remove the diffuser, you can start at either side.
2. Remove the extra platen module at each side of the platen. You will need to remove six screws with the
Torx 10 screwdriver. Remove and disconnect the cable at each side.

3. Remove the LED array profile and the DSDN ramps using a Torx 10 screwdriver. When removing the platen
light assembly, be careful not to touch the strip encoder.
Installation
1. Look for the two-LED arrays (which are already assembled) on the profiles (P4P91-60018 and
P4P91-60019) and 4 DSDN ramps (K4T88-01005).

2. Go to the input side of the printer, on the right. Install the profile with the positioner on one end. Place the
LED profile between the main roller and the platen. Install the DSDN ramps at the same time as the LED
profiles, placing them between the LED profile and the safety cover.
Place the module that has the positioner on the left at the right of the printer.
Install the LED support in the correct position. The LEDs must point to the platen and carriage, not to the
drive roller and scan structure.
3. Attach the LED array profile and the DSDN ramps with four 0515-4880 screws, using a Torx 10 screwdriver.
When attaching the platen light assembly, be careful not to touch the strip encoder.
4. In the same way, place and attach the other module at the left of the printer.
5. When you have attached both profiles, remove the extra platen module at each side of the platen (if you
didn’t remove before during the removal). You will need to remove six screws with the Torx 10 screwdriver.
6. Route the cable as shown below.
7. Reinstall the platen modules that you just removed.

8. Ensure that the cable is placed as shown at the end of the platen.
9. Install the diffuser as shown below, lifting it through the two assembled LED mounts. You can start at
either side. The diffuser should be installed into the corresponding groove in the LED array profile. When
installing the diffuser, take care not to dirty it with grease from the scan axis beam. If it gets dirty, clean it
with alcohol before installing it.
D&N protector (P4P91-67004)

Removal
1. Remove the blue rib cover.
2. Slide the protector through the old rib.
Installation
1. Remove the blue rib cover (if you didn’t remove before during removal).

2. Slide the protector through the new rib.
3. Install the blue rib cover again.
4. Six P4P91-40005 units are provided in this service kit: use the new ones to hold the protector with the Lyra
platen, and scrap the old ones.
MEH standard and D&N sliders (P4P91-67006)

Removal
1. Unclip the D&N Sliders from the D&N MEH Strip as shown in pictures below.

2. Unclip de Standard Sliders from the MEH Strip as shown in pictures below.
Installation
▲ Installation is opposite to the removal procedure.
Motor DRV PCA (CZ056-67190)

Removal
1. You are recommended to remove the spindles.

2. Disconnect the LAN cable from the Motor Drive PCA 317.
3. Remove the old Motor Drive PCA (317) with two 0515-4862 screws.
Installation
1. You are recommended to remove the spindles.
2. Install the new motor PCA.
a. Locate the stand on the input side of the printer and remove the cover to access the cables and Motor
Drive PCAs.
b. Position the new Motor Drive PCA (317) near to the Motor Drive PCA (316) as shown below, and attach
it with two 0515-4862 screws using the existing holes.
3. Remove the terminator from the Motor Drive PCA 316.
4. Connect the LAN Cable from the Motor Drive PCA 316 to the Motor Drive 317. Connect the terminator to the
middle connector of the Motor Drive PCA.
5. Connect and route the cables following the cable instructions
D&N button (K4T88-67195)

Removal
1. Open the latches and the curing module.

2. Disconnect the cable (K4T88-50244, labeled as D&N LED) from the button.
3. Remove the button.
4. Close the curing module and the curing module latches.
Installation
1. Open the latches and the curing module.
2. Remove the hole cover.
3. Add a new sticker beside the hole for the new button.

4. Remove the washer from the button.
5. Place the button, routing the cable through the hole.
NOTE: Use the button provided without LED.
6. Connect the cable (K4T88-50244, labeled as D&N LED) to the button.
7. Close the curing module and the curing module latches.

Forklift (K4T88-67290) – (Accessory)
Removal
1. Ensure that the printer is not printing, and turned off in the correct way for maintenance operations.
2. Reverse the installation instructions shown below.
IMPORTANT: Make sure that you leave the six screws tightened, they are needed to support the vacuum.
Installation
1. Ensure that the printer is not printing, and turned off in the correct way for maintenance operations.
ENWW Forklift (K4T88-67290) – (Accessory) 1363

2. Remove 6 screws.
3. Place the accessory.
4. Insert the 3 top left screws.

5. Insert the 3 top right screws.
6. Place the lower part and fix it with 4 screws on the left.
7. Insert 4 screws on the right.
ENWW Forklift (K4T88-67290) – (Accessory) 1365

Dual roll kit (T0F91A) – (Accessory)

Spindle journal (CZ056-67238)
Removal
1. Remove the affected spindle.
2. Using an Allen key #10 or Torx bit, remove the 4 flat head screws M6x25 that fix the Journal left to the
spindle.
3. The journal left has a slot for placing a screwdriver to pry it open shown below.
4. Lever with a screwdriver, preferably a flat one, until the Journal moves away from the spindle.

5. Continue until the Journal can be removed by hand, normally once the first two O-rings have been
released.
6. Remove the journal from the spindle and check the status of the O-rings. If you notice that some of them
are tweaked or damaged proceed to change them.
Installation
Spindle ruler labels (CZ056-67243)

Removal
▲ Remove the two ruler labels, use a cutter to peel the label if it is necessary.
ENWW Dual roll kit (T0F91A) – (Accessory) 1367

Installation
▲ Paste the new ruler labels, line up the label with the end of the spindle.
Spindle differential cover (CZ056-67244)

Removal
▲ Remove the twelve M2.5 screws and remove the four covers from the differential assembly.

Installation
Spindle gear Hrds (CZ056-67459)

See MI MO gears upgrade and spindles (K4T88-67151) on page 1249.
Dual roll spindle Hrds (CZ056-67461)

Removal
1. Open the IPS and IDS latches.
2. Remove the Dual Roll Spindle.
Installation

Spindle spring air valve (K4G10-67094)

See Spindle air valve (K4G10-67094) on page 1181.
Center support & shims (K4T88-67298)

Removal
▲ Scrap the old Intermediate supports and shims.
Installation
NOTE: There are two dual-roll center supports. The support base marked “I” is for the input dual-roll spindle at
the rear of the printer. Use the longer support shaft with the support base marked “I”. The support base marked
“O” is for the output dual-roll spindle at the front. Use the shorter support shaft with this support base.
1. To assemble the input dual-roll center support (marked I), insert the top shaft into the support base and
turn.
2. Remove the screw in the support base. Keep the screw in a safe place to use later.

3. Loosen the two screws fixing the nut on the top shaft.
4. Repeat the process for the output dual-roll center support (marked with an O) with the shorter support
shaft.
NOTE: To use the dual-roll center support on a Latex 1500, you should add shims at the bottom of the
dual-roll center support. These shims are included in the Accessory Kit.
In image above:
1. M8x25 (x3), M8x40 (x3) M8x55 (x3)
2. Shims (x5)
5. For the HP Latex 1500 printer you should use 1 shim for the Input center support and 2 shims for the
Output center support.
Dual roll differential pinion (T0F91-67001)

Removal
1. Remove the twelve M2.5 screws and the four covers from the differential assembly.

2. Remove the 4 screws (1481-0167).
3. Remove the 4 Gears (CZ060-20002) and the 4 Bushes (1410-2190).
Installation
▲ Reverse the removal steps: Install the 4 new Gears (CZ060-20002 ), the 4 new Bushes (1410-2190) and
the 4 new screws (1481-0167), and assemble the differential covers again.
NOTE: The T0F91-67001 Service Kit contains 8 Gears (CZ060-20002), 8 Bushes (1410-2190) and 8
screws (1481-0167).

IMPORTANT: A drop of Loctite 243 need to be added in the Differential thread hole before installing the
new 1481-0167 screw.
Dual roll center support bearings (T0F91-67002)

Removal
▲ Remove the old Bearing skate assembly (CZ056-60496).
Installation
1. Prepare the new CZ056-60496 Bearing Skate assy parts.
NOTE: There are 2 units of each inside the T0F91-67002 Service Kit.

2. Install the Spring pressing plate through the pin, inside the Bearing skate, as shown below.
3. Install the Bearing skate in the Dual roll center support shaft.
4. Install the M5 screw (hand tighten).

R2FF (Accessory)
Inner pinch hinge (CZ056-67178)
Removal
3. Pull down the lever in order to activate the pinches.
4. Remove the MO spindle and the R2FF roll.
5. Remove twenty T-20 screws from the substrate guide (CZ056-00504) and remove it.
NOTE: If it is necessary, turn the forklift guides 90 degrees in order to gain access to all the substrate
guide screws.
6. Remove two T-20 screws from the sides of the pinch assembly.
ENWW R2FF (Accessory) 1375

7. Remove two T-20 screws from the front of the pinch assembly, and pull the assembly forwards just
deactivating the inner pinch hinge.
8. Lift up and remove the pinch assembly through the MO side.
Installation
Outer pinch hinge (CZ056-67176)

Removal
4. Remove the MO spindle and the R2FF roll.

5. Remove twenty T-20 screws from the substrate guide (CZ056-00504) and remove it.
NOTE: If it is necessary, turn the forklift guides 90 degrees in order to gain access to all the substrate
guide screws.
6. Remove two T-20 screws from the sides of the pinch assembly.

7. Remove four T-20 screws from the front of the pinch assembly, and pull the assembly forwards just
deactivating the outer pinch hinge.
8. Lift up and remove the pinch assembly through the MO side.
Installation
Pinch lever kit (CZ056-67173)

Removal

3. Disconnect the pinch lever assembly cable.
4. Remove the pinch beam following step 2 in the removal of R2FF side plates (W3U61-67001)
on page 1382.
5. Remove the two pointed screws from under the pinch lever assembly.
6. Lift up the pinch lever assembly and remove it.
Installation

R2FF damper (CZ056-67174)

Removal
4. Remove the two T-20 screws from the damper support.
TIP: It is highly recommended use a very small ratchet screwdriver in order to access the two screws.
5. Remove the R2FF damper.
Installation
R2FF substrate collector assy (W3U61-67004)

Removal
1. Remove the pinch beam following removal step 2 of in R2FF side plates (W3U61-67001) on page 1382.

2. Remove the two external screws to remove the Substrate collector cover.
3. Remove the last two screws in the back and two on the front to remove the Substrate collector assy (PCA +
optical sensor) and install the new one.
Installation
R2FF switch cable assy (CZ056-67175)

Removal
4. Disconnect the switch cable from the motor drive PCA cable CZ056-50204 (J4 connector).
5. Follow the CZ056-67173 removal steps if you want to remove the lever switch cable, or follow the removal
steps in R2FF side plates (W3U61-67001) on page 1382 if you want to remove the IPS side plate (latch)
switch cable.

6. Remove the two T-8 screws that hold the switch, and remove the switch (from the lever or from the latch).
Installation
R2FF side plates (W3U61-67001)

IDS side plate
Removal
1. Remove the MO spindle.
2. Remove the pinch beam:
a. Remove the rubber spindle.

b. Remove the TUR cable support from the bottom of the pinch beam.
c. Place an empty pallet jacket under the pinch beam.
d. Disconnect the cables from the optical sensor PCA to the Motor drive PCA, from the Motor drive PCA
to the lever and from the Motor drive PCA to the Sideplate latch.

e. Loosen the screws attaching the pinch beam to the side plate.
f. Remove the pinch beam.
3. Remove all the screws from the IDS side plate located side by side with the MO plate.
IPS side plate
Removal
1. Remove the MO spindle.
2. Remove the pinch beam.
3. Remove the RTFF brushless motor assy (W3U61-67003) on page 1384.
4. Remove the screws to detach the IPS side plate.
RTFF brushless motor assy (W3U61-67003)

Removal
1. Remove the 3 motor cables.

2. Remove the 4 motor screws and remove the motor.
Installation
1. Install the new motor with the 4 motor screws.
2. Connect the 3 motor cables.
R2FF roller (CZ056-67468)

Removal
3. Ensure that both MO spindle latches are closed.
4. Pull up the R2FF pinch lever in order to deactivate the pinches..
5. Remove the hand-removable screw from each R2FF side plate.
6. Open the R2FF right and left roller latches.

7. Remove the R2FF roller.
Installation
1. Install the new R2FF roller.
2. Close the right and left R2FF roller latches.
3. Reinstall the hand-removable screw on each R2FF side plate.
R2FF hardened gears & extraction tool (CZ056-67465)

Removal
Removal process is the same as in MI MO gears upgrade and spindles (K4T88-67151) on page 1249.
1. Extract the roll.
2. Place the gear wheel side in an elevated position.

3. Extract the C-clip.
4. Extract the endcap. If necessary you can use the gear wheel extractor.
5. Use the gear wheel extractor to remove the gear wheel.
6. Follow the Drive gear (CZ056-20258) removal in IPS side plate:

a. Remove the IPS side plate following the removal instructions in R2FF side plates (W3U61-67001)
on page 1382.
b. Remove the screw that holds the tensioner spring to remove the sideplate tensioner.
c. Remove the pulley screw to remove the pulley and the belt.

d. Remove the screws that hold the latch: two in the front, four in the back
e. Remove the spring that holds the latch and remove the latch.

f. Remove the gear axis using the nylon hammer and extract the old gear to install the new one using
the nylon hammer.
Installation
1. If necessary use sandpaper for 5 min. in order to increase the diameter and size of the key slot, in order to
help to mount the gear. The same could be done on the end cap.
One small piece of sandpaper is provided with the upgrade kit. But in case it is not enough, you can use
similar sandpaper.
2. In case the black gear is not well positioned, (mainly when placing the end cap, and without being able to
place the C-clip), steps 3 to 8 have to be performed. If not go to step 9.
3. The reason that in some cases the gear can not be well placed:

4. The axis onto which the gear is slided can have slack. When placing the gear, it is important that there is no
slack, if there is, it is not possible to place the C-clip The picture below shows the 2 possible axis positions,
with the gear also in 2 different positions:
In the upper picture, with the finger just pushing the gear towards the right.
On the lower picture, with the finger, just pushing the gear towards the left. In some cases, there is slack
when moving this gear right and left as the axis can have slack at around 2 mm.
It is important to place the gear against the right journal, so that there is no more space, even when moving
the gear towards the right. In order to do that:
5. A small steel cylinder has been provided within the kit. Here is a sample:
6. Push the gear as much as possible towards the left against the right journal.

7. Place the cylinder as shown in the picture below, pushing with a finger.
So as to not damage your fingers, do not place them between the gear space and right journal. Here are 2
examples:

8. Once the fingers are in place, hit the other part of the cylinder with a hammer to place the gear on the axis.
In case it has not be well inserted, re-perform the step using sandpaper to increase the inner diameter of
the gear, and also the part where the key is inserted.
9. If necessary, insert the end cap following steps 10 to 11. If not, go to step 12.

10. Use sandpaper to help insert it.
11. You can also use a screwdriver to fix the shaft, and hit the end cap with a nylon hammer. Here is the correct
position of the flat screw driver:
While pushing towards the spindle with the end of the screwdriver (the side maintained by the hand), in
order to push towards the middle of the spindle, the gear, and the end caps, hit slightly around the end cap
with a nylon hammer. Below is a picture showing arrows where to hit. Apply pressure on the screwdriver to
push the end cap towards the center of the spindle.

