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HP Indigo Press WS4000, Service Manual

The HP Indigo Press WS4000 is a state-of-the-art digital printing solution. Unlock its full potential with the comprehensive Service Manual available for free download at manualshive.com. This essential manual provides in-depth instructions and troubleshooting tips, ensuring optimal performance and reliability for your printing needs.

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HP Indigo press ws4000 Cluster 1 procedures 

proprietary and confidential 

CA293-00600, Rev 00 

page 89 of 221 

 

Figure 85  Vacuum box hoses with clamps alternated 

a.  Alternate the clamp fittings on the hoses for easier access. 

 

Connecting Unwinder ground cable 

 

 

Figure 86  Unwinder vacuum box ground cables 

Summary of Contents for Indigo Press WS4000

Page 1: ...e date Engineering reviewer Ron Levkovits Name signature date Group manager Aaron Lubelski Name signature date Documentation manager Ronit Shugal Name signature date Written by Asher Reichert Name signature date Configuration control Charles Margy Name signature date Hewlett Packard Company Indigo Division P O Box 150 Kiryat Weizmann P O Box 150 Rehovot 76101 Israel Copyright Hewlett Packard Compa...

Page 2: ...ing the Hardware configuration for Cluster 1 components 53 Total Shutdown procedure 54 Preliminary steps for changing the Cluster 1 hardware components on the press 54 Removing the Unwinder vacuum box 56 Installing the inverters in the electric cabinet 67 Installing the Unwinder Vacuum box 88 Installing the Unwinder Nip roller Drive motor 90 Installing the Unwinder bottom roller 90 Installing the ...

Page 3: ... 203 5 Test procedures 205 BID knobs bracket for ws4000 205 ILD cooling system 205 Anti drip kit assembly 205 Rewinder Antistatic bars 205 Printing CATP job 206 6 Parts list 206 ILD cooling system 206 BID knobs bracket for ws4000 206 Anti drip kit assembly 206 FCO parts 206 Spare parts 206 7 Materials disposition 206 BID knobs bracket for ws4000 206 Scorotron black rod replacement 207 ILD cooling ...

Page 4: ...verify motion profile 40 Figure 31 Opening the Press Configuration parameters 41 Figure 32 Motion Profile field on Press Configuration screen 42 Figure 33 Substrate Scaling Correction wizard Print step 43 Figure 34 Notification to go to Ready mode 43 Figure 35 RL Conflict notification message 44 Figure 36 MMI screen to recalibrate press 45 Figure 37 Periphery edge lines 46 Figure 38 Measuring the ...

Page 5: ... 73 Figure 69 60A0 power supply 74 Figure 70 60A5 electronic block 75 Figure 71 Wrapping two exposed red wires 75 Figure 72 new 22Q3 and 22Q5 circuit breakers 76 Figure 73 Inverters installed on electric cabinet 77 Figure 74 Blower connector box connections 78 Figure 75 3 brown wires to the 22Q3 breaker 79 Figure 76 Connecting the 60A0 power supply 80 Figure 77 Unidrive 81 Figure 78 Unwinder junct...

Page 6: ...k cable bracket 106 Figure 109 Pneumatic manifold 107 Figure 110 Top and bottom ground cables on rear Output wall 108 Figure 111 Removing Output guard interlock cables 108 Figure 112 Pushing Molex out of bracket 109 Figure 113 Removing Output and Exit Nip guard interlock cables 109 Figure 114 Homing sensor 110 Figure 115 Replacing Output rollers and the web break sensor 111 Figure 116 New rollers ...

Page 7: ... screw from front side of pivot shaft 133 Figure 152 Spacers between the drive motor and the plate 135 Figure 153 Washer screw and anaerobic adhesive 135 Figure 154 Reconnecting encoder and power connectors 136 Figure 155 Push interlock cable Molex connector through the wall 137 Figure 156 Connect the interlock Molex 137 Figure 157 Secure the interlock and pneumatic piston 138 Figure 158 Replacing...

Page 8: ...ws in front 166 Figure 195 Remove tray support screw in rear of press 167 Figure 196 Remove the rear bracket 167 Figure 197 Install new rear bracket and cable clamp 168 Figure 198 Install catch tray below PIP drum 169 Figure 199 Fasten catch tray support screw in rear of press 169 Figure 200 Fasten catch tray support screws in front of press 170 Figure 201 Install new IR sensor bracket 170 Figure ...

Page 9: ...2 Tape down the sponge on the sensor strip 193 Figure 233 Ensure the Sensor mode is set to D 193 Figure 234 Lit LEDs seen from the end of the sensor strip on Vacuum box 194 Figure 235 Checking the sensor on the vacuum box 195 Figure 236 Vacuum box TSP Screen showing only the middle sensor is covered 196 Figure 237 Ensure the Sensor mode is set to D 196 Figure 238 Diagnostic screen 198 Figure 239 R...

Page 10: ...rformance of and ease of access to various press components including the following functions Software version 6 2 1 Improves reliability and servicing of scaling job vacuum level control input roll diameter small repeat length correction and corner wizard procedures WHS Software 1 0 9 Software upgrade for WHS ILD firmware Supports auto machine LUT processes Black rod replacement Reduces LE to TE ...

Page 11: ...CA292 00390 Exit 3 FCO delta kit CA292 00420 U W delta kit CA292 00410 Slider FCO kit EHE 4250 51 CABLE ASSY CC250 VACUUM PE EHE 4251 51 CABLE ASSY CC251 VACUUM U W CA261 07470 CABLE ASSY FCO PROFIBUS CA261 07420 CABLE ASSY CC70 CUSTOMER CA254 00570 WS4000 INVERTOR ASSEMBLY CA292 00080 ILD cooling FCO KIT Q5379 00190 DOC BOM REPORT FOR KIT Note The first group of kits is also a group of stand alon...

Page 12: ...c tension meter model 505C MHM 0007 00 Grounding wrist strap P N MTX 0004 01 3 Prerequisites HP Indigo press in proper operating condition Print any job to verify that the press is operating properly Availability of installation CD ROMs for HP Indigo Software version 6 2 or later and HP IndigoServe version 1 5 or later not required for the Beta One day password for accessing the Protected Counters...

Page 13: ...been performed on the O S 3 Backup all jobs in the RAID to a suitable media 4 Backup the downloaded Raster Fonts From the Main Control Panel Options menu select Fonts Manager The Press Font Manager window opens a Select and highlight the fonts in the Downloaded Fonts List Figure 2 Font Manager window b Click Export and navigate to the removable drive directory to save them in a specific customer d...

Page 14: ...chine configuration do the following a Insert a 3 5 formatted and empty disk in the disk drive b In the Main Control Panel click Options and Press Configuration The Press Configuration window opens c Click the Configuration Management tab to bring it forward Figure 4 Press Configuration window Configuration Management tab d Click Save The configuration starts to save e Wait until the saving proces...

Page 15: ...o boot from the CD ROM or diskette prior to booting from the hard drive Note BIOS access and configuration is different for different computers Consult your computer documentation for instructions on reconfiguring the boot order in the BIOS 1 Set the press to Standby 2 Ensure that the Emergency Stop button is pressed At the HP Indigo press exit door 3 Ensure that the the upper nip cover is removed...

Page 16: ...ial CA293 00600 Rev 00 page 16 of 221 Figure 6 ILD hand knobs a Unfasten the two M6 Allen screws or hand knobs that secure the ILD Figure 6 Keep the screws for later use Note the ILD position for re installation b Remove the ILD c Disconnect the wire connector to the ILD ...

Page 17: ...CA293 00600 Rev 00 page 17 of 221 Figure 7 Removing the ILD connector 5 Attach the cable P N EHE 1253 51 to The 9 pin connector on the computer The densitometer The press densitometer connector Figure 8 Cable Connect to computer Connect to ILD Connect to press ILD connector ...

Page 18: ... is a typical procedure for accessing the BIOS for the ILD download a Restart the laptop computer b While the computer is turning on click the key indicated to access the BIOS The directions are usually found on the bottom of the screen when the computer is turning on The most likely keys are F2 F12 or DEL and they differ for each computer c After entering the BIOS screen select the BOOT MENU or i...

Page 19: ...dential CA293 00600 Rev 00 page 19 of 221 Figure 10 Flash Memory Loader Main Menu 10 Select and type option A and wait for the option to load The screen should show the following Figure 11 File Select option 11 Select and type option A and wait for the option to load ...

Page 20: ...prietary and confidential CA293 00600 Rev 00 page 20 of 221 Figure 12 Downloading file 12 Press any key to continue when you are prompted to do so Figure 13 Download complete 13 The download completes The Flash Memory Loader Utility Main Menu opens ...

Page 21: ...press ILD connector and computer 17 Remove the CD ROM or diskette from the laptop computer and turn it off 18 Fasten one of the ILD software version labels P N CA196 00051 to the ILD as shown in Figure 15 Figure 15 Fastening software version label to ILD Callout Number Description 1 ILD label 19 Re connect the ILD to its press connector 20 Insert and fasten the ILD in its original position Use the...

Page 22: ...perly 2 At the prompt type A Loader 3 Click Enter The Flash Memory Loader Utility Main Menu opens 4 Start the procedure described above 5 Change the boot order in the BIOS to its original configuration Press software downgrade If for any reason the press SW version is ever downgraded back to a previous version after the ILD firmware has been updated 1 Open the press software System Table Editor Sy...

Page 23: ...ysTab Window showing angleToStartMeasure parameter Replacing the PLC memory cartridge Memory cartridge insertion marks PLCpanel cdr RUN STOP MRES SF BATF DC5V FRCE RUN STOP BUSF SIEMENS RUN P CPU315 2DP 53A1 Memory cartridge Status and Fault LEDs Status and Fault LEDs for DP interface Mode selector Figure 18 PLC panel ...

