Page 1 HP Indigo press ws4000 Cluster 1 doc p/n: CA293-00600 procedures This document applies to the following products/serial numbers: HP Indigo press ws4000 serial nos. 2210002-22100122 & 110001 This document applies to the following parts/assemblies: Cluster 1 assemblies ⌧yes Software affected: ⌧partial...
Page 2: Table Of Contents
HP Indigo press ws4000 Cluster 1 procedures Contents Purpose .......................10 Components ........................10 Implementation ....................11 Estimated installation time....................11 Required special training ....................12 Special jigs and tools......................12 Prerequisites ......................12 Procedure ......................13 Preliminary steps .......................13 Installing the ILD Firmware update..................15 ILD Troubleshooting ......................22 Replacing the PLC memory cartridge ................23...
Page 3 HP Indigo press ws4000 Cluster 1 procedures Installing the printing engine antistatic brushes ..............173 Leveling the press ......................176 Aligning the Unwinder to the press..................179 Rewinder Antistatic bars....................181 Installing the ILD cooling assembly on the ILD support bar ..........183 Powering up the press.....................185 Setting Inverter parameters for the press................185...
Page 4 HP Indigo press ws4000 Cluster 1 procedures Figure 11 File Select option..................19 Figure 12 Downloading file...................20 Figure 13 Download complete..................20 Figure 14 Flash Memory Loader – Main Menu ............21 Figure 15 Fastening software version label to ILD ............21 Figure 16 Connection error message................22 Figure 17 SysTab Window showing angleToStartMeasure parameter ......23...
Page 5 HP Indigo press ws4000 Cluster 1 procedures Figure 52 Lifting off Unwinder front door ..............59 Figure 53 Take out Unwinder deflector roller to remove vacuum box......60 Figure 54 Removing Unwinder lower roller screw on front wall ........61 Figure 55 Removing Unwinder lower roller screw on rear wall ........62 Figure 56 Unwinder side understep roller to be replaced..........63...
Page 6 HP Indigo press ws4000 Cluster 1 procedures Figure 93 Long antistatic brush installed on the Unwinder bottom roller axle ....93 Figure 94 Longer and shorter axles on understep roller Input press side ....94 Figure 95 Longer and shorter axles on understep roller Unwinder side.......95 Figure 96 Placement of Tension in web label ..............96...
Page 7 HP Indigo press ws4000 Cluster 1 procedures Figure 134 ESB board with old connector on J38 ............122 Figure 135 Ceiling cover gasket.................123 Figure 136 Removing the right Molex from the GDB panel........123 Figure 137 CC108C cables pulled from ESB board on back of press .......124 Figure 138 Output assembly front cover ..............125...
Page 8 HP Indigo press ws4000 Cluster 1 procedures Figure 175 Loosen the inner locking screw..............154 Figure 176 Removing the inner gear pin ..............155 Figure 177 Sliding out the Input section drive belt .............155 Figure 178 Replacing the preheater spidle and screw ..........156 Figure 179 Gates Sonic meter 505C................157...
Page 9 HP Indigo press ws4000 Cluster 1 procedures Figure 216 Leveling pad height adjustment bolt............178 Figure 217 Leveling the vacuum box .................179 Figure 218 Distance jig....................180 Figure 219 Using the distance jig ................180 Figure 220 Antistatic bars and brackets ..............181 Figure 221 Final placement of Rewinder Antistatic bars ..........181 Figure 222 Removing the screws................182...
Page 10: Purpose
HP Indigo press ws4000 Cluster 1 procedures Purpose To include a group of component features in a kit for HP Indigo press ws4000. Combining these features into one kit saves press down time during the upgrade. This cluster of features is generally inter-related and may have prerequisites of other features in the group.
Page 11: Implementation
HP Indigo press ws4000 Cluster 1 procedures Description CA292-00610 FCO KIT SW CA292-00140 ILD firmware CA292-00630 SW 6.2.1 CA272-00041 CD WHS SW 1.0.9 CA274-00141 Memory cassette WHS SW1.0.9 Q5379-00190 DOC. - BOM REPORT FOR KIT Non-software FCOs CA292-00311 Dripping FCO kit...
Page 12: Required Special Training
• Gates Sonic tension meter model 505C (MHM-0007-00) • Grounding wrist strap (P/N MTX-0004-01). 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).
Page 13: Procedure
HP Indigo press ws4000 Cluster 1 procedures Two-hole One-hole bracket bracket Figure 1 ILD bracket Procedure Preliminary steps •1. Print 20 copies of the CATP job to be used as a baseline. •2. Make sure that the Ghost procedure has been performed on the O/S.
Page 14: Figure 3 Export Window
HP Indigo press ws4000 Cluster 1 procedures Figure 3 Export window In the Export window, click Open to save the fonts. The Export window closes. Close the Press Font Manager window by clicking Close. •5. To backup the machine configuration, do the following: Insert a 3.5”...
Page 15: Installing The Ild Firmware Update
HP Indigo press ws4000 Cluster 1 procedures Installing the ILD Firmware update ILD Firmware Prerequisites Laptop computer with a 3.5” Diskette Drive or CD ROM drive. The laptop computer BIOS must be configured to boot from the CD-ROM or diskette prior to booting from the hard drive.