12. Insert the C-clip.
13. Put the rolls back onto the printer.
14. To install the IPS side plate gear follow the removal procedure in reverse.
R2FF cable kit (W3U61-67002)

Removal
▲ See TBD.

Ink collector (Accessory)

Ink collector edge holder (P4P92-67001)
Removal
▲ Use the new MEH and scrap the old ones.
Ink collector module (P4P92-67002)

Removal
1. Open the curing module.
2. Remove the Edge holder (see Ink collector edge holder (P4P92-67001) on page 1396).

3. Remove Ink collector protector (P4P92-67004) on page 1397.
4. Close the curing module.
5. Raise the carriage beam.
6. Remove the desired module.
Installation
Ink collector protector (P4P92-67004)

Removal
1. Remove the hooks.
ENWW Ink collector (Accessory) 1397

3. Remove the protector.
Installation
2. In order to hold the protector with the Ink collector modules follow the steps below:
a. First hold the right protector and use it as a reference to position the others.
b. To hold the right protector put the left protector wings inside the hole beside the left oblong hole.
(see below).

c. Continue holding the intermediate protector, maintaining the right protector as a reference, and line
up the rib guides.
d. Hold the left protector as you hold the intermediate one.
ENWW Ink collector (Accessory) 1399

8 LogMeIn rescue
● Using LogMeIn rescue
1400 Chapter 8 LogMeIn rescue ENWW

Using LogMeIn rescue

LogMeIn is a remote troubleshooting tool which enables customers to obtain support remotely from HP without
the need of a service visit.
Use the remote connection to see customer’s issues and guide them through, or perform support-related tasks
on their behalf.
LogMeIn doesn’t use pre-installed software but does require the user’s permission.
1. Process overview
1. Engage Customer.
2. Gain customer’s permission for remote control.
3. Direct customer to http://www.hp.com/123, accessed through IPS, under the Tools menu, selecting
"Remote support".
4. Agent gets PIN number from LMI.
5. Agent provides PIN to customer.
6. Customer inputs PIN, Clicks "Connect" and installs software.
7. Agent explains written agreement to customer.
8. Customer accepts and clicks "OK".
9. Agent uses LogMeIn LogMeIn to resolve issue.
2. Technician Console
ENWW Using LogMeIn rescue 1401

A. Session Log – Session log displays all Technician actions including chat dialogue for session.
B. Session Toolbar – Create and manage sessions, including Start, End, Transfer and Collaborate.
C. Queue Manager – View incoming sessions.
D. Active Session tab – Switch between up to 10 concurrent sessions – Note that only one is active in the above
screenshot.
E. Technician Workspace – Area where work ( Remote Control, System Information, etc.) is done.
F. Chat entry – Chat, predefined replies, URL push all initiated/entered here.
3. Starting a Remote Support Session
1. Click "New Session".
2. Enter custom field information (Customer Name: Leave Blank; External Case ID: Service Ticket Number).
3. Direct customer to http://www.hp.com/123.
4. Click "Create PIN Code".
5. Give PIN Code to customer.
4. Customer Experience: Internet Explorer Start up Process

1. Select in the IPS "Tools" > "Remote support" or Open Internet explorer http://www.hp.com/123.

2. Enter the 6 code digit (PIN Code).
3. Install the Applet if required.

4. Customer must accept the terms and conditions for the HP remote support intervention.
5. The remote session has been started. "Active".
5. Technician Console
The Technician Console auto-starts incoming sessions.
There are three phases, and they occur in this order: Connecting, Waiting, and Active.
● Connecting (Very interactive step: The agent, as an advisor to the customer should guide them through
these steps: 1. downloading the software, 2. install the software, 3. agree to terms and conditions.
Support Options and Features

The Technician Console auto-starts incoming sessions.
WARNING! For safety reasons no remote operation involving movement of any mechanical part is permitted
without an operator in front of the printer connected by phone with a remote agent.
Several remote actions can be performed when the remote session is active:

● Launch remote Control Session.
● Launch file manager.
● Retrieve System Info.
● Reboot the IPS PC.
To close the session use the red button.
For a full list of features, see the User Guide, section: LMI Rescue Technician Console;
https://secure.logmeinrescue-enterprise.com/welcome/documents/pdfs/rescue_tech_console_userguide.pdf.

9 Moving the printer
● Introduction
● Manpower required
● Tools required for repacking
● Move the printer to a new site (transport temperature below 5°C/41°F)
1406 Chapter 9 Moving the printer ENWW

Introduction
Before moving, make sure the new site is ready. To prepare the new installation site, see the site preparation
guide. To mount and reinstall the printer, see the installation guide.
There are four possible scenarios for moving the printer:
● Move the printer to a new site (transport temperature below 5°C/41°F) on page 1409 In this case, before
switching off the printer, the ink must be removed from the tubes. You need the ink system cleaning tubes
and 5 liters of distilled water.
● B. Move the printer to a new site (transport temperature above 5°C/41°F): If you need to move the printer
to a new site, the printer must be fixed to a pallet. If the temperature will not drop below 5°C/41°F, follow
these instructions. Failure to follow these instructions could cause the ink to freeze, which would damage
the ink system and require heavy repair.
● C. Move the printer to the same site (with ramps or steps): If you need to move the printer within the same
site but there are ramps or steps on the route, you will need to lift the printer with a forklift or a crane.
● D. Move the printer to the same site (no ramps, no steps): If you wish to move the printer a short distance
on the same site, across a horizontal floor with no steps and no slopes, read the instructions.
In any case, some preparations must be made before the printer can be moved, and failure to follow these steps
could cause irreversible damage to the printer.
This repacking guide provides you with step-by-step procedures for the repacking process. This guide is
organized in chronological order and should be followed from beginning to end.
NOTE: After moving the printer, you may in some cases need an electrician to reconnect the power cables. You
may also need to reconfigure the network, from the HP Internal Print Server computer, and from the RIP
computer. See the installation guide for more details.
NOTE: If the printer is moved to a different customer, the Print Care software must be reinstalled to generate a
new customer ID. Then, a service call must be made to HP so that the printer’s serial number is associated with
the new customer ID.
Manpower required
Repacking of your printer requires the following manpower:
● HP specialist
● Customer
● Certified electrician
● Moving specialist
IMPORTANT: The printer must be moved by trained and qualified personnel only.
Tools required for repacking

TIP: Without a heavy-duty electric screwdriver, it could take up to two hours just to reassemble the crate.
Repacking of your printer requires the following tools:
ENWW Introduction 1407

● Step ladder
● Cable Ties
● Heavy-duty adhesive tape
● Heavy-duty electric screwdriver with two batteries
● Phillips screwdrivers
● T-8, T-10, T-15, T-20, T-25, and T-30 Torx screwdrivers
● Long Torx extension pins that have a diameter of approximately 2–3 mm and are more than 15 cm in
length to be able to access all screws
● Two flat head screwdrivers (two sizes)
● 30 mm socket wrench, extension, and 17 mm socket
● 7 mm, 15 mm, and two 30 mm open-ended wrenches

Move the printer to a new site (transport temperature below 5°C/

41°F)
1. Prepare the printer
Remove the printheads, intermediate tanks, ink cartridges, printhead cleaning roll, and aerosol filters.
Initial steps
1. Remove the printheads and store them in their caps. See the user guide.
2. Remove the ink cartridge. See the user guide.
3. Carefully remove the intermediate tanks. See ISM 7x intermediate tank (K4T88-67040) on page 1056.
NOTE: Store the intermediate ink tanks vertically. Failure to store them vertically can cause a broken bag.
Remove the printhead cleaning roll
1. In order to replace the printhead cleaning roll, unlock and open the door on the front right of the printer.
ENWW Move the printer to a new site (transport temperature below 5°C/41°F) 1409
2. Grip the handle and pull the whole printhead cleaning roll assembly out through the door.
3. You can cut the material, removing the used material of the lower core. Dispose of the roll with the used
cleaning material according to the instructions provided with the new roll.
TIP: Keep the empty core to use as a take-up core.
4. Grip the handle and push the whole printhead cleaning roll assembly back into the printer.
5. Close the door with the key.
Remove the aerosol filters
2. Ensure that all windows, covers, and doors are closed and remain in their original position.

3. Open the window.
4. Open one latch on the right side of each aerosol filter module.
5. Open the lid of each filter.
6. Extract the frame from the aerosol container and remove the filter from the frame.
7. Close the lids.
8. Close the latches.
2. Unplug the electrical system

Requirements
An electrician is required for unplugging the electrical system used to power the printer. Make sure that your
electrician is appropriately certified according to local regulations and supplied with all the information regarding
the electrical configuration.
Remember that you are required to follow the local laws, regulations, and standards that pertain to the electrical
installation of your printer.
Unplug power cables
Turn off the printer, using both Branch Circuit Breakers located in the building's Power Distribution Unit (PDU).
Unplug both power cords (including the PE terminal) and un-route them.
Disconnecting the main power cord:
1. Disconnect the PE conductor to the PE 1 pillar terminal.
Protective Earth (PE) terminal mark

2. Disconnect the lines (and neutral if used) conductors from the installation terminal block TB-1 (L1, L2, L3
and N contacts).
3. Pull the cable to un-route it.
3. Remove the computer, monitor, keyboard, mouse, and beacon

Manpower Tools Time
1 person T-20, T-30 Phillips screwdriver 30 minutes
Monitor removal
1. Unplug and unroute the monitor, keyboard, and mouse cables through the hole in the front cover.
2. Use a T-20 screwdriver to remove the monitor holder from the printer.
3. Remove the holder from the monitor by unscrewing the 4 Phillips screws. Keep them and store the
monitor properly.
4. Re-attach the holder to the printer with the four T-20 screws.
5. Disconnect the webcam from the built-in computer of the printer and store it properly.
6. Unplug the computer cables (including the LAN).
7. Remove the computer from the electrical compartment and store it properly.
8. Un-route the customer LAN cable.
9. Dismount the printer status beacon and store it properly.
10. Remove the keyboard and mouse and store them properly.
Remove the air supply
▲ Disconnect the airgun from the customer's air supply and store it properly.
4. Insert additional packaging

Manpower Tools Time
1 person Cutting pliers, Allen keys, T-20 and T-25 10 minutes

screwdrivers
1. Open the printer's window and secure the carriage in the travel position with the T-25 screw.

2. Remove the back left cover from the rear of the printer and then insert the pin to block the printhead
cleaning roll.
3. Add straps, protective foams, cable ties, and orange tapes to fix windows, doors, the curing module, the
loading table, and the service station.
4. Add the foam to cover the substrate advance sensor from the middle of the platen.
5. Open the right back cover at the rear of the printer with the same key used at the front.
6. Empty and clean the condensates bottle and add some straps to secure it. Leave it open in its working
position.
5. Raise the feet

Before moving the feet verify the legs have grease properly applied to help the up/down movement. If they have
not been greased properly, follow these steps to grease them:
1. Lower down the nuts and washers (Use wrench nº 17).
2. Add grease the lower part of the 3 Legs (below the Stand).
3. Raise the printer and 3 legs (keep the printer parallel to the floor) until the wheels touch the floor.
4. Add grease to the upper side of the 3 legs.
Now the leg is completely covered with the grease, proceed raising the feet:
5. Use the nº 17 wrench to unlock the nut at the top of the 5 feet.
6. Raise the two auxiliary feet (left side of the printer, not on the floor) to their maximum height.
7. To avoid damaging the feet when moving the printer, the 3 feet holding the printer must be raised slowly in
order to keep the printer parallel to the floor. To do it so, turn each foot twice clockwise one at a time until
the wheels touch the floor. This avoids too much weight being on a single foot at any one time.

6. Move the printer to the crate base

In order to perform this step, the forklift kit and a forklift are required as the ramps do not allow this operation to
be performed manually.
Forklift specifications to move the printer are:
Weight: 6000 Kg (13228 lb)
Fork length: 1.5 m (59 In)
Inner distance between forks: 1.3 m (51 In)
1. Locate the forklift guides underneath the printer and make sure that the forks on the forklift are spaced 1.3
m apart (A).
2. Move the forklift into position to engage with the printer. You can approach the printer from either side,
whichever is more convenient for you.
3. Carefully lift the printer with the forklift and leave it on the crate base.
7. Attach the printer onto the pallet

1. Manually move the printer to allow the 4 pallet printer supports to be correctly positioned.
2. Fix the support to the printer with the 20mm screw.
3. Fix the pallet printer support to the crate base using six 20mm screws.

4. Wind the feet down until the printer rests on the pallet.
IMPORTANT: When winding the feet up or down, grip the tool on the flat surface of the screw thread and
not on the nut.
5. Lock the 4 wheels.
6. Fix the extra material boxes to the crate.
7. Fix the two spindles to the crate base.
8. Mount the crate packaging

Manpower Tools Time
2 people M17 socket wrench, Phillips screwdriver, pliers, 20 minutes

ladder
The crate is attached together by 16 lag bolts and 128 wood screws.
The panel numbers are shown below:
1. Lift one end of the crate slightly and pull it in to the printer. You will need space of 3 m (10 ft) in order to
attach the crate to the printer.
2. Install the other end of the crate in the same way.
TIP: Alternatively, you can mount the crate; first side panels and then the top panel.

3. Insert the bolts shown below from panels 1, 3, 12, 4, 2, and 9.
4. Insert panels 5, 6, and 7; and, while someone holds them to prevent them from falling, attach their bolts.
5. Insert eight Phillips screws from panel 6 and four screws from panel 5, the central rear panels.
6. Remove sixteen screws from panel 7, the central front panel.
7. Add the two top cross-pieces.
8. Insert panel 10.
9. Using a ladder to reach the top of the crate, insert 16 top screws from panel 10, the central top panel.
WARNING! Do not stand on top of the crate.
10. Wrap the complete package with a plastic sheet.
11. Cover the package in heavy-duty wrapping and shrink-wrap.
9. Move the crate

Manpower Tools Time
2 people Forklift, skates 15 minutes
WARNING! The crate must be lifted with a forklift from the front side of the crate. The front side of the crate is
marked Front. This is important because of the weight distribution inside the crate.
WARNING! Do not stand on top of the crate.
Weight Fork Length Inner distance between forks
Forklift 6000 kg (13228 lb) 2 m (79 in) 1.3 m (51 in)
1. To move the crate with a forklift, insert the forks in the designated slots in the crate. Always lift the crate
from the front and center.