Page 24: ...e 18 5 Program the PLC as described in Programming the PLC below Programming the PLC Resetting and initializing the memory cartridge Reset the memory cartridge as described in this section Note Read the following procedure thoroughly before performing it This procedure deletes the software from the PLC and reloads it from the new cartridge 1 Verify that the mode selector is set to STOP The STOP LE...

Page 25: ...version 1 03 go to Downloading system files to the Unidrive on page 203 and follow the procedure there to download the software Procedure 1 Check Unidrive parameter 17 2 If the value of this parameter is lower than 2 8 refer to Downloading system files to the Unidrive on page 203 and follow those directions for downloading parameters 2 Note the two three character motor name on the label on the Un...

Page 26: ...m the CD ROM drive file TOOLS Winflash winflash exe The WinFlasher 3 Introduction window appears 8 Select the Download an individual file radio button 9 Click Next The WinFlasher 3 Select the operation window appears 10 Select the Download a compiled program radio button 11 Click Next The WinFlasher 3 File selection window appears ...

Page 27: ...ROM to the file SOURCE FILES UNIDRIVES UD75 Files xx BIN where xx is the two three character motor name on the label of the UniDrive Figure 19 Select the file and click Open 13 Click Next The WinFlasher 3 Select the method for downloading window appears 14 In the Serial Port pane select the correct serial port radio button 15 Click Advanced twice ...

Page 28: ...essage window click Next The WinFlasher 3 Download component window appears 21 Click the big red button to begin the download process 22 When the Download Complete message window appears click Finish 23 Quit WinFlasher 3 24 Disconnect the communications cable from the UniDrive port and from the laptop serial port 25 Reconnect the CTNET cable 26 Remount the UniDrive cover 27 Repeat this procedure f...

Page 29: ...ect the Apply changes to this folder subfolders and files radio button and click OK 5 At the touch screen panel remove the side panel TS panel cdr 12V OK OV 5V OK DEF DIRTY Touch screen control panel DOWNLOAD button PROG PORT Figure 20 Touch screen control panel 6 Connect the communications cable P N EHE 4600 51 between the touch screen PROG PORT Figure 20 and the serial port at the rear of the la...

Page 30: ...ws Panel1_uw Unwinder touch screen panel w3200 ws4000 Panel2_pe1 PE1 touch screen panel w3200 ws4000 Panel3_pe2 PE2 touch screen panel w3200 Select the relevant DIR file and click Open The Serial Download window appears Note This step including MICRO is current for the present touchscreen model The next touchscreen model will have a different path in the same CD Micro will be replaced with another...

Page 31: ...nnect the communications cable from the touch screen control panel and from the laptop serial port 16 Remount the touch screen side panel UniDrive User defined error messages trips The list of UniDrive error messages is found in the UniDrive user manual and in the software CD that accompanies the accessories kit To view the list of error messages listed on the accessories CD P N CA272 00050 17 Ope...

Page 32: ... HP Indigo press software version 6 2 1 installation 1 Restart the Windows NT operating system 2 When the Windows NT Logon window opens click OK then press and hold the Shift key until Windows NT initializes completely This prevents the press software from activating 3 Insert the HP Indigo Press Software Version 6 2 1 CD 1 into the computer CD drive 4 The Choose Setup Language window opens Select ...

Page 33: ...you are upgrading from an older version the New Imaging Version message window appears notifying that all your jobs will be deleted To save your jobs do the following a Click No b Backup your jobs using the press software archive feature c Restart the installation If you have already saved your jobs click Yes 12 The Machine Configuration message appears If you want to save the machine configuratio...

Page 34: ...If you have not purchased any of the Kanji fonts click Next 18 In the Information window click Install 19 During the installation process the ReadOnly File Detected message window may appear If it does select the Don t display this message again check box and click Yes Figure 23 Launch failure warning 20 If the launch failure warning appears click OK for each warning See Figure 23 21 After the pro...

Page 35: ...ck box and click OK 25 Restart the hp indigo press software Verifying the RIP Key 1 Click the Windows Start button and select Programs HP Indigo and RIP GUI to enter the RIP Key and activate the RIP 2 The HP Indigo RIP opens An alert message appears Figure 24 Alert message 3 Note your dongle number Click OK 4 In the RIP window click on the Administration button The RIP Administration window opens ...

Page 36: ...tart the RIP 10 Install I Fix1 for software version 6 2 1 i13 11 Insert the I Fix CD in the CD drive and follow the I Fix installation instructions 12 Restart the press software Reinstalling the ink file 1 Reinstall the ink file as follows a In the press software menu select Consumables then Install Ink The Ink Installation window opens b Click on Ink Replacement The Ink Replacement wizard opens c...

Page 37: ...esting procedures Verify ILD firmware version To verify the ILD firmware version 1 Open the press software System Table Editor SysTab 2 Look for the ildPropertiesTopic in the tree 3 Look for the ildSoftwareVersion entry in the right pane of the window For HP Indigo press w3200 look for the ildSoftwareVersion entry in the right pane of the window of each slave tab The value in the Dynamic column sh...

Page 38: ...tware version listed is the current one in this case version 108 Perform full ILD calibration Perform the full ILD calibration after the quick ILD calibration 1 On the press software select Adjustments Color Adjustment and Calibration The Color Adjustment and Calibration Wizard Manager window opens 2 In the Inline Densitometer Calibration area click Full The Full Densitometer Calibration wizard op...

Page 39: ... P N CA272 00530 If the software upgrade procedures only are performed without performing the hardware upgrade procedures go to the Testing section now and skip the other intervening sections Scaling Perform thjis procedure here only if you are iimplementing the woftware only upgrade If you are also performing the Cluster 1 hardware upgrades perform this procedure in the Post installation procedur...

Page 40: ...rd 3 Open the Substrate Scaling Correction wizard from Adjustments Scaling Substrate Scaling Correction Before the Substrate Scaling Correction wizard opens a warning message is displayed Figure 30 Warning to verify motion profile 4 Verify the Motion Profile value see the following section Verifying the Motion Profile Value page 41 before clicking the OK button ...

Page 41: ...rietary and confidential CA293 00600 Rev 00 page 41 of 221 Verifying the Motion Profile Value Figure 31 Opening the Press Configuration parameters 5 In the Main Control Panel click Options and Press Configuration The Press Configuration window opens ...

Page 42: ...o the Web Handling parameters and ensure that the Motion Profile parameter is set to 4 If it is set to 4 click the Close button If the Motion profile parameter is not set to 4 change it to 4 and click the OK button After performing the Verifying the Motion Profile Value 7 Click OK on the Motion Profile warning The Substrate Scaling Correction wizard Print step is displayed ...

Page 43: ...f 221 Figure 33 Substrate Scaling Correction wizard Print step 8 A Print button is displayed on the wizard Click the Print button to print the Scaling job Note If the press is not in Ready mode you will be notified to change the press status to the Ready mode Figure 34 Notification to go to Ready mode ...

Page 44: ... job and the repeat length of the new job a notification message is displayed Figure 35 RL Conflict notification message 9 Click OK on the RL conflict notification message The wizard Print step is displayed 10 Recalibrate the press Recalibration can be performed by two different procedures a Go to Standby state b Go back to Ready state Or in Technician mode a Go to the MMI screen ...

Page 45: ...ubstrate from the press Removing the substrate from the press a In the Touch Screen Panel TSP The System Web Feed screen is displayed Press the Run button middle green button one time and release it immediately b Press the Run button again and hold the button down until the Scaling job is completed Then release the Run button Remove the 10 copies of the Scaling job from the press 1 Examine the Sca...

Page 46: ...cedures proprietary and confidential CA293 00600 Rev 00 page 46 of 221 Figure 37 Periphery edge lines 2 Use the last five sheets of the Scaling job to measure the scaling lengths Figure 38 Measuring the values on the Scaling job printout ...

Page 47: ...ngth and Image width on the last five sheets of the Scaling job according to the directions printed on the Scaling job sheet Figure 39 Write the values in the space provided on each of the five Scaling job sheets Note The thickness of the benchmark ruler mark is 0 1mm Figure 39 Directions for measuring Scaling job as found on job sheet Entering adjustments on the Enter Values step ...

Page 48: ...ength values from the Scaling job sheets and one value of the Image Width into the appropriate fields on the wizard Enter Values step Figure 41 Enter Values step with new values entered 2 Click Next on the wizard Enter Values step If all the values in the scaling settings are within tolerance the wizard displays the Finish screen If there are still some values that must be corrected the Print step...

Page 49: ...r Image width values as needed on the last five sheets of the Scaling job 5 Copy the required values from the Scaling job sheets into the blank fields on the wizard Enter Values step The green values are within tolerance and do not need to be replaced 6 If there are still some values that are not within tolerance click Next on the Enter Values step The wizard Print step is displayed 7 Continue to ...

Page 50: ...e The thickness of the benchmark ruler mark is 0 1mm 1 Place the plastic benchmark ruler at the 0 point on the printed Scaling job ruler Use a magnifying glass to check the deviation between the two rulers 2 If the rulers do not deviate select the No deviation button on the screen a Click the Next button The Finish step is displayed see Finishing the wizard page 51 3 If the rulers deviate select t...

Page 51: ...d on the screen After entering the delta in the Fix step 1 Click the Next button on the wizard Fix step The wizard Print step is displayed 2 Click the Print button to print the Scaling job Ten copies of the Scaling job are printed and the Enter values step is displayed 3 Continue to fill in the values in the Enter Values step and check them by printing the Scaling job until all the values are with...