2. You can also use skates to maneuver the crate around tight corners or to move the crate laterally.
Move the printer over ramps
WARNING! Do not exceed the maximum incline if you must move the printer up or down a ramp. Failure to
respect the maximum incline could damage the printer.
WARNING! Slopes steeper than 3% may cause serious damage to the printer.
10 Service maintenance
● Maintenance status
● 1500 liters or 2.5 million carriage cycles service maintenance – Service Maintenance Kit 2
● Textile Maintenance at 1500 liters
● 5 million cycle scan axis service maintenance
● Dirtiness Check
● Empty the condensation collector bottle
● Clean the aerosol filters
● Clean e-box filters
● Clean e-cabinet fan filters
● Replace the printhead cleaning blade
● Replace aerosol module fans
● Replace the intermediate tank
● Clean the Drop detector
● Check and clean vapor removal filter
● Check and clean dirtiness on scan axis and transmissions
● Clean scan axis encoder
● Clean impelling dust in sax chain
● Replace media drive motor, gears and encoder
● Replace media drive PCA
● Replace impelling
● Replace bearings
● Replace caps
● Replace curing module side foams
● Swap sax rods
1424 Chapter 10 Service maintenance ENWW

● Replace drying fan and resistor module
● Clean and lubricate the Drop detector rods
● Clean ink deposits
● Replace curing fan/heater and internal foams
● Clean aerosol filter nozzle under textile mode
● Replace diverter module service
● In-line slitters blade replacement
● Replace Double-sided day and night kit front output lights
● Replace Double-sided day and night kit back output lights
● Replace Double-sided day and night kit platen substrate protector (P4P91-67004)
● Replace Double-sided day and night kit substrate edge holder (P4P91-67006)
● Replace and/or place spindle ruler labels
● Replace spindle gear and end-cap
● Drop-detector maintenance
● Replace substrate drive OMAS sensor
● Replace service station cap modules
● Replace vapor removal pipes
● Replace curing foams at curing module assembly
● Replace vapor demister filter
● Clean curing PCA fans
● Swap carriage slider rods
● Replace complete tube routing system (TRS) chain with tubes and cables
● Replace carriage bushings and oiling foams and wicks
● Grease drop detector transmission and rods
● Grease substrate drive transmission gears
● Replace primer and latches
● Replace damaged diverter wheels
● Replace pinch clamp
● Replace air valves
● Substrate-advance motor replacement
● Grease the carriage beam screws (PPS)
ENWW 1425
● Summary of maintenance operations

Maintenance status
The following table shows at what ink consumption levels the maintenance status appears in the Print Care
maintenance list.
Table 10-1 HP Latex 1500 maintenance warning triggers
Maintenance Execution (ml) Warning (ml) Halt (ml) On time % < Warning % Critical % Halt % >
name
2.5 million 1,500,000 -100,000 100,000 93 93–100 100–107 107

cycles
maintenance
3000 liters 3,000,000 -250,000 250,000 92 92–100 100–108 108

maintenance
(or 5 million
cycles
maintenance)
450 liters 450,000 -50,000 50,000 89 89–100 100–111 111

maintenance
900 liters 900,000 -100,000 100,000 89 89–100 100–106 106

maintenance
Ink collector 1,500,000 -100,000 100,000 93 93–100 100–107 107

1500 liters
maintenance
Ink collector 3000 7000 100 100–100 100–333 333

3 liters
maintenance
(or at the end
of each roll)
Ink collector 40,000 -10,000 10,000 75 75–100 100–125 125

40 liters
maintenance
Ink collector 500,000 -100,000 100,000 80 80–100 100–120 120

500 liters
maintenance
ENWW Maintenance status 1427

1500 liters or 2.5 million carriage cycles service maintenance –

Service Maintenance Kit 2
This section describes the 2.5 million carriage cycles scan-axis maintenance procedure (done at approximately
1500 liters of usage for average users, but it depends on the print modes and ink levels used). Once the scan
axis reaches 2.5 million cycles, the procedure described below is strongly recommended to ensure correct
printer performance.
NOTE: This maintenance only applies to printers with SN prior to SG73H1N002.
A service maintenance kit is available to perform the procedure, and the required service parts are all included. A
service engineer must perform the procedure.
Kit description
● HP Latex 1500 Printer Service Maintenance kit 2 (K4T88-67299)
Kit content
● Impelling carriage belt assembly (K4T88-67306) (x1)
● Scan-axis belt tensioner (K4T88-67049) (x1)
● Belt installation tool (K4T88-67021) (x1)
Procedure
1. Replace the Impelling carriage belt assembly (K4T88-67306), see Impelling carriage belt assembly
(K4T88-67306) on page 909. (You will need the Belt installation tool (K4T88-67021).)
2. Replace the Scan-axis belt tensioner.
3. Grease the Web wipe lifter golden rings.
To access them, follow these steps:
a. Remove the Web wipe printhead cleaning roller up-down pair. See Web wipe printhead cleaning roller
up-down pair (K4T88-67117) on page 1099.
b. Remove the Web wipe printhead cleaning blade. See Web wipe printhead cleaning blade
(K4T88-67116) on page 1095.
c. Unscrew the 4 screws.

d. Remove the metal part with the handle.
e. Grease in the contact zone of the golden rings with the lifter and the contact zone between the cam
and the roller bearing 1410-1889. PN of the grease is 6040-1299 (Lubricant grease lithium, included
in the HP Latex 1500 cleaning kit).
NOTE: Be careful as there are two different lifters: one on the front side and one on the back side.
Both sides need the greasing to be applied
ENWW 1500 liters or 2.5 million carriage cycles service maintenance – Service Maintenance Kit 2 1429
Textile Maintenance at 1500 liters

This Maintenance is intended to be done only for customers using the Ink collector kit.
Procedure
1. Replace the entire Ink collector kit (P4P92A).
2. Replace the Curing heater and fan module (1HA07-67038) (x 12). See Curing heater and fan module
(1HA07-67038) on page 750.
3. While the Curing heater and fan modules are removed, clean the perforated plate surface internally:
Use first the brush and later on, the cloth moistened with isopropyl alcohol.
NOTE: Do not apply isopropyl alcohol on the plastic parts and take care not to damage the temperature
sensor.
4. Replace the Curing side foams. See Curing Side Foams (K4G10-67122) on page 767.
5. Replace the Lower curing beam EPDM foam (K4G10-67118).
6. Replace the Curing side Sealing rubber (K4G10-67122).
7. Replace the Carriage fan. See Carriage fan (K4T88-67015) on page 691
8. Replace the Drying heater and fan (x8). See Drying heater and fan (K4T88-67107) on page 790.

9. Clean all the Drying diffuser nozzles (check if needed).
10. Replace the Impelling encoder strip. See Impelling encoder strip (K4T88-67044) on page 916.
11. Replace the Impelling carriage belt assembly (you will need the Belt installation tool (K4T88-67021)). See
Impelling carriage belt assembly (K4T88-67306) on page 909.
12. Replace the Aerosol box (x2). See Aerosol box (K4T88-67001) on page 663.
13. Replace the Printhead interconnect color PCA (x3) and the Printhead interconnect optimizer PCA. See
Printhead interconnect color PCA (1HA06-67002) on page 713 and Printhead interconnect optimizer PCA
(1HA06-67003) on page 717.
14. Replace the Service kit rubbers windows (K4T88-67317).
15. Replace the Carriage line sensor (K4T88-67004). If the printer has installed the DSDN Kit you will need to
replace the secondary Line sensor in the carriage as well.
16. Replace the Diverter assembly. See Diverter assembly (K4T88-67135) on page 1272.
17. Replace the Drop detector transmission parts. See Drop-detector transmission parts (K4T88-67080)
on page 1159.
5 million cycle scan axis service maintenance

This chapter describes the 5 million cycle scan-axis maintenance procedure (done at approximately 3000 liters
of usage for average users, but it depends on the print modes and ink levels used). Once the scan axis reaches 5
million cycles, the procedure described below is strongly recommended to ensure correct printer performance.
A service maintenance kit is available to perform the procedure, and the required service parts are all included. A
service engineer must perform the procedure. Further information, as well as the HP Latex 1500 printer
maintenance inspection form, will be provided through newsletters.
The procedure consists of the following steps:
● Printer status logs capture: The service engineer will collect the printer’s main logs and performance
parameters to analyze and track the main critical parameters of the printer.
● Maintenance inspection: The service engineer will use and fill in the Latex 1500 maintenance inspection
form provided to simplify the inspection and determine whether any extra service parts should be
requested.
ENWW 5 million cycle scan axis service maintenance 1431

● Basic cleaning: The service engineer will check the basic cleaning status, and perform main checks on
carriage bottom, curing and bottom plates, print zone, mechanical transmissions, belts and rods, etc.
● Image quality check: The service engineer will check the printer status printing a reference plot to check
image quality.
● Service maintenance kit: Must be requested to perform these operations. The service engineer must follow
the procedures described below to perform all the required maintenance inspection, operations, and
replacement procedures.
NOTE: Some replacement procedures can be done simultaneously to save time. See Service maintenance
on page 1424.
For further information related to each service part replacement included in the service maintenance kit, a
summarized cross-referenced table is at the end of this chapter. See Summary of maintenance operations
on page 1467.
● Image quality check: Once the service maintenance kit replacement and maintenance operations have
been performed, the service engineer must run an image quality check to ensure the printer operates
correctly. See Image quality troubleshooting on page 475.
Part Number Maintenance Operation Parts Notes
— Clean and Oil Lifters beams (PPS) and SVS 1 Kit to carefully clean and grease SVS gears/
transmission gears and rods. transmissions.
Areas of attention: Encoders, avoid touch.
K4T88-67151 Replace spindles, endcaps, and gears (x2) 1 Remove 2 endcaps and gears and replace them.
K4G10-60176 Replace spindle valves (x4) 1 Remove 4 spindle valves and replace them.
CZ056-67228 Replace media drive ME Transmission 1 Replace media drive motor, gears, and encoder.
CZ056-67190 Replace media drive PCA 1 Replace media drive EE´s.
K4T88-67058 Replace tubes routing main chain 1 Replace IGUS chain, including its tubes, FO, and
power cable.
K4T88-67008 Replace impelling and bearings 1 Replace impelling parts: belt, tensioner pulley,
motor , motor pulley and the carriage 4
bearings.
K4T88-67137 Replace OMAS 1 Replace OMAS sensor and PCA.
K4T88-67073 Replace caps (1 set of 4) 1 1 set of 4 caps.
K4T88-67095 Replace vapor demister (Filter) 1 Replace vapor demister filter.
K4G10-67122 Replace curing side foams SRV (1 set) 2 One for each side.
CZ056-67433 Replace diverter module service (3 Submodules) 3 3 Submodules with its wheels to replace
damaged parts.
K4T88-67088 Replace damaged pinchwheels (1 Submodule) 1 1 Submodule with its wheel to replace damaged
wheels.
1HA07-67018 Replace primers and latch serv (1 Set, 4) 1 1 Set with all 4 primers assembly and parts.
— Swap sax rods, and carriage rails NA Swap scan axis rods, front to rear, to reset wear
out zones. Optional.

Dirtiness Check
Clean the print zone
(See maintenance document in the user guide)
Use a wet wipe to clean the printing zone, removing all dust and ink residue.
CAUTION: Be careful not to break diverter wheels.
1. Open the window.
2. Use a wet wipe to clean the printing zone, removing all dust and ink residue. Be careful not to damage
OMAS Sensor.
3. Be sure to cover the entire width of the printing zone from side to side.
4. Clean the media edge holder from dust or wet ink as well.
Clean the bottom of the carriage and the line sensor
Clean the bottom of the carriage of aerosol and dirt.
1. Move the carriage to the central position.
2. Open the window.
3. Lift the scan beam to its highest position.
4. Switch off the printer and clean the bottom side of the carriage structure taking special care of not touching
the printheads from below.
CAUTION: Do not leave the carriage too many minutes out of the capping station.
5. Clean the carriage UCP (protector).
6. Clean the aerosol outlet.
7. Carefully clean the tetris sensor using a cotton swab or a clean wet wipe.
8. Clean SOL Sensor.
ENWW Dirtiness Check 1433

CAUTION: Take care of not breaking the door that uncovers the sensor optics.
Clean the substrate-advance sensor
1. Open the window.
2. Locate and carefully clean the OMAS sensor glass just to the right of the center of the print zone.
CAUTION: Be careful not to damage OMAS sensor.
Clean the pinchwheels and drive roller
1. Open the substrate loading table on the back side of the printer.
2. Raise the scan beam to its highest position.

3. Clean the pinchwheels and the drive roller with a wet wipe.
Clean the substrate input and output wheels
1. Open the window.
2. Open the front curing module latches, and the back loading table ones.
3. Open the curing module, and clean the substrate output diverter wheels.
4. Open the back loading table door and gently clean the substrate input diverter wheels.

Check for and clean condensation
▲ Daily recommendations. TBD
Graphics pending TBD
Check and clean the perforated plate and curing assembly
▲ See user guide. TBD
Grease the carriage beam screws
1. Open the rear covers.
2. Via PrintCare (PrC) diagnostics, lift the scan beam to service position.
3. Carefully grease the encoder taking care of not damaging it.
Clean and grease the service station transmission and rods
1. Open rear cover from the right side.
2. Extract the web wipe in order to have more space to operate.
3. From the back side, access the bottom part of SVS and carefully grease the transmission.
4. Clean the top of SVS carriage rods, and put one drop of oil from the maintenance grease kit oil bottle.
Clean and grease the substrate drive transmission gears and rods
1. From media load position, lift the scan beam.
2. Grease carefully in order to avoid damaging the encoder.
Grease the printhead primers
1. Remove the carriage cover.

2. After lifting the printhead covers, two 'O' rings can be seen, which seal the joints between the printhead
cover and printhead.

3. With a finger, apply a little grease to the 'O' rings to improve their performance. A suitable grease is
available in a syringe from the cleaning kit
The grease should be applied to the black rubber part only. If some grease gets into the central hole,
remove it with a toothpick or similar tool.
4. Close the printhead cover, the carriage cover, and the printhead access door.
Replace spindle valve
▲ TBD (See Replace air valves on page 1463)

Replace pinchwheel submodule
▲ See Pinch assembly (K4T88-67088) on page 1214
Replace primer
▲ TBD (See Replace primer and latches on page 1462)

Empty the condensation collector bottle

1. Using the safety key provided with the printer, open the door that covers the condensation collector bottle.
2. Empty the bottle according with local regulations policy.
Clean the aerosol filters

2. Open the window.
3. Open the aerosol modules.
4. Clean the aerosol filters outlets to optimize air flow (it is not needed to clean the filter itself).
NOTE: If filter is very dirty and/or full, replace with a new one.
5. Use a flat screwdriver to remove the dry aerosol and then a brush to remove any remaining dirt. Try to
avoid loose dirt falling into the filter.
Clean e-box filters


2. Open each filter protector and take the filter out of its slot.
3. Clean each filter with the air gun to get rid of all accumulated dust.
4. Put each filter back on its original position and close them with the filter protector.
Clean e-cabinet fan filters

ENWW Clean e-cabinet fan filters 1441

2. Open each filter protector and take the filter out of its slot.
3. Clean each filter with the air gun to get rid of all accumulated dust.
4. Put each filter back on its original position and close them with the filter protector.
Replace the printhead cleaning blade

1. Ensure that you have the Printhead cleaning roll Rubber blade kit (K4T88-67116), which is included in the
Printer Maintenance Kit (K4T88-67259 or W0R39A) but that can also be purchased separately.

3. Unlock and open the Printhead cleaning door.
4. Pull out the Printhead cleaning roll carriage.
ENWW Replace the printhead cleaning blade 1443

5. Put on gloves to protect your hands.
6. Open the pinchwheel (pull out and rotate the black plastic knob).
7. Move the Printhead cleaning material aside in order to uncover the Rubber blade.
8. Move the Rubber blade to the replacement position and remove it.

9. Place the new one in position.
NOTE: The black element has to sat firmly in place on the corresponding printer support.
IMPORTANT: Be careful not to damage the printhead cleaning material when replacing the rubber blade.
10. Finish off after replacing the rubber blade:
a. Push the Printhead cleaning material back into place and close the pinchwheel (using the black plastic
knob).
b. Carefully push the Printhead cleaning roll carriage back into its working position.
c. Close and lock the door.
d. From Print Care, run the printhead cleaner calibration.
Replace aerosol module fans

▲ Follow the procedure to replace the Aerosol top case (K4T88-67003). See Aerosol top case (K4T88-67003)
on page 670.
Replace the intermediate tank

NOTE: Be careful with leakages.
1. Before starting, ensure that you have enough ink on the corresponding cartridge to refill the empty new
intermediate tank (750 cc).
2. Replace the desired intermediate tank with a new one. Ensure right alignment and insertion. See ISM
intermediate tank (CZ056-67073) on page 1055.
3. If the new intermediate tank is empty, run the diagnostic to refill new the intermediate tank.
4. If the new Intermediate tank is already full, just insert and run the diagnostic for Intermediate tank check.
ENWW Replace aerosol module fans 1445

Clean the Drop detector

The Drop detector diagnostic will be launched in order to move the carriage and the drop detector to the service
position. Please read the instructions below before pressing next:
1. Run the Print Care test 62004 Move drop-detector station.
2. Once the Drop detector is in the service position, turn off the printer.
3. Unlock and open the Printhead cleaning roll door.

5. From the opened door, access the Service station and clean the top surface with a lint-free cloth dampened
with isopropyl alcohol.
6. Take special care of cleaning the metallic plates close to the Drop detector module.
7. Close and lock the Printhead cleaning roll door.
8. Close the right cover.
9. Turn on the printer. When booting up, the Carriage and the Drop detector will move back to the normal
position.
Check and clean vapor removal filter

2. Unscrew and open the back cover guarding the condensation bottle.
3. Using a brush, clean the metal filter.
4. Once here, check if the fans are clean.
Check and clean dirtiness on scan axis and transmissions

2. Open the main window.
ENWW Check and clean vapor removal filter 1447

3. Clean the scan axis rails with a wipe (dirtiness tends to accumulate at the sides). Clean with wipe and
alcohol.
CAUTION: Be careful not to damage your hands with the encoder.
CAUTION: Be careful not to break the encoder.
4. If symptoms of dry rods and high friction at carriage movement along the rods are observed, put a few oil
drops on the rod to lubricate it.
5. If necessary, clean dust accumulated on the axis or beam from the motor side.
6. Run SAX Friction tests.
Clean scan axis encoder

2. Open the window.
3. Check if the encoder strip needs to be cleaned. If so, gently clean it with a wipe.
CAUTION: Take special care as the strip is a weak part, easy to break.

4. Clean dirty areas only.
5. Run the SAX length diagnostic test.
Clean impelling dust in sax chain

2. Open the front window.
3. Visually check the carriage chain for dust accumulation, debris, or pieces of rubber, aerosol, etc. If present,
clean it. You can use a home handheld vacuum cleaner.
4. Run SAX Friction Test (Diagnostic) to ensure right functioning and performance.
Replace media drive motor, gears and encoder

▲ See Substrate drive roller transmission assembly (CZ056-67228) on page 1187.
Replace media drive PCA

▲ See Printhead cleaning system motor drive PCA (CZ056-67190) on page 1131.
Replace impelling
See Impelling motor (K4T88-67043) on page 919.
ENWW Clean impelling dust in sax chain 1449

1. Take the impelling tool from the service kit.
2. Uscrew the tensioner screws to loosen the belt.
3. Once the belt is loose, remove the pulley and the belt, and remove from the carriage attachment.
4. Remove the tensioner module.
5. Remove the motor and motor support.
7. Replace with new parts: encoder, motor, tensioner, belt.
8. Screw in the tensioner, place the belt, and adjust tension.
9. Run the Sax friction test via PrC.
Replace bearings
See Carriage bearings (K4T88-67008) on page 685.
2. Open the window.
4. Take the torque key from the kit.
5. Unscrew the supports and remove the bearings assembly.
6. Insert the new bearings assembly.
7. Before installing, clean he rods manually and carefully in case of dirt.
8. Close cover, switch on printer.
9. Run the SAX friction test.
Replace caps
See Service station cap (K4T88-67073) on page 1150.
1. Move the carriage to the service position in the middle of the print zone. Use the PrC diagnostic.
3. Using the service key, open the front cover.
4. Using a screwdriver and taking special care of not causing any damage, take out and replace caps. Insert
and clip a new one in its place.
5. Insert carefully and check that the carriage capping is well done and the caps park the printheads correctly,
making no noise, and without gaps between each printhead and its cap.

Replace curing module side foams

See Curing Side Foams (K4G10-67122) on page 767.
2. Open the curing module latches and pull the curing module out.
3. Remove the rests of old foams at both sides.
4. Replace the foams. Tape ensuring there is a seal between the curing and frontal bottom plate to avoid
vapor condensation leakage.
Swap sax rods

▲ Reduce carriage belt tension. TBD
Replace drying fan and resistor module

See Drying heater and fan (K4T88-67107) on page 790.
CAUTION: Be careful not to damage your hands.
CAUTION: Be careful not to throw dirtiness to other printer parts.
2. Open the dryer cover.
3. Remove fans and the resistor module unscrewing the 4 support screws.
4. Clean filters with a vacuum cleaner or manually.
Clean and lubricate the Drop detector rods

2. Unlock and open the Printhead cleaning roll door.
ENWW Replace curing module side foams 1451

4. Clean both rods with a lint-free cloth dampened with isopropyl alcohol.
5. Put a few drops of oil along the Drop detector rods.
6. Close and lock the printhead cleaning roll door.
7. Turn on the printer
Clean ink deposits

2. Open the web wipe cover.
3. Carefully clean the ink deposits with cotton swabs.
Replace curing fan/heater and internal foams

See Curing heater and fan module (1HA07-67038) on page 750.
1. Open front window.
2. Open both latches and pull the curing module out.
3. Using a screwdriver, open the affected curing module cover.
4. Replace the heater and the fan module block.
5. Close and run the diagnostic to check if the fan and the heater are working properly.
Clean aerosol filter nozzle under textile mode

1. Move the carriage to service position.

4. Open the clips and replace the filter inside. Take care of putting them in its correct orientation.
IMPORTANT: Check there is no dirt inside.
Replace diverter module service

1. Open the curing module and the main window.
2. Remove the damaged diverter wheels.
3. Remove the module.
4. Replace with a new one.
In-line slitters blade replacement

WARNING! Handle in-line slitters with care and avoid touching the blade.
Risk of cutting your fingers Risk of trapped fingers Risk of burns
For more safety information, see Safety requirements on page 119.
NOTE: There is no part number for the replacement blades. Generic SLOTTED BLADES measuring 2.25” x 0.75”
are compatible.
1. Loosen the lateral thumb screw holding the blade.
ENWW Replace diverter module service 1453

2. Handle the protected blade carefully and remove it from the support.
WARNING! Handle with care and be careful to avoid cutting your fingers.
3. Remove the blade from the protector.
4. Turn the blade over, then reinstall the blade with the sharp side facing out, unless both sides of the blade
are worn; in this case, replace with a new one.
5. Put the blade into the protector, then insert the assembly into the support.
6. Tighten the lateral thumb screw to set the blade into the correct position.
Replace Double-sided day and night kit front output lights

▲ See Front light assy (K4G10-67047) on page 1331.
Replace Double-sided day and night kit back output lights

▲ See Back light assy (K4G10-67048) on page 1334.

Replace Double-sided day and night kit platen substrate protector

(P4P91-67004)
1. Place the protector on the platen and drop the far side of the protector on the far side of the platen, in the
space between the platen and the roller; it is magnetic and it will attach itself. Nevertheless, make sure it is
attached to the base and not to the LED guide.
2. Unroll the platen substrate protector fabric covering all the platen. Try to cover all the platen with the
protector, or use two protectors. It is important to try to cover at least all the printed content
ENWW Replace Double-sided day and night kit platen substrate protector (P4P91-67004) 1455
3. Use the elements (Tensioners) provided with the protector to brace the protector to the diverter wheels.
Make sure the fabric is flat with no wrinkles on it.
Replace Double-sided day and night kit substrate edge holder

(P4P91-67006)
1. Standing in front of the printer, place the edge holder onto the far side of the platen at the furthest edge of
the platen substrate protector.
2. Clip the edge holder onto the rear side of the platen substrate protector situated between the printer
platen and the Double-sided day and night platen light.
3. Then, attach the other side of the edge holder to the protector tensioner, covering the edge of the
substrate.

4. Provide the correct tension to the edge holder using a flat screwdriver.
NOTE: If the edges of the protector extend beyond the substrate, use the regular edge holders to hold
the protector. If required, use the Double-sided day and night kit specific edge holders to hold the
substrate. If the protector is hidden below the substrate, use the regular edge holders to hold the
substrate.
Replace and/or place spindle ruler labels

▲ Spindle ruler label (CZ056-67239).
Replace spindle gear and end-cap

Perform the spindle gear and end cap replacement procedure. See MI MO gears upgrade and spindles
(K4T88-67151) on page 1249.
Check that tolerances are OK, that the spindle fits well inside the printer, and that the movement is smooth.
Drop-detector maintenance
Prepare to clean the drop-detector ink deposits
1. Ensure that you have a brush.
3. Move drop-detector station to service position (Print Care diagnostic 52004).
ENWW Replace and/or place spindle ruler labels 1457

Clean the drop-detector ink deposits
There is one ink deposit and ink vessel for every pen to be cleaned:
For each drop-detector, perform the following steps:
1. Dampen the surface of each ink deposit with a cloth dampened in isopropyl alcohol. Use the brush if
needed to clean the difficult parts.
NOTE: If you are in an area (such as California) that regulates VOC cleaning and maintenance fluids,
instead of isopropyl alcohol use a VOC-certified cleaner such as a properly diluted simple green all-purpose
cleaner.
2. Clean the surface of each ink deposit with a cloth dampened in isopropyl alcohol.
NOTE: If you are in an area (such as California) that regulates VOC cleaning and maintenance fluids,
instead of isopropyl alcohol use a VOC-certified cleaner such as a properly diluted simple green all-purpose
cleaner.
Finish off after cleaning the drop-detector ink deposits
1. Ensure that the cleaned parts are completely dry.
2. If you removed it earlier, return the upper section of the right front cover and screw it into place.
3. Close the right front cover and screw it into place.
4. Check that the printheads are in good condition, check printhead alignment, and check the section that
shows the health of the nozzles.
5. Turn on the printer in the correct way for maintenance operations.

Replace substrate drive OMAS sensor

Perform the OMAS platen assembly replacement procedure. See OMAS platen assembly (K4T88-67137)
on page 1200.
TBC
Replace service station cap modules

For each service station cap, perform its replacement procedure. See Service station caps kit (K4T88-67074)
on page 1147.
NOTE: Notice that there are 7 caps to be replaced.
1. Move the carriage to the service position in the middle of the print zone.
3. Using the service key, open the web wipe door.
4. Using a screwdriver and taking special care of not causing any damage, take out and replace damaged
caps. Insert and clip a new one on its place.
5. Once completed, move the carriage back to its capping position and turn on the printer to check it is seated
in the correct position without any crash.
Replace vapor removal pipes

Perform the vapor removal pipes replacement procedure. See Vapor removal link pipe (K4T88-67093)
on page 1323.
2. Open the ink module station covers.
3. Protect and cover the electronics of the ISM to avoid missing ink or condensation drops on critical parts.
4. Remove the plastic pipes, unscrewing the parts needed.
CAUTION: Be careful not to drop condensations or liquids to the electronics on the ink station.
5. Replace with new ones.
6. Close the covers.
7. Print and check there are no leakages of condensations or vapors inside the ISM.
Replace curing foams at curing module assembly

Perform the curing bottom plate side foams replacement procedure. See Curing Side Foams (K4G10-67122)
on page 767.
2. Remove the foams with a knife.
ENWW Replace substrate drive OMAS sensor 1459

3. Clean the metal surface.
4. Tape the new ones.
Replace vapor demister filter

Perform the vapor removal impactor replacement procedure. See Vapor removal link pipe (K4T88-67093)
on page 1323.
2. Open the ISM back door.
3. Open the vapor removal box.
4. Remove the vapor removal demister, unclipping the old one and clipping the new one.
NOTE: Check for dirt in the area, clean if necessary.
5. Run the vapor removal diagnostic to measure pressures.
Clean curing PCA fans

1. Remove the curing PCA fan from the printer. See Curing PCA cooling fan (K4T88-67304) on page 768.
2. Clean the curing PCA fan.
3. Install the curing PCA fan. See Curing PCA cooling fan (K4T88-67304) on page 768.
Swap carriage slider rods

Perform the carriage slider rods replacement procedure. See Scan axis slider rods (K4T88-67048) on page 930.
TBD
NOTE: This procedure is only required at 10 million cycles.
Replace complete tube routing system (TRS) chain with tubes and
cables
Perform the complete TRS chain with tubes and cables replacement procedure. See TRS eChain (K4T88-67058)
on page 1274.
2. Avoid twisting cables when assembling/inserting, this overstress cables (power, fiber-optics, ink tubes).
3. Ensure there is no high friction or kink in the tubes due limited space in the route of the tubes.
Replace carriage bushings and oiling foams and wicks

Perform carriage bushings and oiling foams and wicks replacement. See Carriage bearings (K4T88-67008)
on page 685

Grease drop detector transmission and rods

NOTE: Use gloves to grease all parts.
4. Clean both rods.
5. Put a few oil drops along the drop detector rods.
Grease substrate drive transmission gears

Grease the Drive roller gear
NOTE: Use gloves when applying grease to the gears.
1. Move the scan axis to the substrate load position to raise the carriage beam all the way. If you cannot start
the printer in the normal way due to some failure, use diagnostic mode.
3. Open the pinch.
5. Using gloves put some grease on your finger.
6. Apply some grease to the exposed part of the substrate drive roller gear by moving your finger up and
down the gear, filling the threads with grease.
WARNING! Do not remove the gear plastic cover to grease it as it will uncover the encoder disc also, and
therefore it could get dirty.
ENWW Grease drop detector transmission and rods 1461

7. Spin the drive roller motor coupling by hand, applying grease to all the gear threads.
NOTE: Do not put grease on the outside of the threads or on the bottom or top of the screw.
8. Clean both rods.
9. Put a few drops of oil along both the capping and the drop detector rods.
Grease the Drive roller worm gear
1. Perform the corresponding drive roller worm gear removal procedure. See Substrate drive roller
NOTE: Use gloves when applying grease to the gears.
2. Apply some grease to the substrate drive worm gear by moving your finger up and down the gear, filling
the threads with grease.
3. Perform the corresponding drive roller worm gear installation procedure. See Substrate drive roller
Replace primer and latches

Perform the primer and latches replacement procedure. See Primer and latch (1HA07-67018) on page 708.
1. Move the carriage to service position.
3. Disconnect the primers’ cables.
4. Twist primer and disengage.
5. Place the new one.
6. Switch on the printer.
7. Run the primer calibration check.

Replace damaged diverter wheels

Perform the diverter wheels replacement procedure. See Diverter wheel parts (K4T88-67134) on page 1273.
1. Open the substrate loading table.
2. Using a screwdriver, remove the covers as indicated.
3. Remove the damaged parts.
4. Replace with new ones, ensure there are all aligned with the rest of the wheels. Check pressure is
acceptable when closing.
Replace pinch clamp

Perform the pinch clamp replacement procedure. See Pinch clamp (K4G10-67106) on page 1207.
To replace the Pinch Clamp, just unscrew the part to replace as indicated in the picture, then screw the new one
into the same place.
Replace air valves

Perform the air valves replacement procedure. See Spindle air valve (K4G10-67094) on page 1181.
ENWW Replace damaged diverter wheels 1463

Substrate-advance motor replacement

The following procedure describes replacement of all the service parts listed below. Perform their corresponding
procedure in case a replacement is needed:
● Drive roller worm gear. See Substrate drive roller transmission assembly (CZ056-67228) on page 1187.
● Drive roller encoder disc and PCA. See Drive roller encoder disc and PCA (CZ056-67374) on page 1185.
Grease the carriage beam screws (PPS)
For more safety information, see Safety requirements on page 119.
Prepare to grease the carriage beam screws
2. Ensure that all windows, covers, and doors are closed and remain in their original position.
3. Move the carriage beam to its highest position (this takes about 2 minutes).