Page 52: ... Technician mode may continue to perform the Updating the Web Scaling Correction parameter procedure See Updating the Web Scaling Correction parameter on page 52 Updating the Web Scaling Correction parameter This procedure is only performed by Customer Engineers when the press is first installed or when deviations occur between the benchmark and the Scaling job printed rulers over several substrat...

Page 53: ... button will become active 3 Click the OK button This parameter is disabled in the Operator mode Printing the CATP job 1 Print the CATP job and verify that the press print quality is the same as before End of the Software upgrade section of the FCO This concludes the software only portion of the package Continue to the following section to perform the hardware portion of the package Performing the...

Page 54: ...ill shut off Preliminary steps for changing the Cluster 1 hardware components on the press Note To facilitate ease of access to the press during removal and installation of components remove all doors that might interfere in access to the components Remove the substrate from the press Remove the substrate roll from the Unwinder Leave the substrate lift in the UP position Open the Output side paper...

Page 55: ...m box sensor cable The vacuum box sensor cable will be replaced in this procedure 3 Remove the vacuum box sensor cable from the junction box Note On some older presses the impression web break sensor cable must be removed in order to remove the junction box In some presses the impression web break sensor cable is long enough to remove the junction box without removing the cable 4 Lift the junction...

Page 56: ...s lift the paper feed cover off the hinges and put it aside Figure 48 Unscrewing the bottom cover 2 Unscrew the two screws on the lower corners and remove the bottom cover from the Input assembly Figure 48 Removing the Unwinder vacuum box Removing the Unwinder covers 1 Remove the Unwinder front cover a Loosen the three Allen screws on the bottom of the front cover ...

Page 57: ...v 00 page 57 of 221 Figure 49 Pull out the bottom of the front Unwinder cover b Pull out the bottom of the cover c Lift the cover up and off the Unwinder 2 Remove the Unwinder rear cover a Release the air pressure by pressing on the air nozzle trigger b Lift the rear cover off the bracket ...

Page 58: ... ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 58 of 221 Figure 50 Disconnecting Unwinder rear panel c Disconnect the air hose from the air connector d Disconnect the Molex connector ...

Page 59: ...ietary and confidential CA293 00600 Rev 00 page 59 of 221 Figure 51 Removing the Unwinder rear panel e Lift off the rear panel Note Lifting off Unwinder panels require two people 3 Lift off Unwinder front door Figure 52 Lifting off Unwinder front door ...

Page 60: ...ter 1 procedures proprietary and confidential CA293 00600 Rev 00 page 60 of 221 Removing the Unwinder and understep rollers Figure 53 Take out Unwinder deflector roller to remove vacuum box 4 Remove the Unwinder deflector roller ...

Page 61: ...HP Indigo press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 61 of 221 Figure 54 Removing Unwinder lower roller screw on front wall ...

Page 62: ...der b Remove the roller The rear of roller axle is shorter and has a spacer on its end The front side of the roller axle is longer than the rear side of the axle The roller must be replaced in the same orientation c Save the Unwinder lower roller screws and label them so they can be used during the roller reinstallation d Place the deflector roller aside until the vacuum box is removed and reinsta...

Page 63: ... plate b Remove the two screws that secure the roller to the walls of the stepping plate assembly c Remove the roller The rear of roller axle is shorter and has a spacer on its end The front side of the roller axle is longer than the rear side of the axle The roller must be replaced in the same orientation d Save the Unwinder stepping plate roller screws and label them so they can be used during t...

Page 64: ...he roller must be replaced in the same orientation c Save the roller screws and label them so they can be used during the roller reinstallation Removing the Unwinder Nip roller Drive motor 1 Remove the Unwinder Nip roller drive motor d Unscrew and remove the encoder and power connectors to the NIP roller drive motor e From the outside of the Unwinder wall remove the four bolts that secure the moto...

Page 65: ...um box sensor 1 Remove the Unwinder vacuum box sensor Figure 59 Unplugged vacuum box sensor a Unplug the Unwinder vacuum box sensor Molex b Push the cable through to the vacuum box Removing the Unwinder vacuum box Note When removing screws that have to be reinstalled place them in a cup or other container and mark the container so the screws can be identified when needed Closeup view of ...

Page 66: ...screws 2 Remove the screws on the Output side brackets Figure 61 Rear vacuum box bracket spacer 3 Save the rear bracket spacers Figure 61 4 Push the vacuum box forward in order to more easily access the vacuum hoses 5 Disconnect the four vacuum hoses from the vacuum box Note Removing the vacuum box requires two people 6 Cut the ties that secure the vacuum box sensor cable 7 Cover the plasma roller...

Page 67: ...onfidential CA293 00600 Rev 00 page 67 of 221 9 Discard the vacuum box Installing the inverters in the electric cabinet Figure 62 VBFU and VB1 Inverters The following procedure describes the installation of the VBFU and VB1 inverters on the electric cabinet door ...

Page 68: ...proprietary and confidential CA293 00600 Rev 00 page 68 of 221 Figure 63 Electric cabinet before inverter installation Note Disconnect the two cables from the 53A5 Profibus and the X60 plug during the inverter wiring procedure so they don t break ...

Page 69: ...Figure 64 22Q3 and 22Q5 switches 1 Disconnect the 22Q3 wires from the T1 T2 T3 positions that go to the 71K1 circuit protectors in the L1 L2 L3 positions Remove the wires 2 Disconnect the 22Q5 wires from the T1 T2 T3 positions that go to the 71K2 circuit protectors in the L1 L2 L3 positions Remove the wires ...

Page 70: ...roprietary and confidential CA293 00600 Rev 00 page 70 of 221 Figure 65 71K1 71K2 and 71K4 circuit protectors 3 Disconnect the 71K1 wires from the T1 T2 T3 positions that go to the X15 AC block connection in the L1 L2 L3 positions Remove the wires ...

Page 71: ...om the T1 T2 T3 positions that go to the X16 AC block connection in the L1 L2 L3 positions Remove the wires 5 Disconnect the CC203 cable that goes to the bottom of the X15 AC block connection 6 Disconnect the CC204 cable that goes to the bottom of the X16 AC block connection 7 Remove the tie wraps along the CC203 and CC204 cables that go to the blowers Connecting the blowers ...

Page 72: ...HP Indigo press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 72 of 221 Figure 67 Blower connector boxes a Open the blower connector boxes ...

Page 73: ...n may blow in the reverse direction 8 Disconnect the 22Q3 wires CC203 cable from the L1 L2 L3 positions These wires will be connected to the new 22Q3 switches Note The wires are labeled with their insert points 9 Disconnect the 22Q5 wires CC204 cable from the L1 L2 L3 positions These wires will be connected to the new 22Q5 switches 10 Disconnect the violet wire from the 14 slot in the 22Q3 switch ...

Page 74: ...69 60A0 power supply 11 Disconnect the violet wire from the 14 slot in the 22Q5 switch and follow it back to the 60A0 pin 2 position on the bottom of the power supply Remove the violet wire 12 Disconnect the violet wire that goes from the 71K1 A1 circuit protector to the 60A5 electronic block pin 1 Remove the wire ...

Page 75: ...k 13 Disconnect the violet wire that goes from the 71K2 A1 circuit protector to the 60A5 electronic block pin 2 Remove the wire Note Leave the ground wires in place 14 On the 22Q3 switch disconnect the two red wires from the 13 pin 15 On the 22Q5 switch disconnect the two red wires from the 13 pin Figure 71 Wrapping two exposed red wires ...

Page 76: ...sulated tape ensure they are fully insulated and fit the wires into the wire channel 17 Release the clip on the bottom of the 22Q3 and 22Q5 switch boxes and remove both switch boxes 18 Clip the two new 16 amp circuit breakers 22Q3 22Q5 on the bar into the same positions as the previous 22Q3 and 22Q5 switches Figure 72 new 22Q3 and 22Q5 circuit breakers ...

Page 77: ...r b Place the inverter plate in position and leave any existing screws on the door in place c Install the inverter plate with the two inverter units on the electric cabinet door with three screws on the right side of the door and three screws on the left side of the door d Run the wires from the inverters to the electric cabinet through the wire channels on the door and in the electric cabinet 20 ...

Page 78: ...re labeled W to the left terminal d Connect the green and yellow wires to the ground terminal 22 Tie the orange blower wires in place in the cable track Connecting the inverter wires to the electric cabinet The wires are color coded and their ends are labeled to indicate their destination 1 Separate the wires by color as they come from the bottom of the inverters 2 Tie them up and run them through...

Page 79: ...r 1 procedures proprietary and confidential CA293 00600 Rev 00 page 79 of 221 Figure 75 3 brown wires to the 22Q3 breaker a Connect 3 brown wires to the 22Q3 breaker and 3 brown wires to their labeled positions on the 22Q5 breaker ...

Page 80: ...confidential CA293 00600 Rev 00 page 80 of 221 Figure 76 Connecting the 60A0 power supply b Connect one violet wire to the 60A0 1pin c Connect one violet wire to the 60A0 2pin d Connect one violet wire to the 60A5 1pin e Connect one violet wire to the 60A5 2pin ...

Page 81: ...6UO 25 g Connect one red to the Unwinder blower unit 26UO 9 h Connect one black wire to the Unwinder blower unit 26UO 11 i Connect one violet wire to the Feed unit blower unit 24UO 25 j Connect one red wire to the Feed unit blower unit 24UO 9 k Connect one black wire to the Feed unit blower unit 24UO 11 l Connect the two green and yellow wires to the bottom of the X15 and X16 terminals PE ...

Page 82: ...ev 00 page 82 of 221 Replacing the Unwinder vacuum box power sensor cable Figure 78 Unwinder junction box 1 Open the junction box on the rear Unwinder wall 2 Remove the CC500 cable that consists of 9 wires connections in the junction box 3 Replace the CC500 cable with the new CC251 cable ...

Page 83: ...ctor terminal The connector terminal consists of a lower row of positive terminals a middle row of negative terminals and a top bridge of signal numbered terminals Figure 80 Unwinder junction box connections closeup a Connect the brown wire to the bottom positive row in 15 slot b Connect the black wire to the bottom positive row in slot 6 ...

Page 84: ... wire to the middle negative row in slot 16 f Connect the yellow wire to the middle negative row in slot 6 g Connect the gray wire to the top numbered row in slot 6 h Connect the white wire to the top numbered row in slot 16 i Connect the purple wire to the top numbered row in slot 15 4 Run the Molex connector end of the CC251 cable through the hole in the Unwinder wall Replacing the Press vacuum ...

Page 85: ...nction box 3 Replace the CC521 cable with the new CC250 cable a Connect the brown wire to the bottom positive row in slot 15 b Connect the black wire to the bottom positive row in slot 3 c Connect the green wire to the bottom positive row in slot 16 d Connect the red wire to the middle negative row in slot 15 e Connect the blue wire to the middle negative row in slot 16 f Connect the yellow wire t...

Page 86: ...sensor cable to the vacuum box 4 Run the Molex connector end of the new cable along the rear of the press to the vacuum box 5 Connect the two cables from the 53A5 Profibus and the X60 plug 6 Reinstall the junction box cover Testing the Inverter installation 1 Use an DVM to test the conductivity between the affected terminals a Ensure Inverter covers are removed before performing the following test...

Page 87: ...22Q3 4 L2 U1 VB FU FL in L3 22Q3 6 L3 U2 VB1 FL in L1 22Q5 2 L1 U2 VB1 FL in L2 22Q5 4 L2 U2 VB1 FL in L3 22Q5 6 L3 U1 VB FU PWR I L1 U1 VB FU FL Out L1 U1 VB FU PWR I L2 U1 VB FU FL Out L2 U1 VB FU PWR I L3 U1 VB FU FL Out L3 U2 VB1 PWR IL1 U2 VB1 FL Out L1 U2 VB1 PWR IL2 U2 VB1 FL Out L2 U2 VB1 PWR IL3 U2 VB1 FL Out L3 Inverter VBFU 1 FU26UO 11 Inverter VBFU 2 FU26UO 9 Inverter VB1 1 FU24UO 11 I...

Page 88: ...vacuum box Input side brackets in place using the old bracket spacers Make sure that the round holes in the bracket are on the bottom and the slots are on the top 2 Install the Output side vacuum box brackets on the vacuum box 3 From the Output side of the Unwinder place the vacuum box in place in the Unwinder 4 Reinstall the screws in the Input side of the brackets to secure the vacuum box 5 Secu...

Page 89: ...prietary and confidential CA293 00600 Rev 00 page 89 of 221 Figure 85 Vacuum box hoses with clamps alternated a Alternate the clamp fittings on the hoses for easier access Connecting Unwinder ground cable Figure 86 Unwinder vacuum box ground cables ...

Page 90: ...Drive motor 1 Install the Unwinder Nip roller drive motor a Put the motor through the motor belt and the hole in the Unwinder wall b While one person holds the motor a second person should install and tighten the screws that secure the motor in place from the outside of the Unwinder wall Ensure that the encoder and power connectors face the Input side of the Unwinder Figure 87 Installing the Unwin...

Page 91: ... so the shorter side of the roller axle is on the rear of Unwinder b Install the spacer on its shorter axle Figure 89 Installing Unwinder roller screws c From the outside of the Unwinder install and tighten the two screws that secure the roller to the walls of the Unwinder Replacing the Unwinder stepping plate rollers 1 Install the Unwinder stepping plate deflection roller d Lift stepping plate ...

Page 92: ...ar of roller axle is shorter and has a spacer on its end The front side of the roller axle is longer than the rear side of the axle The roller must be replaced in the same orientation Reinstall the two screws that secure the roller to the walls of the stepping plate assembly Installing the long anti static brush Figure 91 Long brush assembly for the Unwinder bottom roller ...

Page 93: ...the brass rod c Unscrew and remove the two screws on each antistatic clamp See inset Figure 91 Figure 92 Clamps on the right and left sides of the roller axle d Place the clamp on the right and left sides of the roller axle and reinstall the screws in the clamp e Push the brass rod into the holes in the clamp Figure 93 Long antistatic brush installed on the Unwinder bottom roller axle ...

Page 94: ...roprietary and confidential CA293 00600 Rev 00 page 94 of 221 Replacing the second stepping plate deflection rollers 1 Install the Input side stepping plate deflection roller Figure 94 Longer and shorter axles on understep roller Input press side ...

Page 95: ...ler axles are shorter than the front axles see Figure 94 and Figure 95 and have a spacer on their ends The rollers must be replaced in the same orientation Reinstall the two screws that secure each roller to the walls of the stepping plate assembly Installing the Tension in Web label on the Unwinder The Tension in Web label P N MLB 1039 01 must be installed on top of the Unwinder Top panel ...

Page 96: ...rietary and confidential CA293 00600 Rev 00 page 96 of 221 Figure 96 Placement of Tension in web label 1 Attach the label on the Unwinder top panel so it is centered relative to the Air pressure control knob and along the center line of the top panel ...

Page 97: ...uster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 97 of 221 Removing the printing engine FP Substrate transport motor 1 Remove the FP motor Figure 97 Disconecting ground cable a Disconnect the ground cable ...

Page 98: ... press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 98 of 221 Figure 98 Disconnecting the encoder and power supply b Disconnect the Encoder and Power connections to the motor ...

Page 99: ...removing the other screws One person should unscrew the motor screws and another person should hold the motor and lift it out of the press Figure 100 Loosen long belt on motor drive shaft d Cut and remove the long belt on the drive shaft e Ensure that the interlock cable that goes to the junction box does not get in the way when removing the motor from the press f Pull motor out of press sliding i...

Page 100: ...go press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 100 of 221 Removing the Input assembly Figure 101 Motor plate and Input section drive belt 1 Remove the FP motor plate ...

Page 101: ...HP Indigo press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 101 of 221 Figure 102 Impression encoder connector 2 Unplug the impression encoder connector ...

Page 102: ... and the printing engine vacuum box 4 Cut any ties that secure the second transfer cable 5 Push the encoder cable out of the way 6 Remove the vacuum box brackets a On the Output side of the vacuum box remove the lower two vacuum box bracket screws that secure the vacuum box to the Unwinder walls This releases the strain on the bracket when the Input side brackets are removed and the vacuum box rem...

Page 103: ...confidential CA293 00600 Rev 00 page 103 of 221 Figure 104 Removing Input side vacuum box bracket b Remove the screws holding the Input side vacuum box brackets Figure 105 Output side vacuum box brackets c Remove the remaining screws on the Output side brackets ...

Page 104: ...he three screws on the rear Input walls Alternate sides as you loosen the screws to avoid placing stress on either side 11 Carefully lift out the Input assembly from the press and place it on a pallet Note This procedure requires two people Removing the printing engine vacuum box Removing the printing engine vacuum box can best be performed after removing the printing engine FP motor and the Input...

Page 105: ...in removing the printing engine vacuum box 2 On the Output side of the press remove the remaining screws on the vacuum box brackets 3 On the Input side of the press remove the remaining screws on the vacuum box brackets 4 Remove the vacuum box from the Input side of the press Removing the Output assembly Figure 107 Removing the interlock 1 Remove the Upper Nip interlock Figure 107 ...

Page 106: ...ctor out of the bracket Note On older presses the hole in the press wall is too small to push the connector through In that case the interlock cable will be removed with the Output assembly The interlock cable must be kept out of the way when the Output assembly is removed so it won t be cut by the Output assembly wall c Remove the interlock by unscrewing the screw on top and on bottom of the brac...

Page 107: ... of 221 Figure 109 Pneumatic manifold 2 Disconnect the pneumatic manifold connector and air supply a Unscrew the screw on the end manifold module b Slide out the pneumatic manifold from the track c Unscrew and remove the cable connector from the manifold d Unplug the main air supply from the manifold ...

Page 108: ...bottom ground cables on rear Output wall 3 Unscrew and disconnect the top and bottom ground cables from the rear wall Figure 111 Removing Output guard interlock cables 4 Remove the web handling system Output and Exit Nip guard interlock cables a Unplug the Output guard interlock cable connector b Unscrew the interlock assembly ...

Page 109: ... CA293 00600 Rev 00 page 109 of 221 Figure 112 Pushing Molex out of bracket c Push the Output guard Molex connector out of the bracket Figure 113 Removing Output and Exit Nip guard interlock cables d Unplug the Output Nip guard interlock Molex connector e Remove the cables ...

Page 110: ...om the FP drive motor 7 Remove the Output assembly from the press a Unscrew and remove the three screws on the front and the three screws on the rear Output walls Alternate sides as you loosen the screws to avoid placing stress on either side b Carefully lift out the Output unit from the press and place it on a pallet Note This procedure requires two people Replacing the Output rollers and web bre...

Page 111: ...k sensor 1 Replace the Output assembly upper rollers a Unscrew and remove the upper roller screws on the rear and the front walls of the Output assembly b Remove the roller The rear of roller axle is shorter and has a spacer on its end The front side of the roller axle is longer than the rear side of the axle The roller must be replaced in the same orientation ...

Page 112: ...0 page 112 of 221 Figure 116 New rollers from kit c Replace the rollers with the two rollers from the kit Ensure that the longer side of the axle longer front side of the roller axle is installed on the front side of the Output wall d Reinstall the screws and spacers that secure the rollers ...