Grease the carriage beam screws
1. Put some grease on your finger.
2. Apply the grease to the exposed, middle part of the carriage beam screw by moving your finger up and
down the screw, filling the threads with grease.
3. Continue applying the grease until the whole middle section of the screw, all the way around the screw, is
greased.
NOTE: Do not put grease on the outside of the threads or on the bottom or top of the screw.
4. Repeat the above steps for each screw.
Spread the grease
1. Move the carriage beam back to its normal position so that the grease spreads along the screw (this takes
about 2 minutes).
ENWW Grease the carriage beam screws (PPS) 1465

2. Move the carriage beam to its highest position (this takes about 2 minutes).
3. Repeat the above steps twice more to spread the grease fully.
Finish off after greasing the carriage beam screws
1. Remove any extra grease.
2. Make sure that the platen and the carriage beam low switch does not have any grease that will prevent it
from working correctly. If grease is interfering with the switch, remove the switch, and gently clean the
grease from it.
3. Close the front door and ensure that all doors and covers are back in place.
4. Move the carriage beam back to its normal position (this takes about 2 minutes).

Summary of maintenance operations

The following table shows a summary of mandatory maintenance operations and how the service maintenance
kit should be used to perform them, with cross-references giving further information about these service parts,
maintenance operations, and replacement.
All of the maintenance operations in the table should be performed after every 5 million cycles.
Service Maintenance Kit CZ056-67310
Maintenance operation Cross-references Part number Description
Grease Carriage Beams Screws See ? CZ056-67463 Machine grease kit
Grease Service Station See Grease drop detector CZ056-67463 Machine grease kit
Transmission and Rods (Drop transmission and rods
Detector Station). on page 1461
Grease Substrate Drive See Grease substrate drive CZ056-67446 Drive roller worm gear grease
Transmission Gear transmission gears
on page 1461
Replace primer and latches See Primer and latch CZ056-67396 Primer and latch
(1HA07-67018) on page 708
Clean Curing PCA Fans (Fans See Clean curing PCA fans
incorporated in the PCA) on page 1460
Check/Adjust Carriage Belt See Scan axis belt tensioner

Tension (K4T88-67049) on page 923
Replace Complete TRS Chain See TRS eChain (K4T88-67058) CZ056–67319 Complete chain and tubes
with Tubes and Fiber Optics on page 1274
Replace Substrate Advance See Drive roller encoder disc and CZ056-67374 Drive roller encoder disc and
Motor Service Part (Gears+PCA PCA (CZ056-67374) PCA. Substrate drive roller
+Encoder) on page 1185. See Substrate CZ056-67228 transmission assembly
drive roller transmission
assembly (CZ056-67228)
on page 1187
Replace ISM 14x Intermediate See ISM intermediate tank CZ056-67074 ISM intermediate tank set
Tank (CZ056-67073) on page 1055
Replace Substrate Drive OMAS See OMAS platen assembly CZ056-67111 OMAS platen assembly
Sensor (K4T88-67137) on page 1200
Replace Service Station Caps See Service station caps kit CZ056-67036 Caps kit
modules (7) (K4T88-67074) on page 1147
Empty Drop Detectors Ink See Drop-detector maintenance

Vessel. Dismount Drop on page 1457.
Detectors and clean manually
Ink Vessels.
Replace Carriage Bushings and See Replace carriage bushings CZ056-67018 & CZ056-67295 Carriage bushing kit A
Oiling Foams and Wicks and oiling foams and wicks
on page 1460. CZ056-67440 new carriage bushing kit B
Replace Vapor Removal See Vapor removal link pipe CZ056-67380 Vapor removal impactor
Impactor (K4T88-67093) on page 1323
Replace Curing Foams at Curing See Curing Side Foams K4G10-67122 Curing bottom plate side foam
Module Assembly (K4G10-67122) on page 767.
ENWW Summary of maintenance operations 1467

Service Maintenance Kit CZ056-67310
Maintenance operation Cross-references Part number Description
Swap Slider rods (Front/Rear) at See Scan axis slider rods Scan-axis carriage 2 rods
10 Million Cycles (K4T88-67048) on page 930
Maintenance Inspection: See MO transmission box MI hardened support spindle

Replace Media Input and Media (K4T88-67150) on page 1248 plate
Output Transmission Box (Side and Motorized MI side plate
plates with the Transmission (K4T88-67145) on page 1242. MO hardened support spindle
(Gears, Bearings…) plate
Maintenance Inspection: See MI MO gears upgrade and Spindle gear hardened and end-
Replace spindle gear and end- spindles (K4T88-67151) cap set
cap on page 1249
Dual-roll spindle gear end-cap
Replace vapor removal pipes See Vapor removal link pipe Vapor extractor pipe kit
(K4T88-67093) on page 1323
Replace damaged diverter See Diverter wheel parts Diverter wheel

wheels (K4T88-67134) on page 1273
Replace pinch clamp See Pinch clamp Pinch clamp

(K4G10-67106) on page 1207
Replace air valves See Spindle air valve Spindle air valve
(K4G10-67094) on page 1181

A Cables
● K4T88-50001 – CS to P Data
● K4T88-50003 – Pen Primer Extension
● K4T88-50004 – Cs to P Power Cable Short
● K4T88-50005 – Cs to P Power Cable Short
● K4T88-50008 – VEGA to SEPIAS
● K4T88-50009 – Day and Night Line Sensor Cable
● K4T88-50010 – Carriage Encoder
● K4T88-50013 – Carriage Encoder
● K4T88-50014 – 42V Trailing
● K4T88-50015 – Slinky to Color PH board
● K4T88-50016 – Slinky to PT PH Board DAT
● K4T88-50017 – 24V IDS
● K4T88-50019 – E-box Fiber Optic
● K4T88-50020 – VEGA to Slinky Power
● K4T88-50021 – Air Pump and Relief Valve Cable
● K4T88-50026 – PAZ and FREYA Power Cable
● K4T88-50029 – Drying Power Cable Long
● K4T88-50030 – Drying Power Cable short
● K4T88-50031 – Drying 24V Long Cable
● K4T88-50032 – Drying 24V Short Cable
● K4T88-50033 – Drying Data Cable
● K4T88-50035 – Drying Data Parton to Parton
● K4T88-50036 – Drying Temperature Sensor Short
● K4T88-50037 – Drying Temperature Sensor Medium
ENWW 1469
● K4T88-50038 – Drying Temperature Sensor Long
● K4T88-50039 – Drying Heater Sensor Cable
● K4T88-50040 – Drying Heater Medium Cable
● K4T88-50041 – Drying Heater Long Cable
● K4T88-50042 – Drying Heater Short Cable
● K4T88-50043 – Drying Heater Medium Cable
● K4T88-50044 – Drying Fan Long Cable
● K4T88-50054 – LY PPS Power in T Cable
● K4T88-50055 – LY-Power in T Extension Cable
● K4T88-50056 – LY-Luna J4 to PPS Encoder Cab
● K4T88-50061 – ISS LEDs 0 to 3 Cable
● K4T88-50068 – Aerosol Harness
● K4T88-50071 – VR Pump Control Cable
● K4T88-50073 – VR Cable Power 24V Split to PA
● K4T88-50075 – VR Cable Power 230V Split to B
● K4T88-50089 – Ink Cartridge Cable
● K4T88-50090 – Supply Engagement Cable
● K4T88-50091 – Ground Braid L190mm
● K4T88-50102 – MI Motor Data Cable
● K4T88-50103 – MA PWM Data Cable
● K4T88-50104 – MA PWM Data Cable
● K4T88-50106 – AM80 Vacuum Pump Control
● K4T88-50109 – MO Encoder Cable
● K4T88-50110 – MI Encoder Cable
● K4T88-50114 – E-box to WW Cable
● K4T88-50117 – Vacuum PCA to Vacuum Pump
● K4T88-50118 – Vacuum Supply PCA Cable
● K4T88-50121 – E-cabinet to WW Power Cable
● K4T88-50123 – Curing Power
● K4T88-50124 – 24V Curing PCA
● K4T88-50125 – VR Fans Power Cable
1470 Appendix A Cables ENWW

● K4T88-50128 – Curing Data Cable
● K4T88-50136 – Sensor Box Cable
● K4T88-50142 – Luna to DD Motor and Encoder
● K4T88-50143 – DC Cable to Vega
● K4T88-50147 – ISS LEDs 0 to 3 Cable
● K4T88-50148 – Freya CAN Cable
● K4T88-50151 – DD Daisy Chain Cable
● K4T88-50153 – VR Pump Power Cable
● K4T88-50154 – Cable between Drop Mux PCA J5
● K4T88-50155 – Data Cable from Luna PCA to E
● K4T88-50156 – SAX Power Cable
● K4T88-50157 – Braking Resistor Enclosure PO
● K4T88-50158 – E-cab-MI Resistor Power Cable
● K4T88-50159 – VR Fans Array Cable
● K4T88-50160 – E-cab-MO Resistor Power Cable
● K4T88-50161 – Solenoid to SOL Cable
● K4T88-50162 – Line Sensor Cable
● K4T88-50163 – Drying Power
● K4T88-50164 – Wire from E-stop1 to TB
● K4T88-50165 – Wire from E-stop1 to E-stop2
● K4T88-50168 – Wire from E-stop4 to TB
● K4T88-50169 – Wire from Interlock1 to TB
● K4T88-50170 – Wire between Interlocks
● K4T88-50171 – Wire from Interlock2 to TB
● K4T88-50172 – Cable to Interlock1
● K4T88-50173 – Cable to Interlock2
● K4T88-50175 – E-box to E-cabinet PCA Cable
● K4T88-50176 – HP Nexus Viking Cable Freya T
● K4T88-50177 – HP Nexus Viking Cable Freya T
ENWW 1471
● K4T88-50180 – Leakage
● K4T88-50182 – VR Cable LAN Split to Parton
● K4T88-50183 – HDE15P-HDE115S-From Freya
● K4T88-50185 – SAX Data Cable
● K4T88-50186 – E-cab- MA Motor Power
● K4T88-50187 – MI Resistor-MI Motor Power CA
● K4T88-50188 – MO Resistor-MO Motor Power CA
● K4T88-50189 – Buzzer Extension Cable
● K4T88-50190 – E-box to Luna TUR Cable
● K4T88-50191 – Pinch Switch Right Structure
● K4T88-50200 – LY EC Vacuum Supply
● K4T88-50201 – LY EC VR Supply
● K4T88-50202 – LY EC PSU-1 DC Out
● K4T88-50210 – LY EC EN Light
● K4T88-50211 – LY EC Safety Relay Assy
● K4T88-50212 – LY EC Fan1 Assy
● K4T88-50213 – LY EC Fan2 Assy
● K4T88-50214 – LY EC Fan Extension
● K4T88-50215 – LY EC Contactors FB
● K4T88-50216 – LY EC Curing AC
● K4T88-50217 – LY EC Drying AC
● K4T88-50224 – Drying Temperature Sensor Medium
● K4T88-50225 – Drying Fan Medium Cable SVS
● K4T88-50226 – Drying Heater Medium Cable SV
● K4T88-50227 – E-cabinet to Luna Power Cable

● K4T88-50230 – LY-Power in T extension Cable
● K4T88-50231 – Gabi PCA to Lifter ID1 Cable
● K4T88-50232 – Gabi PCA to Lifter ID2 Cable
● K4T88-50233 – Gabi PCA to Contactor Cable
● K4T88-50234 – E-cabinet to Contactor Cable
● K4T88-50235 – Luna to Luna Cable
● K4T88-50236 – PPS Data Cable
● K4T88-50237 – Broken Bag 0-3 Cable
● K4T88-50238 – Broken Bag 4-7 Cable
● K4T88-50239 – Carriage Interconect to Primer Valves 1
● K4T88-50240 – Primer Pump Cable
● K4T88-50243 – PZ LEDs (Printzone LED)
● K4T88-50244 – Luna PZ LEDs Cable (Buttons)
● K4T88-50246 – Interlock 3 to Interlock 1 Cable
● K4T88-50247 – E-cabinet PCA to Interlock 3 Cable
● K4T88-50248 – Aerosol FAN Lyra to PCA
● K4T88-50250 – Safety Wiring to E-stop 1 Cable White
● K4T88-50251 – E-stop 1 to E-stop 2 Cable White
● K4T88-50254 – Safety Wiring to E-stop 4 Cable White
● K4T88-50261 – E-cabinet PCA to SAX Resistor Contactor
● K4T88-50264 – E-cabinet PCA to SAX Resistor Contactor Feedback
● K4T88-50268 – Brown Line Cable for Curing, Drying and Autotransformers
● K4T88-50269 – Brown Line Cable for Drying and Cooling
● K4T88-50270 – Black Line Cable for Drying, Curing and Autotransformers
● K4T88-50271 – Black Line Cable for Curing and Drying
● K4T88-50272 – Grey Line Cable for Drying, Curing and Autotransformers
● K4T88-50273 – Grey Line Cable for Curing and Drying
● K4T88-50274 – Blue Neutral Cable for Drying, Curing and Autotransformer
● K4T88-50275 – Blue Neutral cable for Curing and Drying
ENWW 1473
● K4T88-50276 – Brown Line Cable for PSU and Other
● K4T88-50277 – Brown Line Cable for Autotransformers
● K4T88-50278 – Brown Line Cable for PSU and E-box, Aux Connectors
● K4T88-50279 – Black Line Cable for PSU and Other
● K4T88-50280 – Black Line Cable for Autotransformers
● K4T88-50282 – Grey Line Cable for PSU and Other
● K4T88-50283 – Grey Line Cable for Autotransformers
● K4T88-50284 – Blue Neutral Cable for PSU and Others
● K4T88-50285 – Blue Neutral Cable for Autotransformers
● K4T88-50286 – IDS i2c Data
● K4T88-50287 – E-box-VR Fans Cable
● K4T88-50289 – Beacon Cable Extension
● K4T88-50290 – IPS to Beacon Light Cable
● K4T88-50291 – Ink Cartridge Cable Lyra
● K4T88-50292 – Supply Engagement Cable Lyra
● K4T88-50313 – Black Line Cable for Curing and Drying
● K4T88-50318 – Grey Line Cable for Curing and Drying
● K4T88-50393 – Brown Line Cable
● K4T88-50394 – Blue Line Cable
● K4T88-50413 - IPS to E-box LAN Cable
● K4T88-50415 – LY_EC_PSU-8 DC OUT
● CQ105-50010 – Hard Disk Data Cable
● CZ056-50001 – AM 80 Tokamok to Tomamok 1
● CZ056-50002 – AM 80 Tokamok to Tomamok 2
● CZ056-50003 – Engine Adaptor PCA Power Cable
● CZ056-50019 – AM80 LAN Curing PCA to Curing
● CZ056-50036 – MA Encoder Cable
● CZ056-50038 – Vacuum Control - OMAS Encoder

● CZ056-50039 – Vacuum Control - OMAS
● CZ056-50040 – Vacuum Control - OMAS Power
● CZ056-50114 – Vacuum Pump Power
● CZ056-50116 – Capping Motor Encoder Cable
● CZ056-50121 – Heater Cable
● CZ056-50133 – Engine PCA to Engine Adaptor P
● CZ056-50134 – Engine PCA to Engine Adaptor PCA Cable
● CZ056-50156 – Engine PCA to Engine Adaptor PCA Cable
● CZ056-50161 – WW Power in T Cable
● CZ056-50170 – TUR Sensor Cable
● CZ056-50183 – Temp Extension Curing
● CZ056-50202 – OMAS Controller to Sensor Cab
● CZ056-50218 – AC Parton to Parton
● CZ056-50219 – DC Parton to Parton
● CZ056-50220 – Tokaheart-slinky Long
● CZ056-50221 – ATX to Slinky Power Cable
● CZ056-50222 – Formatter Output Data Cable
● CZ056-50231 – AC Connector to Partons
● CZ056-50232 – DC Connector to Partons
● CZ056-50252 – CAN B Bus Cable
● CZ056-50281 – Curing Fan Cable
● K4G10-50013 – E-box to E-cabinet PCA Cable
● Q6702-50003 – SOL Cable
● Q6703-50031 – Data Cable Luna-Luna
ENWW 1475
K4T88-50001 – CS to P Data
Subsystem: IDS
Quantity: 2x printer
Included in the following service parts:
● K4T88-67007 Carriage Cables SERV

K4T88-50003 – Pen Primer Extension

Subsystem: IDS
ENWW K4T88-50003 – Pen Primer Extension 1477

K4T88-50004 – Cs to P Power Cable Short

Subsystem: IDS

K4T88-50005 – Cs to P Power Cable Short

Subsystem: IDS
ENWW K4T88-50005 – Cs to P Power Cable Short 1479

K4T88-50008 – VEGA to SEPIAS

Subsystem: IDS

K4T88-50009 – Day and Night Line Sensor Cable

Subsystem: IDS
ENWW K4T88-50009 – Day and Night Line Sensor Cable 1481

K4T88-50010 – Carriage Encoder

Subsystem: IDS

K4T88-50013 – Carriage Encoder

Subsystem: DD
● K4T88-67077 Drop Detection Station
ENWW K4T88-50013 – Carriage Encoder 1483

K4T88-50014 – 42V Trailing

Subsystem: Carriage
● K4T88-67058 TRS E-chain SERV

K4T88-50015 – Slinky to Color PH board

Subsystem: Carriage
● K4T88-67007 Carriage Cable SERV
ENWW K4T88-50015 – Slinky to Color PH board 1485

K4T88-50016 – Slinky to PT PH Board DAT

Subsystem: Carriage
● K4T88-67007 Carriage Cable SERV

K4T88-50017 – 24V IDS

Subsystem: IDS
● K4T88-67022 IDS Cable SERV
ENWW K4T88-50017 – 24V IDS 1487

K4T88-50019 – E-box Fiber Optic

Subsystem: E-box
● K4T88-67056 TRS Fiber Optics Trailing Cab

K4T88-50020 – VEGA to Slinky Power

Subsystem: Carriage
ENWW K4T88-50020 – VEGA to Slinky Power 1489

K4T88-50021 – Air Pump and Relief Valve Cable

Subsystem: IDS
Included in the following service parts: K4T88-67022

K4T88-50026 – PAZ and FREYA Power Cable

Subsystem: IDS
● K4T88-67022 IDS Cables SERV
ENWW K4T88-50026 – PAZ and FREYA Power Cable 1491

K4T88-50029 – Drying Power Cable Long

Subsystem: Drying
● K4T88-67230 Drying Power Cables Kits SERV

K4T88-50030 – Drying Power Cable short

Subsystem: Drying
ENWW K4T88-50030 – Drying Power Cable short 1493

K4T88-50031 – Drying 24V Long Cable

Subsystem: Drying

K4T88-50032 – Drying 24V Short Cable

Subsystem: Drying
ENWW K4T88-50032 – Drying 24V Short Cable 1495

K4T88-50033 – Drying Data Cable

Subsystem: Drying
● K4T88-67228 Drying Data Kit Cable SERV

K4T88-50035 – Drying Data Parton to Parton

Subsystem: Drying
ENWW K4T88-50035 – Drying Data Parton to Parton 1497

K4T88-50036 – Drying Temperature Sensor Short

Subsystem: Drying
● K4T88-67229 Drying PCA Cables Kit SERV

K4T88-50037 – Drying Temperature Sensor Medium

Subsystem: Drying
ENWW K4T88-50037 – Drying Temperature Sensor Medium 1499

K4T88-50038 – Drying Temperature Sensor Long

Subsystem: Drying

K4T88-50039 – Drying Heater Sensor Cable

Subsystem: Drying
ENWW K4T88-50039 – Drying Heater Sensor Cable 1501

K4T88-50040 – Drying Heater Medium Cable

Subsystem: Drying

K4T88-50041 – Drying Heater Long Cable

Subsystem: Drying
ENWW K4T88-50041 – Drying Heater Long Cable 1503

K4T88-50042 – Drying Heater Short Cable

Subsystem: Drying

K4T88-50043 – Drying Heater Medium Cable

Subsystem: Drying
ENWW K4T88-50043 – Drying Heater Medium Cable 1505

K4T88-50044 – Drying Fan Long Cable

Subsystem: Drying

K4T88-50054 – LY PPS Power in T Cable

Subsystem: PPS
● K4T88-67065 PPS Cables Kit SERV
ENWW K4T88-50054 – LY PPS Power in T Cable 1507

K4T88-50055 – LY-Power in T Extension Cable

Subsystem: PPS

K4T88-50056 – LY-Luna J4 to PPS Encoder Cab

Subsystem: PPS
ENWW K4T88-50056 – LY-Luna J4 to PPS Encoder Cab 1509

K4T88-50061 – ISS LEDs 0 to 3 Cable

Subsystem: IDS

K4T88-50068 – Aerosol Harness

Subsystem: IDS
● K4T88-67003 Aerosol Top Case Assy SERV
ENWW K4T88-50068 – Aerosol Harness 1511

K4T88-50071 – VR Pump Control Cable

Subsystem: Vapor Removal
● K4T88-67250 Vapor Removal Kit Cable SERV

K4T88-50073 – VR Cable Power 24V Split to PA

ENWW K4T88-50073 – VR Cable Power 24V Split to PA 1513

K4T88-50075 – VR Cable Power 230V Split to B


K4T88-50089 – Ink Cartridge Cable

Subsystem: IDS
● K4T88-67022 IDS Kit Cable SERV
ENWW K4T88-50089 – Ink Cartridge Cable 1515

K4T88-50090 – Supply Engagement Cable

Subsystem: IDS
● K4T88-67022 IDS Kit Cable SERV

K4T88-50091 – Ground Braid L190mm

Subsystem: Curing
● K4T88-67224 Curing Grounding Cables Kit SERV
ENWW K4T88-50091 – Ground Braid L190mm 1517

K4T88-50102 – MI Motor Data Cable

Subsystem: SAX
● K4T88-67242 MI Motor Data Cable SERV

K4T88-50103 – MA PWM Data Cable

Subsystem: SAX
● K4T88-67244 MO Motor Data Cable SERV
ENWW K4T88-50103 – MA PWM Data Cable 1519

K4T88-50104 – MA PWM Data Cable

Subsystem: SAX
● K4T88-67239 MA Motor Data Cable SERV

K4T88-50106 – AM80 Vacuum Pump Control

Subsystem: Vacuum
● K4T88-67237 OMAS and Vacuum Cables Kit SR
ENWW K4T88-50106 – AM80 Vacuum Pump Control 1521

K4T88-50109 – MO Encoder Cable

Subsystem: Vacuum
● K4T88-67244 MO Motor Encoder Cable SERV

K4T88-50110 – MI Encoder Cable

Subsystem: Vacuum
● K4T88-67241 MI Motor Encoder Cable SERV
ENWW K4T88-50110 – MI Encoder Cable 1523

K4T88-50114 – E-box to WW Cable

Subsystem: Web Wipe
● K4T88-67251 Web Wipe Cables Kit SERV

K4T88-50117 – Vacuum PCA to Vacuum Pump

Subsystem: Web Wipe
● K4T88-67238 Vacuum Pump Cable Kit SERV
ENWW K4T88-50117 – Vacuum PCA to Vacuum Pump 1525

K4T88-50118 – Vacuum Supply PCA Cable

Subsystem: Vacuum
● K4T88-67237 OMAS and Vacuum Cables Kit SR

K4T88-50121 – E-cabinet to WW Power Cable

Subsystem: WW
ENWW K4T88-50121 – E-cabinet to WW Power Cable 1527

K4T88-50123 – Curing Power

Subsystem: Curing
● K4T88-67225 Curing Power Cables Kit SERV

K4T88-50124 – 24V Curing PCA

Subsystem: Curing
ENWW K4T88-50124 – 24V Curing PCA 1529

K4T88-50125 – VR Fans Power Cable

● K4T88-67249 Vapor Removal Interconnect Kit

K4T88-50128 – Curing Data Cable

Subsystem: Curing
● K4T88-67222 Curing Lan Cables Kit SERV
ENWW K4T88-50128 – Curing Data Cable 1531

K4T88-50136 – Sensor Box Cable

Subsystem: Curing
● K4T88-67005 Sol SERV

K4T88-50142 – Luna to DD Motor and Encoder

Subsystem: DD
● K4T88-67077 Drop Detector Station
ENWW K4T88-50142 – Luna to DD Motor and Encoder 1533

K4T88-50143 – DC Cable to Vega

Subsystem: Carriage

K4T88-50147 – ISS LEDs 0 to 3 Cable

Subsystem: IDS
ENWW K4T88-50147 – ISS LEDs 0 to 3 Cable 1535

K4T88-50148 – Freya CAN Cable

Subsystem: IDS

K4T88-50151 – DD Daisy Chain Cable

Subsystem: DD
● K4T88-60103 Drop Detect Station Assy
ENWW K4T88-50151 – DD Daisy Chain Cable 1537

K4T88-50153 – VR Pump Power Cable

● K4T88-67249 Vapor Removal Interconnect Kit

K4T88-50154 – Cable between Drop Mux PCA J5

Subsystem: DD
ENWW K4T88-50154 – Cable between Drop Mux PCA J5 1539

K4T88-50155 – Data Cable from Luna PCA to E

Subsystem: DD
● K4T88-67227 Drop Detector System Motor Kit

K4T88-50156 – SAX Power Cable

Subsystem: SAX
● K4T88-67046 SAX Motor Power Cable SERV
ENWW K4T88-50156 – SAX Power Cable 1541

K4T88-50157 – Braking Resistor Enclosure PO

Subsystem: SAX
● K4T88-67046 SAX Motor Power Cable SERV

K4T88-50158 – E-cab-MI Resistor Power Cable

Subsystem: SAX
● K4T88-67247 MI Resistors Power Cable SERV
ENWW K4T88-50158 – E-cab-MI Resistor Power Cable 1543

K4T88-50159 – VR Fans Array Cable


K4T88-50160 – E-cab-MO Resistor Power Cable

Subsystem: SAX
● K4T88-67248 MO Resistors Power Cable SERV
ENWW K4T88-50160 – E-cab-MO Resistor Power Cable 1545

K4T88-50161 – Solenoid to SOL Cable

Subsystem: TUR
● K4T88‐67252 SOL PCA Kit Cables SERV

K4T88-50162 – Line Sensor Cable

Subsystem: Carriage
● K4T88-67004 Line Sensor SERV
ENWW K4T88-50162 – Line Sensor Cable 1547

K4T88-50163 – Drying Power

Subsystem: Drying
● K4T88-67230 Drying Power Cable Kit SERV

K4T88-50164 – Wire from E-stop1 to TB

Subsystem: E-stops
● K4T88-67234 E-stop Kit Cables SERV
ENWW K4T88-50164 – Wire from E-stop1 to TB 1549

K4T88-50165 – Wire from E-stop1 to E-stop2

Subsystem: E-stops


Subsystem: E-stops
ENWW K4T88-50166 – Wire from E-stop2 to E-stop3 1551


Subsystem: E-stops

K4T88-50168 – Wire from E-stop4 to TB

Subsystem: E-stops
ENWW K4T88-50168 – Wire from E-stop4 to TB 1553

K4T88-50169 – Wire from Interlock1 to TB

Subsystem: E-stops
● K4T88-67235 Interlocks Sensors Kit Cables

K4T88-50170 – Wire between Interlocks

Subsystem: E-stops
ENWW K4T88-50170 – Wire between Interlocks 1555

K4T88-50171 – Wire from Interlock2 to TB

Subsystem: E-stops

K4T88-50172 – Cable to Interlock1

Subsystem: E-stops
● K4T88-67236 PCA Interlocks Kit Cables SERV
ENWW K4T88-50172 – Cable to Interlock1 1557

K4T88-50173 – Cable to Interlock2

Subsystem: E-stops
● K4T88-67236 PCA Interlocks Kit Cables SERV

K4T88-50175 – E-box to E-cabinet PCA Cable

Subsystem: E-box
● K4T88-67231 LY E-box Cables Kit SERV
ENWW K4T88-50175 – E-box to E-cabinet PCA Cable 1559

K4T88-50176 – HP Nexus Viking Cable Freya T

Subsystem: IDS

K4T88-50177 – HP Nexus Viking Cable Freya T

Subsystem: IDS
ENWW K4T88-50177 – HP Nexus Viking Cable Freya T 1561

K4T88-50180 – Leakage
Subsystem: IDS

K4T88-50182 – VR Cable LAN Split to Parton

ENWW K4T88-50182 – VR Cable LAN Split to Parton 1563

K4T88-50183 – HDE15P-HDE115S-From Freya

Subsystem: IDS

K4T88-50185 – SAX Data Cable

Subsystem: SAX
● K4T88-67047 SAX Motor Data Cable SERV
ENWW K4T88-50185 – SAX Data Cable 1565

K4T88-50186 – E-cab- MA Motor Power

Subsystem: SAX and MP
● K4T88-67240 MA Motor Power Cable SERV

K4T88-50187 – MI Resistor-MI Motor Power CA

● K4T88-67243 MI Motor Power Cable SERV
ENWW K4T88-50187 – MI Resistor-MI Motor Power CA 1567

K4T88-50188 – MO Resistor-MO Motor Power CA

● K4T88-67246 MO Motor Power Cable SERV

K4T88-50189 – Buzzer Extension Cable

Subsystem: TUR
● K4T88-67252 SOL PCA Kit Cables
ENWW K4T88-50189 – Buzzer Extension Cable 1569

K4T88-50190 – E-box to Luna TUR Cable

Subsystem: TUR

K4T88-50191 – Pinch Switch Right Structure

Subsystem: Pinch
● K4T88-67254 Pinch Complete Assy
ENWW K4T88-50191 – Pinch Switch Right Structure 1571