Page 113: ...ak sensor Figure 117 Sensor kit parts a Remove the sensor pieces from the kit discard the bracket keep the screws and washer Note The sensor kit is a third party product Their sensor bracket does not fit our assembly We must discard the third party bracket and use our own Figure 118 Extra sensor bracket b Remove the old reflector from the reflector support bar ...

Page 114: ...f 221 Figure 119 Position of the reflector the reflector plate and the bar c Screw the new reflector on the reflector plate Figure 120 Screwing reflector on support bar d Screw the reflector plate on the front of the reflector support bar using the same two screws that held the old reflector on the bar ...

Page 115: ... orientation of the old sensor plate The sensor plate has four holes and the sensor fits on it only one way on the two holes that are closest together Figure 122 Screw sensor on the bottom of the sensor plate h Screw the sensor on the bottom two holes of the sensor plate i Install the new sensor bar onto the Output assembly with one screw on each side of the wall j Screw the sensor plate s top two...

Page 116: ...s bracket Figure 123 Output side printing engine 1 Remove the old wire cover Figure 123 2 Loosen the four screws that attach the Output assembly cover Figure 123 Figure 124 Press Output with Output assembly cover removed 3 Remove the Output assembly cover from the press The press Output side will appear as in Figure 124 Drive NIP guard Old wire cover Output assembly cover ...

Page 117: ... using White out or equivalent white paint to mark their rotational position Figure 125 5 For each of the knobs write down the number of clockwise turns required to fully tighten each knob Fill out the table below BID engage knob number Number of turns clockwise 3 to tighten 1 2 3 4 5 6 7 separate from 6 BID terminal assembly Mark knobs with White out paint ...

Page 118: ...osen the two screws holding the face plate on the new terminal assembly MPQ 2773 51 Figure 127 Figure 127 BID engage assembly 8 Take the face plate off the assembly Figure 127 9 Install the new BID engage assembly in the press Fasten each cable end to its BID according to Figure 132 Turn each cable fully clockwise to tighten It is recommended to start with BID 6 having the shortest cable and conti...

Page 119: ...D 1 cable 10 The longest path is to BID 1 shown inside the press in Figure 128 Figure 129 BID 7 cable location 11 BID 7 is connected to a cable which is not a part of the new 6 BID engage assembly It is located in the upper front area Figure 129 Remove the old cable for BID 7 BID 1 cable on inside front wall BID 7 cable PIP drum ...

Page 120: ...assembly P N MPQ 2924 31 Figure 130 Figure 131 New BID 7 assembly in place 13 Install the new BID 7 assembly in the front top part of the press Figure 131 14 Fasten the cable of BID 7 in place turning it fully clockwise 3 Figure 129 Bracket mounting holes Mounting Mark the knob at the 12 o clock position using white paint White out after BID 7 cable is fastened in place ...

Page 121: ...cket to its original position by carefully lowering it over the web break sensor 2 Tighten the two knob screws Figure 133 Figure 133 Output view fully assembled 3 Put the Output assembly cover back in place held by four screws Figure 133 Mark each knob at the 12 0 clock position using white paint White out after BID cables are fastened in place Connects to BID 1 at the bottom Connects to BID 6 at ...

Page 122: ...ral screws Figure 133 An enlarged hole in the new wire cover allows room for the master screw already fastened in place 6 Fasten the terminal assembly MPQ 2773 51 using three screws Figure 133 Installing the ILD cooling system 1 On the rear of the press open the ESB board Figure 134 ESB board with old connector on J38 2 Remove the connector P N EHE 4108 51 from the ESBJ38 position and replace it w...

Page 123: ...d ILD Engage and that comes from the ESB board Tie up this cable and leave it near the ESB board 4 Pass the GDB cable and the ILD Cooling cable through to the Output part of the press 5 Remove the top panel Figure 135 Ceiling cover gasket 6 Remove the rubber gasket that sits under the top panel This will enable the removal of the GDB panel Figure 135 7 Access the GDB panel by unscrewing the two sc...

Page 124: ...onnector J7 from the GDB panel and discard the P N EHE 4108 51 cable Plug CC 108C cable into right GDB socket CC108C cable from the ESB board Top panel Figure 137 CC108C cables pulled from ESB board on back of press 9 Connect one connector CC108C from the ESB panel to the first connector GDB J7 in the GDB panel See Figure 137 Rear BID ...

Page 125: ...e it in place Screws that secure the laser shroud tube assembly Laser shroud tube assembly Figure 139 Laser shroud tube assembly seen from Output of press 11 From the Output side of the printing engine unscrew and remove the two M3 Allen screws that secure the laser shroud tube assembly 12 Slide the panel gently on top of the scorotron bridge Save the screws for later reinstallation GDB cover ILD ...

Page 126: ...e 138 and Figure 141 The ILD cooling cable will connect to the ILD cooling fan Left channel cover removed Light guard assembly Ozone hose hose connection plate Top panel Figure 140 Roof top panel and left channel cover removed 14 On the top of the press lift the roof top panel off of the press See Figure 140 15 There are three Allen M2 5 screws that secure the left channel cover Remove the left ch...

Page 127: ...el 16 Pull the ILD cooling cable through to the top of the press Leave it near the front of the press to be connected to the ILD cooling fan See Figure 141 and Figure 144 17 Secure the left channel cover in place with three M2 5 Allen screws Installing the ILD cooling fan Note When removing the light guard assembly See Figure 140 save the screws to use in installing the new panel ...

Page 128: ...ion plate and remove the filter from the light guard assembly Save the screws for later reinstallation 3 There are four M6 Allen screws two in front and two in back that secure the light guard assembly in place Unscrew the light guard assembly and remove it from the press 4 Three M3 Allen screws secure the carbon filter housing to the light guard Remove the carbon filter housing and save the screw...

Page 129: ...gh the slot in the back of the assembly See Figure 142 10 Connect the ozone filter hose to the connection plate 11 Screw on the hose connection plate to the assembly using the wing screws ILD Cooling fan connector CCJ38 cablel Figure 144 ILD cooling fan and CC108C connectors 12 Connect the ILD fan connector to the CC108C cable See Figure 144 13 Continue installing the ILD cooling assembly after th...

Page 130: ...of the scorotron and scorotron bridge that appear in this procedure include the following 1 2 3 4 5 6 7 8 Figure 145 Scorotrons and scorotron bridge 1 Bridge control handle 2 Scorotrons 3 Pivot levers 4 Spring 5 Cam follower arm 6 Front cam follower 7 Bushing assembly 8 Pivot shaft Note This procedure requires two people To replace the Scorotron pivot shaft perform the following ...

Page 131: ...d the UPS is switched off 2 Cover the PIP during this procedure so that it does not get damaged Figure 146 Removing the scorotrons 3 At the front of the press remove the three scorotrons from the press See Figure 146 Place them upside down in a safe place SCOROTRON LEVER1 Figure 147 Scorotron Bridge control handle 4 On the Input side of the press lift the bridge control handle See Figure 147 ...

Page 132: ...See Figure 148 Note Hold the pivot shaft steady if the screw turns during removal Figure 149 Removing the C clips from the pivot shaft 6 From the Output side of the press remove the C clip from the groove behind the laser shroud shaft on the pivot shaft See Figure 149 Leave the C clip on the shaft 7 On the front of the press remove the spring from the left pivot lever See Figure 145 part 4 Place i...

Page 133: ...proprietary and confidential CA293 00600 Rev 00 page 133 of 221 Figure 150 Removing the pivot arms 8 Unscrew the front cam follower on the cam follower arm See Figure 145 part 6 Figure 150 Figure 151 Removing screw from front side of pivot shaft ...

Page 134: ...rod 15 When the pivot rod is in place screw in the pivot shaft screw in the back of the press 16 Put the C clip into the groove 17 On the front of the press place the pivot levers on the bushings 18 Put the C clips on the bushing assemblies 19 Put the left pivot lever onto the pivot shaft 20 Screw in the screw on the front of the pivot shaft that holds the left pivot lever in place 21 Place the ca...

Page 135: ...135 of 221 WHSU_4974B1 Figure 152 Spacers between the drive motor and the plate 2 Place two washers P N MWP 1016 05 on the 13mm screw Figure 153 Figure 153 Washer screw and anaerobic adhesive 3 Put a drop of omniFIT1560 see Figure 153 on the end of each screw Figure 153 4 Reinstall the 13 mm screw ...

Page 136: ...he Output assembly unit and set it on the pins on the front and rear walls of the press Note Be careful that all cables are pulled out of the way and do not get caught between the Output assembly walls and the press 4 Tighten the three screws on the front wall and the three screws on the rear wall to secure the Output assembly unit in the press Alternate the tightening of the screws to ensure that...

Page 137: ...00 Rev 00 page 137 of 221 Figure 155 Push interlock cable Molex connector through the wall a Push the interlock cable Molex connector through the wall Figure 156 Connect the interlock Molex b Fit the Molex connector into the interlock bracket and connect the interlock Molex connector ...

Page 138: ...tial CA293 00600 Rev 00 page 138 of 221 Figure 157 Secure the interlock and pneumatic piston c Install the interlock assembly and the pneumatic piston onto the Output rear wall d Ensure the air hose is connected to the pneumatic piston Plug it in if it is not connected ...

Page 139: ...ocedures proprietary and confidential CA293 00600 Rev 00 page 139 of 221 Figure 158 Replacing the interlock cable cover e Replace the interlock cable cover on the Output assembly frame and tighten the screws Figure 159 Pneumatic manifold ...

Page 140: ...93 00600 Rev 00 page 140 of 221 7 Connect the pneumatic manifold connector and air supply a Unscrew the screw on the end manifold module b Slide out the pneumatic manifold from the track Figure 160 Connecting the manifold connector c Connect the cable connector to the manifold ...

Page 141: ...digo press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 141 of 221 Figure 161 Connecting the main air supply to the manifold d Connect the main air supply to the manifold ...

Page 142: ...uster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 142 of 221 Figure 162 Engage NIP roller air hoses 8 Ensure that the air hoses to the engage NIP roller are connected Figure 163 Attaching the ground cables ...

Page 143: ...Upper Nip interlock and the FP motor 10 Run the cable web break sensor cable along the side of the rear wall to the junction box keeping it away from the rollers 11 Route the air hoses from the front wall to the rear wall by way of the back of the web break reflector bar Installing the printing engine vacuum box Installing the vacuum box supporters ...

Page 144: ...ox supporter pieces from the kit Each supporter consists of two pieces that are secured together by three screws Figure 165 Installed vacuum box supporters 2 Place the supporters on the bottom of the printing engine The supporters are secured by two screws to the base of the press Note Ensure that the supporters lie flat on the press bottom before they are secured ...

Page 145: ...Rev 00 page 145 of 221 Installing the vacuum box ground cables Figure 166 Vacuum box ground cables 3 Connect the two vacuum box ground cables onto the vacuum box Installing the vacuum box brackets 1 Install the Printing engine vacuum box brackets on the front and back of the vacuum box ...

Page 146: ...HP Indigo press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 146 of 221 ...

Page 147: ...acuum box in the press and attach the vacuum box brackets to the press walls Do not tighten the screws 3 After installing the Input assembly level the vacuum box 4 Connect the ground cable from the vacuum box to the side of the press Note Ensure that the point to which the ground cable is connected does not interfere with the placement of the Input assembly 5 Connect the vacuum hoses ...

Page 148: ... press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 148 of 221 Figure 168 Vacuum box hoses with clamps alternated a Alternate the clamp fittings on the hoses for easier access ...

Page 149: ... junction box and Profibus a Connect the gray touchscreen connector cable that comes out of the bottom of the junction box to the side of the touchscreen b Connect the green touchscreen Profibus cable from the junction box to both Unwinder and Output touchscreens c Connect one wire from the new web break sensor cable to the bottom positive row in slot 22 d Connect the other wire from the new web b...

Page 150: ...equires two people 3 Lift the Input assembly unit and set it on the pins on the front and rear walls of the press Note Be careful that all cables are pulled out of the way and do not get caught between the Input assembly walls and the press 4 Tighten the three screws on the front wall and the three screws on the rear wall to secure the Input assembly unit in the press Alternate the tightening of t...

Page 151: ...51 of 221 Figure 170 Motor plate position e Place the motor plate over the NIP drive belt and the Input section drive belt so the belts fit in the groove on the side of the plate that faces the press wall Note Replace the Input section drive belt long belt This belt comes with the new Input assembly ...

Page 152: ...rs facing down through the motor plate NIP drive belt the Input section drive belt and the hole in the press wall g Insert the screws in the four holes on the motor base h Connect the encoder and the power cables to the Nip motor i Use the sonic meter to test the belt tension Replacing the FP motor belt The following procedure describes replacing the Input section drive belt on the Feed III gear ...

Page 153: ...etary and confidential CA293 00600 Rev 00 page 153 of 221 Figure 172 Removing the preheater connector bracket cover 1 Unscrew the preheater connector bracket cover Figure 173 Removing the preheater spindle screws 2 Unscrew the preheater spindle screws ...

Page 154: ...es proprietary and confidential CA293 00600 Rev 00 page 154 of 221 Figure 174 Removing the reheater spindle and spring 3 Remove preheater spindle and spring from the press 4 Remove the preheater roller Figure 175 Loosen the inner locking screw ...

Page 155: ... proprietary and confidential CA293 00600 Rev 00 page 155 of 221 5 Use the jig to loosen the inner locking screw from the gear Figure 176 Removing the inner gear pin 6 Remove the inner gear pin Figure 177 Sliding out the Input section drive belt ...

Page 156: ... inner gear pin into the gear assembly and tighten it with an Allen wrench 11 Tighten the gear assembly with the gear jig 12 Install the preheater roller onto its spindle on the rear wall Figure 178 Replacing the preheater spidle and screw 13 Put the preheater spindle and spring into the outside of the press front wall 14 Secure the spindle in place with the original screws 15 Reinstall the prehea...

Page 157: ...HP Indigo press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 157 of 221 Figure 179 Gates Sonic meter 505C 2 Press the Power button Figure 180 Measuring belt tension ...

Page 158: ... the Hz button Hz must appear within the meter window at the right 4 Take a measurement press Select and then Measure Figure 181 Plucking the belt to get a reading To make a measurement with the Gates Sonic meter pluck the belt with the microphone placed next to it Figure 180 The locations of the belts to be tested are indicated in Figure 182 ...

Page 159: ... the other hand pluck the belt close to the microphone as one would a guitar string The reading in Hz appears in the meter window 6 Pull the belt by hand until a different section of belt is at the measurement point Take a second measurement as described in step 5 7 Pull the belt again by hand until a different section of belt is at the measurement point Take a third measurement as described in st...

Page 160: ...g the anti drip kit assembly The procedure below involves the removal of certain parts in the Input side of the press and their replacement with new parts Prerequisites The following kit parts are required for installation Figure 184 Parts to be installed In addition a cable clamp and a variety of fastening hardware are included in the FCO kit dripping for ws4000 CA292 00311 Note It is not necessa...

Page 161: ...d to assist the operator in installing part 2 Old part removal 1 Turn off the press 2 Open the press input door Figure 186 Figure 186 Press input 3 Open the guard door Figure 186 4 Remove the ITM hood To remove the ITM hood first disengage it using the retaining latch Figure 187 Push the ITM hood toward the rear of the press lift it up and remove it from the press Figure 186 Part 1 Part 2 Part 3 P...

Page 162: ...aning station blade Figure 187 Figure 187 Press front 6 Remove the cleaning station connector Figure 188 Figure 188 Remove cleaning station connector 7 Remove the cleaning station Figure 189 Cleaning station blade Lever used to disengage the ITM hood lever down for ITM hood removal Cleaning station connector Cleaning station ...

Page 163: ...ure 189 Remove the cleaning station 8 Remove the IR sensor First remove the bracket which holds the IR sensor cable in position Figure 190 Figure 190 IR sensor and bracket 9 Disconnect the IR sensor electrical connector Figure 191 Cleaning station IR sensor bracket IR sensor IR sensor cable bracket Marking tape ...

Page 164: ...all toward the inside of the press 11 Mark the depth of the IR sensor relative to its mounting bracket using a piece of tape or a marking pen Figure 190 12 Remove the two set screws which hold the IR sensor in place 13 Unscrew the IR sensor from its mounting bracket Figure 192 Two screws hold the IR sensor bracket in place one from the inner front wall and one from the outer front wall IR sensor e...

Page 165: ...t 14 Remove the four screws which support the tray below the PIP drum Figure 193 Two screws are accessible from the outer front wall another screw is accessible from the outer rear wall and a fourth screw is accessible from the feed side IR sensor bracket mounting screw on inner front wall IR sensor bracket mountings screw on outer front wall ...

Page 166: ...y Figure 194 Figure 194 Remove two tray support screws in front 16 Move the blower cabinet aside and open the back door behind it Remove the third screw located behind the flywheel at the rear wall of the press Figure 195 Remove two tray support screws PIP brake controller PIP drum Tray below PIP drum Front mounting two screws accessible from outer front wall Fourth screw Rear mounting third screw...

Page 167: ...e the tray shown in Figure 193 from the press and discard it 18 Remove the old bracket which holds the cleaning station hose and cable assembly held by two remaining screws Figure 196 Discard the old rear bracket Figure 196 Remove the rear bracket New part installation 1 Make sure the press is off Tray mounting screw Flywheel Rear bracket Remove two rear bracket screws ...

Page 168: ...t has a screw built into it for attaching the new cable clamp Figure 197 Install new rear bracket and cable clamp Manually turn the ITM drum to make sure that it moves freely 3 Put the new catch tray in place below the PIP drum and fasten it with four screws starting with the one attached to the new rear bracket Figure 198 Note A second person will be needed to assist the operator in installing th...

Page 169: ...tray below PIP drum 4 Fasten the screw which attaches the catch tray from the rear of the press Figure 199 Figure 199 Fasten catch tray support screw in rear of press 5 Fasten the two screws located below the PIP brake controller which support the catch tray Figure 200 New catch tray Fasten screw PIP drum Tray mounting screw Flywheel ...

Page 170: ... Install new IR sensor bracket 7 Insert the IR sensor into its holder and screw it in down as far as the mark which was put on it during its removal Fasten it in place using the two set screws shown in Figure 201 taken from the old bracket 8 Put the IR sensor cable through the front wall Figure 202 Mounting screws 2 top screw accessible from front of press see Figure 192 IR sensor set screws PIP b...

Page 171: ...s in the IR sensor bracket allow access to lubrication points 10 Connect the IR sensor connector at the front wall Figure 203 Figure 203 Connect mating connectors 11 Loosen the Allen screw holding the sliding bracket on the guide rail Move the bracket to the center Figure 204 1 Route IR sensor connector through the front wall Connect mating connectors for the IR sensor 2 Tighten this screw to hold...

Page 172: ...acket Figure 205 Figure 205 Attach gutter 13 Attach the gutter at the other end with a screw and tighten Figure 205 14 Tighten the screw first used to attach the gutter Figure 205 15 Return the sliding bracket back to its original position and tighten its Allen screw 16 Reinstall the cleaning station Figure 189 2 mm Allen key Sliding bracket Guide rail Gutter Fasten screw at one end leaving it loo...