K4T88-50200 – LY EC Vacuum Supply

Subsystem: E-cabinet
● K4T88-67276 E-cabinet Bundle Cables

K4T88-50201 – LY EC VR Supply
ENWW K4T88-50201 – LY EC VR Supply 1573

K4T88-50202 – LY EC PSU-1 DC Out



ENWW K4T88-50203 – LY EC PSU-2 DC Out 1575











K4T88-50210 – LY EC EN Light
ENWW K4T88-50210 – LY EC EN Light 1581

K4T88-50211 – LY EC Safety Relay Assy


K4T88-50212 – LY EC Fan1 Assy

ENWW K4T88-50212 – LY EC Fan1 Assy 1583

K4T88-50213 – LY EC Fan2 Assy


K4T88-50214 – LY EC Fan Extension

ENWW K4T88-50214 – LY EC Fan Extension 1585

K4T88-50215 – LY EC Contactors FB

K4T88-50216 – LY EC Curing AC
ENWW K4T88-50216 – LY EC Curing AC 1587

K4T88-50217 – LY EC Drying AC

K4T88-50224 – Drying Temperature Sensor Medium

Subsystem: Drying
ENWW K4T88-50224 – Drying Temperature Sensor Medium 1589

K4T88-50225 – Drying Fan Medium Cable SVS

Subsystem: Drying

K4T88-50226 – Drying Heater Medium Cable SV

Subsystem: Drying
ENWW K4T88-50226 – Drying Heater Medium Cable SV 1591

K4T88-50227 – E-cabinet to Luna Power Cable

Subsystem: DD
● K4T88-67077 Drop Detector Station

K4T88-50230 – LY-Power in T extension Cable

Subsystem: PPS
● K4T88-67065 PPS Cables Service
ENWW K4T88-50230 – LY-Power in T extension Cable 1593

K4T88-50231 – Gabi PCA to Lifter ID1 Cable

Subsystem: PPS

K4T88-50232 – Gabi PCA to Lifter ID2 Cable

Subsystem: PPS
ENWW K4T88-50232 – Gabi PCA to Lifter ID2 Cable 1595

K4T88-50233 – Gabi PCA to Contactor Cable

Subsystem: PPS

K4T88-50234 – E-cabinet to Contactor Cable

Subsystem: PPS
ENWW K4T88-50234 – E-cabinet to Contactor Cable 1597

K4T88-50235 – Luna to Luna Cable

Subsystem: PPS

K4T88-50236 – PPS Data Cable

Subsystem: PPS
ENWW K4T88-50236 – PPS Data Cable 1599

K4T88-50237 – Broken Bag 0-3 Cable

Subsystem: IDS

K4T88-50238 – Broken Bag 4-7 Cable

Subsystem: IDS
ENWW K4T88-50238 – Broken Bag 4-7 Cable 1601

K4T88-50239 – Carriage Interconect to Primer Valves 1

Subsystem: Carriage
● K4T88-67013 Primer and Latch SERV

K4T88-50240 – Primer Pump Cable

Subsystem: Carriage
● K4T88-67013 Primer and Latch SERV
ENWW K4T88-50240 – Primer Pump Cable 1603

K4T88-50243 – PZ LEDs (Printzone LED)

Subsystem: D&N LED Beacon

K4T88-50244 – Luna PZ LEDs Cable (Buttons)

ENWW K4T88-50244 – Luna PZ LEDs Cable (Buttons) 1605

K4T88-50246 – Interlock 3 to Interlock 1 Cable

Subsystem: e-Cabinet

K4T88-50247 – E-cabinet PCA to Interlock 3 Cable

ENWW K4T88-50247 – E-cabinet PCA to Interlock 3 Cable 1607

K4T88-50248 – Aerosol FAN Lyra to PCA


K4T88-50250 – Safety Wiring to E-stop 1 Cable White

● K4T88-67234 E-stop Kit Cables
ENWW K4T88-50250 – Safety Wiring to E-stop 1 Cable White 1609

K4T88-50251 – E-stop 1 to E-stop 2 Cable White



ENWW K4T88-50252 – E-stop 2 to E-stop 3 Cable White 1611



K4T88-50254 – Safety Wiring to E-stop 4 Cable White

ENWW K4T88-50254 – Safety Wiring to E-stop 4 Cable White 1613

K4T88-50261 – E-cabinet PCA to SAX Resistor Contactor

Subsystem: SA MI MO MA

K4T88-50264 – E-cabinet PCA to SAX Resistor Contactor Feedback

Subsystem: SA MI MO MA
ENWW K4T88-50264 – E-cabinet PCA to SAX Resistor Contactor Feedback 1615

K4T88-50268 – Brown Line Cable for Curing, Drying and

Autotransformers
● K4T88-67275 E-cabinet AC-6AWG cables
From To
Device Terminal Device Terminal Color Length
ACB-1 4 K-1 6 BROWN 180

K4T88-50269 – Brown Line Cable for Drying and Cooling

From To
K-1 5 TB-4 2 BROWN 220
ENWW K4T88-50269 – Brown Line Cable for Drying and Cooling 1617
K4T88-50270 – Black Line Cable for Drying, Curing and

Autotransformers
From To
ACB-1 6 K-1 4 BLACK 180

K4T88-50271 – Black Line Cable for Curing and Drying

From To
K-1 3 TB-4 4 BLACK 200
ENWW K4T88-50271 – Black Line Cable for Curing and Drying 1619
K4T88-50272 – Grey Line Cable for Drying, Curing and

Autotransformers
From To
ACB-1 8 K-1 2 GREY 180

K4T88-50273 – Grey Line Cable for Curing and Drying

From To
K-1 1 TB-4 6 GREY 200
ENWW K4T88-50273 – Grey Line Cable for Curing and Drying 1621
K4T88-50274 – Blue Neutral Cable for Drying, Curing and

Autotransformer
From To
ACB-1 2 TB-11 1 BLUE 170

K4T88-50275 – Blue Neutral cable for Curing and Drying

From To
TB-11 1 TB-4 1 BLUE 220
ENWW K4T88-50275 – Blue Neutral cable for Curing and Drying 1623
K4T88-50276 – Brown Line Cable for PSU and Other

From To
ACB-1 4 TB-2 2 BROWN 160

K4T88-50277 – Brown Line Cable for Autotransformers

From To
K-1 5 TB-3 2 BROWN 500
ENWW K4T88-50277 – Brown Line Cable for Autotransformers 1625

K4T88-50278 – Brown Line Cable for PSU and E-box, Aux

Connectors
From To
TB-2 2 TB-5 2 BROWN 930

K4T88-50279 – Black Line Cable for PSU and Other

From To
ACB-1 6 TB-2 4 BLACK 160
ENWW K4T88-50279 – Black Line Cable for PSU and Other 1627
K4T88-50280 – Black Line Cable for Autotransformers

From To
K-1 3 TB-3 4 BLACK 560

K4T88-50282 – Grey Line Cable for PSU and Other

From To
ACB-1 8 TB-2 6 GREY 160
ENWW K4T88-50282 – Grey Line Cable for PSU and Other 1629
K4T88-50283 – Grey Line Cable for Autotransformers

From To
K-1 1 TB-3 6 GREY 600

K4T88-50284 – Blue Neutral Cable for PSU and Others

From To
ACB-1 2 TB-2 1 BLUE 180
ENWW K4T88-50284 – Blue Neutral Cable for PSU and Others 1631
K4T88-50285 – Blue Neutral Cable for Autotransformers

From To
TB11 1 TB-3 1 BLUE 460

K4T88-50286 – IDS i2c Data

● K4T88-67249 VR Interconnect Kit
ENWW K4T88-50286 – IDS i2c Data 1633

K4T88-50287 – E-box-VR Fans Cable

● K4T88-67249 VR Interconnect Kit

K4T88-50289 – Beacon Cable Extension

ENWW K4T88-50289 – Beacon Cable Extension 1635

K4T88-50290 – IPS to Beacon Light Cable


K4T88-50291 – Ink Cartridge Cable Lyra

Subsystem: IDS
● K4T88-67027 IDS K Cartridge Connector WIT
ENWW K4T88-50291 – Ink Cartridge Cable Lyra 1637

K4T88-50292 – Supply Engagement Cable Lyra

Subsystem: IDS

K4T88-50313 – Black Line Cable for Curing and Drying

Subsystem:
From To
TB-4 4 RCD2 3 BLACK 250
ENWW K4T88-50313 – Black Line Cable for Curing and Drying 1639
K4T88-50318 – Grey Line Cable for Curing and Drying

From To
TB-4 6 RCD1 3 GREY 210


From To
TB-4 5 RCD1 1 BLUE 200

From To


From To
K4T88-50393 – Brown Line Cable

From To
TB-3 2 RCBO-1 1 BROWN 410

K4T88-50394 – Blue Line Cable

From To
TB-3 1 RCBO-1 3 BLUE 370
ENWW K4T88-50394 – Blue Line Cable 1645

K4T88-50413 - IPS to E-box LAN Cable

Subsystem: E-box

K4T88-50415 – LY_EC_PSU-8 DC OUT

● K4T88-67276 E-cabinet Bundle cables
From To
PSU-8 24V CONN3 1 RED 650
GND CONN3 2 BLACK
ENWW K4T88-50415 – LY_EC_PSU-8 DC OUT 1647

CQ105-50010 – Hard Disk Data Cable

Subsystem: E-box
● K4T88-67268 E-box HDD SERV

CZ056-50001 – AM 80 Tokamok to Tomamok 1

Subsystem: E-box
● K4T88-67231 E-box Cables Kit SERV
ENWW CZ056-50001 – AM 80 Tokamok to Tomamok 1 1649

CZ056-50002 – AM 80 Tokamok to Tomamok 2

Subsystem: E-box

CZ056-50003 – Engine Adaptor PCA Power Cable

Subsystem: E-box
ENWW CZ056-50003 – Engine Adaptor PCA Power Cable 1651

CZ056-50019 – AM80 LAN Curing PCA to Curing

Subsystem: Curing
● K4T88-67222 Curing LAN Cables Kit SERV

CZ056-50036 – MA Encoder Cable

Subsystem: Vacuum
● K4T88-67094 MA Motor Encoder Cable SERV
ENWW CZ056-50036 – MA Encoder Cable 1653

CZ056-50038 – Vacuum Control - OMAS Encoder

Subsystem: Vacuum
● K4T88-67321 OMAS and Vacuum PCA SERV

CZ056-50039 – Vacuum Control - OMAS

Subsystem: Vacuum
ENWW CZ056-50039 – Vacuum Control - OMAS 1655

CZ056-50040 – Vacuum Control - OMAS Power

Subsystem: Vacuum

CZ056-50114 – Vacuum Pump Power

Subsystem: Vacuum
● K4T88-67238 Vacuum Pump Cable Kit SERV
ENWW CZ056-50114 – Vacuum Pump Power 1657

CZ056-50116 – Capping Motor Encoder Cable

Subsystem: Web Wipe

CZ056-50121 – Heater Cable

Subsystem: Curing
● K4T88-67126 Curing Right Module SERV
ENWW CZ056-50121 – Heater Cable 1659

CZ056-50133 – Engine PCA to Engine Adaptor P

Subsystem: E-box

CZ056-50134 – Engine PCA to Engine Adaptor PCA Cable

Subsystem: E-box
ENWW CZ056-50134 – Engine PCA to Engine Adaptor PCA Cable 1661

CZ056-50156 – Engine PCA to Engine Adaptor PCA Cable

Subsystem: Web Wipe

CZ056-50161 – WW Power in T Cable

Subsystem: Web Wipe
ENWW CZ056-50161 – WW Power in T Cable 1663

CZ056-50170 – TUR Sensor Cable

Subsystem: TUR

CZ056-50183 – Temp Extension Curing

Subsystem: Curing
● K4T88-67055 Curing Temperature Sensor Kit
ENWW CZ056-50183 – Temp Extension Curing 1665

CZ056-50202 – OMAS Controller to Sensor Cab

Subsystem: OMAS
● K4T88-67137 OMAS Platen Assembly

CZ056-50218 – AC Parton to Parton

Subsystem: Curing
● K4T88-67223 Curing PCA Cables Kit SERV
ENWW CZ056-50218 – AC Parton to Parton 1667

CZ056-50219 – DC Parton to Parton

Subsystem: Curing
● K4T88-67223 Curing PCA Cables Kit SERV

CZ056-50220 – Tokaheart-slinky Long

Subsystem: E-box
ENWW CZ056-50220 – Tokaheart-slinky Long 1669

CZ056-50221 – ATX to Slinky Power Cable

Subsystem: E-box

CZ056-50222 – Formatter Output Data Cable

Subsystem: E-box
● K4T88-67
ENWW CZ056-50222 – Formatter Output Data Cable 1671

CZ056-50231 – AC Connector to Partons

Subsystem: Curing

CZ056-50232 – DC Connector to Partons

Subsystem: Curing
ENWW CZ056-50232 – DC Connector to Partons 1673

CZ056-50252 – CAN B Bus Cable

Subsystem: E-box

CZ056-50281 – Curing Fan Cable

Subsystem: Curing
● K4T88-67126 Curing Right Module SERV
ENWW CZ056-50281 – Curing Fan Cable 1675

K4G10-50013 – E-box to E-cabinet PCA Cable

Subsystem: E-box

Q6702-50003 – SOL Cable

Subsystem: Carriage
● K4T88-67005 SOL SERV
ENWW Q6702-50003 – SOL Cable 1677

Q6703-50031 – Data Cable Luna-Luna

Subsystem: Web Wipe

Index
A 01.06.04:04 152 10.03.06:18 177

automatic tracking 460 01.06.04:10 153 10.03.06:19 178
01.60.00:01 153 10.03.07:01 178
B 01.60.00:75 154 10.03.07:10 179
banding problems 460 01.60.01:03 154 10.03.07:18 180
01.60.02:03 155 10.03.07:19 180
C 01.60.03:03 155 10.04.11:10 181
color calibration 458 10.01.01:01 156 10.04.12:10 182
color consistency between printers 10.01.02:01 157 10.04.13:10 182
460 10.02.00:01 157 10.04.14:10 183
color profile 460 10.02.00:03 158 10.04.15:10 183
10.02.00:04 159 10.04.21:10 184
P 10.02.00:11 159 10.04.22:10 184
print-quality problems 10.02.00:13 160 10.04.31:10 185
general 475 10.02.00:15 160 10.04.32:10 185
printhead 10.02.00:20 161 10.04.33:10 186
align 450 10.02.00:21 161 10.04.34:10 186
printhead alignment diagnostics 10.02.00:41 162 10.04.35:10 187
plot 455 10.03.01:01 163 10.04.35:40 187
10.03.01:18 164 10.04.41:10 188
S 10.03.01:19 164 10.04.42:10 188
substrate 10.03.02:01 165 10.04.51:10 189
advance compensation 460 10.03.02:10 166 10.04.52:10 189
System error codes 10.03.02:18 166 10.04.61:10 190
01.01.00:01 142 10.03.02:19 167 10.04.62:10 190
01.02.01:02 143 10.03.03:01 168 10.04.71:10 191
01.02.01:76 143 10.03.03:10 169 10.04.72:10 191
01.02.02:02 144 10.03.03:18 169 10.05.11:40 192
01.02.02:76 145 10.03.03:19 170 10.05.13:40 192
01.02.03:02 145 10.03.04:01 170 10.05.14:40 193
01.02.03:76 146 10.03.04:10 171 10.05.15:40 193
01.02.04:02 146 10.03.04:18 172 10.05.21:40 194
01.02.04:76 147 10.03.04:19 172 10.05.22:40 195
01.06.01:04 148 10.03.05:01 173 10.05.31:40 195
01.06.01:10 148 10.03.05:10 174 10.05.32:40 196
01.06.02:04 149 10.03.05:18 174 10.05.33:40 196
01.06.02:10 150 10.03.05:19 175 10.05.34:40 197
01.06.03:04 150 10.03.06:01 176 10.05.42:40 198
01.06.03:10 151 10.03.06:10 177 10.05.51:40 198
ENWW Index 1679