Page 173: ...e 187 Note Be sure to perform the IR calibration wizard after the power is turned ON Installing the printing engine antistatic brushes Note This procedure is performed if the Input assembly does not contain the new antistatic brushes Normally they will be included with the new Input assembly Figure 206 Antistatic brush on second transfer knob housings 1 There is a spring in the antistatic brush br...

Page 174: ...4 of 221 Figure 208 Short anistatic brush installed on the inspection plate 3 Install the inspection plate above the Exit roller The pins in the front and rear of the Output assembly wall fit in the slot in the plate see Figure 209 and Figure 210 Figure 209 Pin on Output assembly for Inspection plate ...

Page 175: ...d clamps a Install the long brush on the brass rod if it is not already installed b Unscrew and remove the two screws on each antistatic clamp See inset Figure 211 Note The brush clamps are interchangeable This enables them to be used for any of the antistatic brushes anywhere in the press As a result they can be set to two possible positions Ensure when you install the brushes that the clamps loc...

Page 176: ...amp on the right and left sides of the roller axle and reinstall the screws in the clamp Figure 213 Long antistatic brush installed on lower Exit roller axle d Push the brass rod into the holes in the clamp Leveling the press After performing these changes to the press it is advisable to check the leveling of the press If the press is level the Input and Output assemblies will be level ...

Page 177: ...s used to level the press at each of the corners of the press They are used to raise or lower the level of each corner Figure 215 Leveling the press 1 Use the leveling jig and level to determine the level on the printing engine Place the leveling jig on the chassis base Place the level on the leveling jig Figure 215 LEVEL LEVELING JIG CHASSIS LEVELING POSITION ...

Page 178: ...fidential CA293 00600 Rev 00 page 178 of 221 PAD1 SHOCK ABSORBING THICK SIDE ON FLOOR Figure 216 Leveling pad height adjustment bolt 2 Using a 19 mm wrench adjust the height of the leveling pads so that the engine is level Figure 216 TURN THIS BOLT TO ADJUST HEIGHT ...

Page 179: ...rews in the four brackets and tighten them when vacuum box is level Note It is required to level the vacuum box from side to side but also leveling the vacuum box from front to back reduces a major cause of substrate scratches Aligning the Unwinder to the press 1 Place the V section of the distance jig Figure 218 on the roller at the entrance to the printing engine Figure 219 2 Use the length adju...

Page 180: ...nd the Unwinder lower output roller at both the front and rear Figure 17 View the distance on the dial If necessary use the long crowbar to move the Unwinder slightly until the difference between the front and rear is less than 0 02 mm 4 Tighten the footstep bracket bolts that secure the Unwinder to the printing engine 5 Re check the level of the Unwinder Re adjust if necessary 6 Re check the diff...

Page 181: ...page 181 of 221 Rewinder Antistatic bars Antistatic bars and brackets Figure 220 Antistatic bars and brackets The following procedure describes how to install the antistatic bars on the Rewinder Final placement of Rewinder Antistatic bars Figure 221 Final placement of Rewinder Antistatic bars ...

Page 182: ...emove the four screws on the Rewinder table Figure 222 Removing the screws Figure 222 Removing the screws 2 Place the four brackets in place over the holes so the slots face each other Figure 223 Note Ensure that the slots of the brackets face the center of the table Bracket and slot Figure 223 Bracket and slot ...

Page 183: ...ling assembly on the ILD support bar 1 Take the ILD from where it was placed near the junction box and install it on the ILD bar 2 From the Output of the printing engine install the ILD cooling unit hose onto the bottom of the ILD cooling assembly to the right of the filter housing Use two M3 Allen screws 3 The ILD cooling unit has a screw M3 and pin on its bottom to secure it to the ILD cooling b...

Page 184: ... unit on its bracket 7 Fit the screw and pin into the two center holes in the bracket Ensure that the screw is in the top hole and the pin fits into the bottom hole of the bracket as it sits on the ILD support bar Figure 225 8 Reconnect the hose onto the ILD cooling bracket 9 Replace the ILD system on its original position on the ILD bar SIGHT BLADE ILD COOLING BRACKET for ws4000 Figure 226 Aligni...

Page 185: ...r source from the wall 4 Turn ON the Main switch on the electric cabinet 5 Turn on the UPS and the press Setting Inverter parameters for the press The following procedure describes setting the Inverter parameters Figure 227 Inverter panel The left LED displays the parameter The right LED displays the parameter value When you start setting the parameter values the parameter LED should display rd fo...

Page 186: ...eter LED displays 03 and flickers 7 Use the UP and Down arrows to enter the parameter 05 8 Press the M button The left parameter LED displays 05 The right value LED displays 3 and flickers 9 Use the UP and Down arrows until the value A1 PR is displayed in the LED 10 Press the M button The right value LED shows A1 PR The left parameter LED displays 05 and flickers 11 Use the UP and Down arrows to e...

Page 187: ... test and adjust the vacuum box so it sits level in the press If the vacuum box must be leveled release the screws in the four brackets and tighten them when vacuum box is level 4 Ensure that the Unwinder long antistatic brush brushes against the paper as it comes out of the Unwinder Post installation procedures Before printing for the first time after the above described installations procedures ...

Page 188: ... adjustment BID pressure adjustment Ink flow calibration Corner job calibration Scaling wizard Corner job calibration For the corner job calibration the press puts a mark on the blanket but does not transfer it to the substrate This mark is used to locate the image on the blanket At each printing engine in turn 1 From the Adjustments menu click Image Placement ...

Page 189: ... opening this wizard from the master console the press software prompts with the following screen to perform the wizard from the slave and then automatically opens the wizard on the slave The wizard opens on the relevant printing engine slave 2 Click the Go to Ready button 3 When the press is in Ready mode click Next ...

Page 190: ...idential CA293 00600 Rev 00 page 190 of 221 PUBLISHER 564 PIP DRUM RECTANGLE CORNER PRINT ON DRUM Figure 229 Printing the rectangle corner on the drum 4 Click Print to print a corner rectangle on the drum See Figure 229 The wizard automatically opens the next window ...

Page 191: ...HP Indigo press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 191 of 221 Figure 230 Measuring from the left side of the drum old and new drums ...

Page 192: ...ts lower edge touches the edge of the blanket clamp See Figure 231 7 Compare the rectangular corner horizontal line position to the jig center mark on the top scalar If the jig does not show 0 corner offset then enter the offset reading i e the number of lines on the jig in the Top field 8 Repeat steps 4 6 until the jig shows 0 corner offset and the left offset is 89 mm for old or new ITM drums 9 ...

Page 193: ...dential CA293 00600 Rev 00 page 193 of 221 For the vacuum box sensor 1 Turn the sensor strip on its back on top of the vacuum box Figure 232 Tape down the sponge on the sensor strip 2 Tape down the sponge so it won t tear Figure 233 Ensure the Sensor mode is set to D ...

Page 194: ...justing hole and turn the SENSOR screw counterclockwise 4 until both the green and red LEDs are lit 8 Turn the SENSOR screw clockwise 3 until both LEDs turn off Continue slowly turning the SENSOR screw clockwise until the green LED is lit Turn the SENSOR screw just a little bit more so it is clearly in the proper position When the vacuum box sensor strip is right side up on the vacuum box you can ...

Page 195: ... The green LED indicates that there is nothing under the sensor The red LED indicates that there is something under the sensor When there is something under the sensor ensure that the red LED shines steady and brightly 9 Put a sheet of clear plastic under the sensor that was adjusted Note Ensure that the transparent substrate lies flat and is not crinkled when it is under the sensor ...

Page 196: ... Screen showing only the middle sensor is covered 10 When there is something under the sensor the Touch screen display should change from clear to dark covered where the plastic blocks the reflector under the sensor The LEDs will display both red and green For web break sensor calibration Figure 237 Ensure the Sensor mode is set to D ...

Page 197: ... Usually both LEDs go out and then the green LED lights up If the red and green LEDs light up and then just the green LED check that the MODE is set to D Testing web break sensors The green LED indicates that there is nothing under the sensor The red LED indicates that there is something under the sensor When there is something under the sensor ensure that the red LED shines steady and brightly 7 ...

Page 198: ...dicating Uncovered 14 If a sensor indicates COVERED remove the sensor strip and see whether something is covering the sensor or the hole in the vacuum box a Realign the sensor strip on the vacuum box b Reinstall the sensor strip on the vacuum box c Ensure that the screws are tightened all the way d If the sensor still does not register replace it Replacing a vacuum box or web break sensor This pro...

Page 199: ...Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 199 of 221 To replace the sensor Figure 239 Remove the sensor 1 Unscrew the two screws that hold the sensor to the sensor strip 2 Turn the sensor over ...

Page 200: ...nsor 3 Using a flat head screwdriver twisting the screwdriver in a clockwise 3 and counterclockwise 4 direction gently remove the clip from the back of the sensor Figure 241 Pull sensor off its base 4 Gently pull the sensor off the base Figure 242 Fitting sensor into sensor base 5 Install the new sensor The sensor fits into a groove on the base ...

Page 201: ...t It is not necessary to upload parameters to the Unidrive unless the WHS software is lower than version 1 03 If the WHS software is lower than version 1 03 use the Unisoft software to perform the following Viewing or changing UniDrive parameter values UniDrive keypad cdr Up Right Down Left Modify Parameter value Parameter name M 1 2 3 4 5 6 1 2 3 4 Figure 244 UniDrive keypad The parameter name co...