10.05.52:40 199 16.01.04:41 212 16.11.06:01 217
10.06.09:40 199 16.01.05:01 207 16.13.01:01 217
10.08.00:01 200 16.01.05:02 208 16.13.02:01 217
10.09.00:11 201 16.01.05:03 209 16.13.03:01 217
11.01.01:01 201 16.01.05:04 209 16.13.04:01 217
11.01.01:04 202 16.01.05:09 210 16.13.05:01 217
11.02.01:09 202 16.01.05:10 211 16.13.06:01 217
11.03.01:04 203 16.01.05:41 212 16.14.01:15 218
11.04.01:09 203 16.01.06:01 207 16.14.02:15 218
11.04.02:09 203 16.01.06:02 208 16.14.03:15 218
11.04.03:09 203 16.01.06:03 209 16.14.04:15 218
11.04.04:09 203 16.01.06:04 209 16.14.05:15 218
11.05.01:01 204 16.01.06:09 210 16.14.06:15 218
11.05.01:04 204 16.01.06:10 211 16.15.01:01 219
11.05.02:01 204 16.01.06:41 212 16.15.02:01 219
11.05.02:04 204 16.02.01:01 213 16.15.03:01 219
11.05.03:01 204 16.02.01:04 214 16.15.04:01 219
11.05.03:04 204 16.02.01:10 214 16.15.05:01 219
11.05.04:01 204 16.02.01:21 215 16.15.06:01 219
11.05.04:04 204 16.02.02:01 213 16.20.01:20 220
16.01.00:05 205 16.02.02:04 214 16.20.02:20 220
16.01.00:86 206 16.02.02:10 214 16.20.03:20 220
16.01.00:97 207 16.02.02:21 215 16.20.04:20 220
16.01.01:01 207 16.02.03:01 213 16.20.05:20 220
16.01.01:02 208 16.02.03:04 214 16.20.06:20 220
16.01.01:03 209 16.02.03:10 214 16.21.01:01 221
16.01.01:04 209 16.02.03:21 215 16.21.02:01 221
16.01.01:09 210 16.02.04:01 213 16.21.03:01 221
16.01.01:10 211 16.02.04:04 214 16.21.04:01 221
16.01.01:41 212 16.02.04:10 214 16.21.05:01 221
16.01.02:01 207 16.02.04:21 215 16.21.06:01 221
16.01.02:02 208 16.02.05:01 213 16.23.01:01 221
16.01.02:03 209 16.02.05:04 214 16.23.02:01 221
16.01.02:04 209 16.02.05:10 214 16.23.03:01 221
16.01.02:09 210 16.02.05:21 215 16.23.04:01 221
16.01.02:10 211 16.02.06:01 213 16.23.05:01 221
16.01.02:41 212 16.02.06:04 214 16.23.06:01 221
16.01.03:01 207 16.02.06:10 214 16.24.01:15 222
16.01.03:02 208 16.02.06:21 215 16.24.02:15 222
16.01.03:03 209 16.10.01:20 216 16.24.03:15 222
16.01.03:04 209 16.10.02:20 216 16.24.04:15 222
16.01.03:09 210 16.10.03:20 216 16.24.05:15 222
16.01.03:10 211 16.10.04:20 216 16.24.06:15 222
16.01.03:41 212 16.10.05:20 216 16.25.01:01 223
16.01.04:01 207 16.10.06:20 216 16.25.02:01 223
16.01.04:02 208 16.11.01:01 217 16.25.03:01 223
16.01.04:03 209 16.11.02:01 217 16.25.04:01 223
16.01.04:04 209 16.11.03:01 217 16.25.05:01 223
16.01.04:09 210 16.11.04:01 217 16.25.06:01 223
16.01.04:10 211 16.11.05:01 217 16.33.01:01 223
1680 Index ENWW

16.33.01:09 224 17.01.04:04 229 17.24.03:15 242
16.33.02:01 223 17.01.04:09 230 17.24.04:15 242
16.33.02:09 224 17.01.04:10 231 17.25.01:01 242
16.33.03:01 223 17.01.04:41 232 17.25.02:01 242
16.33.03:09 224 17.02.01:01 233 17.25.03:01 242
16.33.04:01 223 17.02.01:04 234 17.25.04:01 242
16.33.04:09 224 17.02.01:10 234 17.33.01:01 243
16.33.05:01 223 17.02.01:21 235 17.33.03:01 243
16.33.05:09 224 17.02.02:01 233 17.90.01:90 244
16.33.06:01 223 17.02.02:04 234 17.90.02:90 244
16.33.06:09 224 17.02.02:10 234 17.90.03:90 244
16.90.01:90 224 17.02.02:21 235 17.90.04:90 244
16.90.02:90 224 17.02.03:01 233 17.91.01:01 244
16.90.03:90 224 17.02.03:04 234 17.91.02:01 244
16.90.04:90 224 17.02.03:10 234 17.91.03:01 244
16.90.05:90 224 17.02.03:21 235 17.91.04:01 244
16.90.06:90 224 17.02.04:01 233 22.00.00:73 245
16.91.01:01 225 17.02.04:04 234 22.01.00:01 246
16.91.02:01 225 17.02.04:10 234 22.01.00:04 247
16.91.03:01 225 17.02.04:21 235 22.01.00:16 248
16.91.04:01 225 17.10.01:20 236 22.01.01:76 249
16.91.05:01 225 17.10.02:20 236 22.02.01:06 249
16.91.06:01 225 17.10.03:20 236 22.02.01:07 250
17.01.00:05 226 17.10.04:20 236 22.02.01:74 251
17.01.00:86 227 17.11.01:01 237 22.02.02:06 249
17.01.00:97 227 17.11.02:01 237 22.02.02:07 250
17.01.01:01 228 17.11.03:01 237 22.02.02:74 251
17.01.01:02 228 17.11.04:01 237 22.02.03:06 249
17.01.01:03 229 17.13.01:01 237 22.02.03:07 250
17.01.01:04 229 17.13.02:01 237 22.02.03:74 251
17.01.01:09 230 17.13.03:01 237 22.02.04:06 249
17.01.01:10 231 17.13.04:01, 237 22.02.04:07 250
17.01.01:41 232 17.14.01:15 238 22.02.04:74 251
17.01.02:01 228 17.14.02:15 238 22.02.05:06 249
17.01.02:02 228 17.14.03:15 238 22.02.05:07 250
17.01.02:03 229 17.14.04:15 238 22.02.05:74 251
17.01.02:04 229 17.15.01:01 239 22.02.06:06 249
17.01.02:09 230 17.15.02:01 239 22.02.06:07 250
17.01.02:10 231 17.15.03:01 239 22.02.06:74 251
17.01.02:41 232 17.15.04:01, 239 22.02.07:06 249
17.01.03:01 228 17.20.01:20 240 22.02.07:07 250
17.01.03:02 228 17.20.02:20 240 22.02.07:74 251
17.01.03:03 229 17.20.03:20 240 22.05.01:02 252
17.01.03:04 229 17.20.04:20 240 22.05.01:27 253
17.01.03:09 230 17.23.01:01 241 22.05.01:70 254
17.01.03:10 231 17.23.02:01 241 22.05.01:83 255
17.01.03:41 232 17.23.03:01 241 22.05.02:02 252
17.01.04:01 228 17.23.04:01 241 22.05.02:27 253
17.01.04:02 228 17.24.01:15 242 22.05.02:70 254
17.01.04:03 229 17.24.02:15 242 22.05.02:83 255
ENWW Index 1681

22.05.03:02 252 22.10.02:16 263 41.02.00:84 290
22.05.03:27 253 22.11.00:09 265 41.02.00:85 290
22.05.03:70 254 22.11.00:16 266 41.04.00:61 291
22.05.03:83 255 22.11.01:01 266 41.05.00:51 291
22.05.04:02 252 22.13.00:09 267 41.05.00:61 292
22.05.04:27 253 22.15.00:09 267 41.05.01:51 293
22.05.04:70 254 22.15.00:16 268 41.10.01:08 293
22.05.04:83 255 22.16.00:09 269 43.01.00:01 294
22.05.05:02 252 22.17.00:16 269 43.03.00:04 294
22.05.05:27 253 22.17.00:41 270 43.03.00:30 295
22.05.05:70 254 22.18.00:02 270 43.03.00:83 295
22.05.05:83 255 22.19.01:02 271 46.03.00:40 300
22.05.06:02 252 22.19.02:02 271 46.03.01:04 301
22.05.06:27 253 22.21.01:02 271 46.04.01:40 301
22.05.06:70 254 22.21.01:09 272 46.04.03:40 301
22.05.06:83 255 22.21.02:02 271 46.05.01:06 296
22.05.07:02 252 22.21.02:09 272 46.05.01:40 302
22.05.07:27 253 22.21.03:09 272 46.05.02:06 296
22.05.07:70 254 22.21.04:09 272 46.05.02:40 302
22.05.07:83 255 22.21.05:09 272 46.05.03:06 296
22.06.00:09 256 22.21.06:09 272 46.05.03:40 302
22.06.01:06 257 22.21.07:09 272 46.05.04:06 296
22.07.00:01 258 22.22.01:02 273 46.05.04:40 302
22.07.00:04 258 22.22.03:02 273 47.00.00:50 303
22.08.01:02 259 22.22.05:02 273 47.00.00:80 304
22.08.02:02 259 22.22.07:02 273 47.00.00:82 304
22.08.03:02 259 22.23.00:16 274 47.01.01:01 305
22.08.04:02 259 30.01.00:01 275 47.01.01:02 306
22.08.05:02 259 30.01.00:02 275 47.01.02:01 306
22.08.06:02 259 30.01.00:63 276 47.01.02:02 307
22.08.07:02 259 30.02.00:01 277 47.01.04:01 308
22.09.01:02 260 30.02.00:02 277 47.01.04:02 309
22.09.01:05 261 30.02.00:03 278 47.01.05:01 310
22.09.02:02 260 30.02.00:04 278 47.01.05:02 311
22.09.02:05 261 30.02.00:05 279 47.01.06:52 311
22.09.03:02 260 30.02.00:10 280 47.04.00:01 312
22.09.03:05 261 30.03.01:01 281 47.05.11:04 313
22.09.04:02 260 30.03.01:42 282 47.05.12:04 313
22.09.04:05 261 30.03.02:01 281 47.05.14:04 314
22.09.05:02 260 30.03.02:42 282 47.05.15:04 315
22.09.05:05 261 41.00.00:62 282 48.01.01:59 316
22.09.06:02 260 41.00.00:66 283 48.01.02:59 316
22.09.06:05 261 41.00.00:67 284 48.03.00:38 320
22.09.07:02 260 41.00.00:85 284 48.03.00:65 321
22.09.07:05 261 41.00.01:62 285 48.03.01:05 317
22.10.01:02 262 41.01.00:51 285 48.03.01:47 318
22.10.01:16 263 41.01.00:61 286 48.03.02:05 317
22.10.01:30 263 41.02.00:08 287 48.03.02:47 318
22.10.01:32 264 41.02.00:61 287 48.05.21:04 321
22.10.02:02 262 41.02.00:83 289 48.05.22:04 321
1682 Index ENWW

49.01.01:01 323 86.00.00:02 357
49.01.02:01 323 86.01.00:01 357
49.04.00:09 323 86.01.00:02 358
49.05.00:09 324 86.03.01:92 359
49.06.00:01 325 86.03.02:92 360
49.07.00:16 325 86.05.00:92 360
50.00.01:00 326 89.05.16:04 361
50.00.01:68 327 90.02.01:01 362
50.00.01:89 328 90.02.02:01 362
50.01.01:00 329 90.06.00:01 363
50.01.01:01 329 90.06.00:90 364
50.01.01:77 330 90.06.00:92 365
50.03.01:01 331 90.06.00:93 366
50.03.01:03 331 90.06.00:94 366
50.07.01:04 332 90.06.00:95 367
52.00.00:01 333 90.06.00:96 368
52.01.01:01 333 90.06.00:98 369
52.01.02:01 333 SRTSPL64.SYS 352
52.01.03:01 333
52.01.04:01 333
52.03.00:01 335
52.04.00:02 335
52.04.00:08 336
52.05.12:04 337
52.06.00:01 337
52.07.01:01 338
52.07.02:01 338
52.07.03:01 338
52.07.04:01 338
55.00.00:02 339
55.01.00:83 340
55.02.00:83 340
58.00.00:01 341
58.00.00:02 342
58.00.00:75 342
58.00.00:85 343
58.01.00:04 343
58.02.00:02 344
58.03.00:04 344
58.03.00:84 345
58.03.00:85 346
59.4:10 347
59.5:19 347
59.7:14 348
61.09.00:04 348
79.05.00:01 356
79.1:04 356
79.2:04 356
79:03 355
79:04 356
ENWW Index 1683

Service Manual v7 - 1500

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Service Manual v7 - 1500

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HP Latex 1500 Printer

HP shall not be liable for errors contained herein

The Warning symbol calls attention to a

The Caution symbol calls attention to an

1 Using this manual ..................................................................................................................................................................................... 1

2 Printer systems ......................................................................................................................................................................................... 4

3 Safety requirements ............................................................................................................................................................................ 119

4 Troubleshooting ................................................................................................................................................................................... 131

5 Diagnostics ............................................................................................................................................................................................ 533

6 Parts and diagrams .............................................................................................................................................................................. 599

7 Removal and installation .................................................................................................................................................................... 662

8 LogMeIn rescue .................................................................................................................................................................................. 1400

9 Moving the printer ............................................................................................................................................................................. 1406

10 Service maintenance ...................................................................................................................................................................... 1424

1 Using this manual

Some diagnostic tests or calibrations must be performed after removing a component.

6: Service parts and diagrams

● Official service part names

● Illustrations of the service parts

2 Chapter 1 Using this manual ENWW

Use this chapter whenever you need to order a service part.

7: Removal and installation

9: Moving the printer

● Within the same site, over flat ground

● To a different site, with no possibility of freezing

10: Service maintenance

● Electrical system: E-cabinet

● Universal mounting beam

● Pen to Rib Space (PRS)

● Printhead cleaning system

● Printer status beacon

● Subsystem block diagrams

4 Chapter 2 Printer systems ENWW

Electrical system: E-cabinet

The e-cabinet has 2 input AC power lines:

● The IPS power line (single phase)

L1-N, L2-N, L3-N

● Low line voltage: a 200–240 V line-to-line system separated into:

L1-L2, L2-L3, L3-L1

The picture below shows an example of the terminal block configured:

ENWW Electrical system: E-cabinet 5

Simplified diagram and general electrical explanation

6 Chapter 2 Printer systems ENWW

120V 24VDC CURING 1

HP Latex 1500 PS eCabinet

Electrical system: E-cabinet

Main switch and PC switch

AC protections: ACBs and RCDs (GFIs)

Safety circuit and contacts

Power jumper and power transformer

DC power and the e-cabinet PCA

Detailed electrical diagram

8 Chapter 2 Printer systems ENWW

AC-14AWG GND PSU-LPS -

N101 N128 N128 N130

L115 L115 L119 ALM + ON/OFF

L117 L117 L120

** FUSES ** ** FUSES ** CTRL PSU7

[2.5mm2] N-IEC4 N124

FP7: 8A#~5x20 Short connection to GND

Vapor Removal Short connection to GND PSU1

PSU holder screw DC-10AWG [6mm2]

1x WPE4 AC-14AWG PSU-1

PL-4 PSU-5 DC-22AWG [0.34mm2]

FUSES FUSES CTRL PSU7