Page 202: ...wing 1 Press the left right arrow buttons to change the menu number of the parameter name to 0 00 2 Press the modify M button 3 Press the up down arrow buttons to change the parameter number of the parameter name to 1000 4 Press the modify M button 5 Press the Red button Manually entering the new motor offset number to the Unidrive IP1 Note Parameter value 149 is the technician code that allows ac...

Page 203: ...procedure to download system files to the Unidrive 1 Connect the communications cable P N EHE 4602 51 between the software download port Figure 19 and the serial port at the rear of the laptop Note Note the part number of the communications cable Make sure that you use the correct cable 2 Insert the hp indigo press whs software for w3200 ws4000 CD ROM into the laptop CD ROM drive 3 Start WinFlashe...

Page 204: ...io button from Download a compiled program to Download a system file 7 Click Next 8 Browse tot the CD Go to Source files Unidrives Sys UD770Net sys 9 Click Next 10 The Select the method for downloading screen appears Select the Set to COM1 option 11 Click Next A safety pop up window appears indicating the download will begin ...

Page 205: ...in the press 16 Perform the BID engage wizard 17 Print the gray20 job and adjust the BID engage knobs for best performance ILD cooling system 1 Go to Standby mode 2 In the menu options click Diagnostics then Transfer to display the transfer diagnostics screen 3 Click ILD to display the ILD diagnostic options 4 Click the ILD Cooling button to activate the ILD cooling fan 5 Remove the top cover and ...

Page 206: ...erminal adjustment 7th BID cable assembly P N CA245 000240 quantity 1 Wire cover MPQ 1366 02 quantity 1 Washer spring M4 MWL 0401 50 quantity 6 Washer flat M4 MWP 0401 50 quantity 6 Screw Allen M4 x 12 mm MBA 0412 51 quantity 6 Anti drip kit assembly 1 IR sensor bracket CA244 00310 quantity 1 2 Catch tray CA244 01190 quantity 1 3 Gear guard CA245 03210 quantity 1 4 Cable clamp EZC 0001 10 quantity...

Page 207: ...M BOX CA245 01552 FEED 3 MAIN ASSEMBLY CA245 02242 EXIT 3 CA292 00390 U W CA292 00420 SLIDER CA292 00410 ILD COOLING CA292 00080 ILD FIRMWARE CA292 00140 BLACK ROD CA292 00400 BID KNOB CA292 00350 SW 6 2 1 CA292 00630 POP I NEW CHIP PRE 2000 52 CABLE ASSY CC250 VACUUM EHE 4250 51 CABLE ASSY CC251 VACUUM EHE 4251 51 CABLE ASSY CC252 VACUUM EHE 4252 51 CABLE ASSY FCO PROFIBUS CA261 07470 CABLE ASSY ...

Page 208: ...245 01552 VACUUM BOX UNWINDER Component Part Numbers Description Qty CA240 01920 HOLDER FRONT V B L 2 CA240 01930 HOLDER REAR V B LO 1 CA240 01940 HOLDER REAR V B LO 1 CA244 00371 WEB KNIFE ASSY V B 1 CA245 00462 VCUUM BOX BASIC TOP 1 CA249 00410 DOC PI VACUUM BOX TO 1 CA249 00620 DOC ENG NOTES FOR 1 MBA 0510 50 BOLT M5X10CAP ALL ST 4 MBA 0610 50 SCREW ALLEN M6x10 S 2 MBA 0616 50 SCREW ALLEN M6X16...

Page 209: ... 10 SCREW SHOULDER M8 D1 5 MBS 0830 10 SCREW SHOULDER M8 D1 3 MLB 1086 01 LABEL S N FOR WHS UN 1 MPQ 0471 51 BELT TIGTHTER ASSY 1 MPQ 0517 01 PAPER GUIDE 1 MPQ 0771 32 SHAFT PAPER SUPPOR 1 MPQ 0780 01 SHAFT HOLDER ILD 2 MPQ 1187 51 DEFLECTION IDLER D58 1 MPQ 1535 52 INTERLOCK UNIT PE1 1 MPQ 2082 01 DISTANCE WASHER 3 MPQ 2183 01 THREADING ATS 3 MPQ 2184 01 THREADING BDS 3 MPQ 2216 01 THRUST WASHER ...

Page 210: ...9 51 CABLE ASSY CC249 PWR 1 MBA 0310 50 SCREW ALLEN M3x10 S 2 MBA 0410 50 SCREW ALLEN M4x10 ST 8 MBG 0620 50 SCREW M6X20 FLAT HEA 2 MBS 0820 10 SCREW SHOULDER M8 D1 2 MBS 0830 10 SCREW SHOULDER M8 D1 2 MPQ 0425 32 RETRACTABLE SHEET OU 1 MPQ 1187 51 DEFLECTION IDLER D58 2 MPQ 2731 01 BRACKET PAPER SENSO 1 MWL 0301 50 WASHER SPRING M3 D5 2 MWL 0401 50 WASHER SPRING M4 D7 2 MWP 0301 50 WASHER FLAT M3...

Page 211: ...SHER SPRING M5 D8 4 MWP 0501 50 WASHER FLAT M5 D9 S1 4 Q5379 00190 DOC BOM REPORT FO 1 FCO Description CA292 00080 KIT FCO ILD COOLING FOR Component Part Numbers Description Qty CA245 00840 ILD COOLING ASSY F 1 EHE 4108 52 CABLE ASSY CC108B PE 1 MBA 0410 50 SCREW ALLEN M4x10 ST 2 MBA 0610 50 SCREW ALLEN M6x10 S 4 MWL 0401 50 WASHER SPRING M4 D7 2 MWL 0601 50 WASHER SPRING M6 D9 4 MWP 0401 50 WASHE...

Page 212: ... 2773 51 TERMINAL ADJUSTMENT 1 MWL 0401 50 WASHER SPRING M4 D7 7 MWL 0601 50 WASHER SPRING M6 D9 2 MWP 0401 50 WASHER FLAT M4 D8 S0 7 MWP 0601 50 WASHER FLAT M6 D11 S 2 Q5379 00190 DOC BOM REPORT FO 1 FCO Description FCO 3517 01 BLOWER CAB INN DOOR IN FCO Description CA292 00510 KIT FOR REWINDER ANTISTATIC BARS Component Part Numbers Description Qty CA040 05570 BRACKET 4 CA040 05750 ANTISTATIC BAR...

Page 213: ...S 0500 00 TUBING SHRINK 1 2 BL 06 FCO Description EHE 4252 51 CABLE ASSY CC252 VACUUM Component Part Numbers Description Qty 1990 3140 OPTO SENSOR 3 ENO 5210 13 CONN 10 PIN MINI FIT 1 EZM 0292 33 MARKER ADHESIVE 12 7 5 EZP 6701 08 PIN MALE 22 28 AWG 9 EZS 0250 00 TUBING SHRINK 1 4 BL 06 FCO Description CA292 00520 UNWINDER AND PAPER THREADING LABEL PLACEMENT Component Part Numbers Description Qty ...

Page 214: ...Description Qty CA254 00510 INVERTOR ASSEMBLY W 1 CA259 00550 DOC MI FOR WS4000 IN 1 EHW 0101 01 WIRE 16AWG BRN STRAN 16 2 EHW 0118 54 WIRE 18AWG PVC GRN Y 46 EHW 0118 80 WIRE 18AWG PVC STRAN 6 5 EHW 0118 82 WIRE 18AWG PVC STRAN 6 EHW 0118 87 WIRE 18AWG PVC STRAN 13 EHW 0118 94 WIRE 18AWG PVC STRAN 4 9 ENT 0105 02 FORK TERMINAL INSULA 16 ENT 0115 00 CABLE END TERMINAL I 12 ENT 0126 03 FERRULES 1MM...

Page 215: ...nt knob housing The new housing enables the installation of static charge brushes The procedure describes changing one knob housing but it must be performed on both knob housings Figure 245 Knobs and housings on Input assembly wall 6 Unscrew and remove the second transfer adjustment knob and knob housing brackets from the Input assembly wall and cut the ties that hold the cable in place 7 Unscrew ...

Page 216: ...ry and confidential CA293 00600 Rev 00 page 216 of 221 Figure 247 Lifting off the knob cover 9 Lift off the cover on the knob Figure 248 Set screw 10 Unscrew and remove the set screw on the outside of the knob 11 Remove the adjustment knob from the cable ...

Page 217: ...re 249 Removing C clip 12 Remove the C clip from the cable 13 Unscrew and remove the adjustment knob housing from the Input assembly walls Figure 250 Installing housing on Input assembly wall 14 Use two screws through the outer two holes in the inside of the housing to install the new housing on the assembly wall ...

Page 218: ... of wall 15 Feed the second transfer cable through the bottom of the housing Figure 252 Second transfer cable in housing 16 Install the C clip on the cable 17 Put the knob on the end of the cable aligning it so the set screw faces the flat surface on the end of the cable 18 Tighten the set screw in the knob 19 Push the cover on the knob ...

Page 219: ...s proprietary and confidential CA293 00600 Rev 00 page 219 of 221 Figure 253 Second transfer cable clip Note Ensure that the clip on the Input assembly wall that holds the second transfer cable prevents the cable from rubbing against the roller ...

Page 220: ...HP Indigo press ws4000 Cluster 1 procedures proprietary and confidential CA293 00600 Rev 00 page 220 of 221 9 Attached documents Appendix ...

Page 221: ...re any specific difficulties or problems in implementing this FCO General remarks Thank you for your cooperation FCO feedback Complete this form immediately after implementation of the FCO Send the fax to Att Fax Customer Support Yossi Bahar Hewlett Packard Company Indigo Division 972 8 938 5517 Date d Mon yr FCO number Press serial number Customer name Country state Technician name Tel Fax If any...

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