Page 16: Figure 6 Ild Hand Knobs
HP Indigo press ws4000 Cluster 1 procedures 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.
Page 17: Figure 7 Removing The Ild Connector
HP Indigo press ws4000 Cluster 1 procedures 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. Connect to press ILD connector...
Page 18: Figure 9 Connecting The Cable To The Ild
HP Indigo press ws4000 Cluster 1 procedures Figure 9 Connecting the cable to the ILD •6. Release the Emergency Stop button and place the press in Standby mode. •7. Insert the diskette or CD Rom into the computer. •8. Configure your laptop computer to boot using the CD ROM or diskette.
Page 19: Figure 10 Flash Memory Loader - Main Menu
HP Indigo press ws4000 Cluster 1 procedures 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: Figure 12 Downloading File
HP Indigo press ws4000 Cluster 1 procedures 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: Figure 14 Flash Memory Loader - Main Menu
HP Indigo press ws4000 Cluster 1 procedures Figure 14 Flash Memory Loader – Main Menu •14. Type F to exit the Flash Memory Loader Utility. The A:\> prompt displays. •15. Press an Emergency Stop button. •16. Disconnect the cable from the ILD, press ILD connector and computer.
Page 22: Ild Troubleshooting
HP Indigo press ws4000 Cluster 1 procedures •22. Release the Emergency Stop button. ILD Troubleshooting If the following message appears at any stage in the process: Figure 16 Connection error message •1. Disconnect the ILD power branch of the cable and reconnect it again to ensure that it is connected properly.
Page 23: Replacing The Plc Memory Cartridge
HP Indigo press ws4000 Cluster 1 procedures Figure 17 SysTab Window showing angleToStartMeasure parameter Replacing the PLC memory cartridge PLCpanel.cdr -53A1 Status and Mode Fault LEDs selector Status and Fault LEDs for DP interface Memory cartridge Memory cartridge insertion marks...
Page 24: Programming The Plc
HP Indigo press ws4000 Cluster 1 procedures The PLC software memory cartridge (Figure 18) contains the software necessary to download parameters to the PLC. To replace the memory cartridge, do the following: •1. Press the Emergency Stop button. •2. Turn the PLC mode selector (Figure 18) counterclockwise to STOP.
Page 25: Downloading Software To The Unidrives Using Winflasher 3
Note the part number of the communications cable. Make sure that you use the correct cable. •5. Disconnect the CTNET cable. •6. Insert the “hp indigo press whs software for w3200/ws4000” CD-ROM P/N CA272-00041 into the laptop CD-ROM drive. proprietary and confidential...
Page 26 HP Indigo press ws4000 Cluster 1 procedures •7. Start WinFlasher 3 from 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.
Page 27 HP Indigo press ws4000 Cluster 1 procedures •12. Click Browse and navigate on the CD-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.
Page 28: Programming The Touch Screen
Programming the touch screen This procedure must be performed on both touchscreens. •1. Press the Emergency Stop button. •2. Insert the “hp indigo press whs software for w3200/ws4000” CD-ROM into the laptop CD-ROM drive. proprietary and confidential CA293-00600, Rev 00...
Page 29: Figure 20 Touch Screen Control Panel
HP Indigo press ws4000 Cluster 1 procedures •3. If the Galileo software is not installed on your laptop, install it from the “hp indigo press whs software for w3200/ws4000” CD-ROM, from file \TOOLS\Galileo Workshop\Disk1\setup.exe. •4. At the laptop, do the following: Copy the \SOURCE FILES\TSP folder from the CD-ROM to your laptop’s local disk.
Page 30 HP Indigo press ws4000 Cluster 1 procedures •10. Navigate on the laptop’s local drive in the Tsp folder that you copied, to the file: \Tsp\MICRO\ PANELx_yy\appl\PANELx_yy.DIR, where PANELx_yy is as follows: Panel1_uw Unwinder touch screen panel (w3200, ws4000) – Panel2_pe1 PE1 touch screen panel (w3200, ws4000) –...
Page 31: Unidrive - User Defined Error Messages (Trips)
HP Indigo press ws4000 Cluster 1 procedures Password Data Recipe Data Reboot Panel after download From the Communications Port drop-down list, select the correct serial port. From the Baudrate drop-down list, select 115200. •12. Click Download. The download progress bar displays on the touch screen.
Page 32: Hp Indigo Press Software Version 6.2.1 Installation
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 a setup language and click OK.
Page 33: Figure 21 Press Setup, Setup Data Folders Window
HP Indigo press ws4000 Cluster 1 procedures Figure 21 Press Setup, Setup Data Folders window •9. The HP Indigo Press Setup – Setup Data Folders window opens, click Next. •10. If orange or violet are not installed on the press, a message similar to the following may appear: Figure 22 sysTabInit.pl message...
Page 34: Figure 23 Launch Failure Warning
•14. After 100% progress is reached and the HP Indigo Press software installation completes, wait for the HP Indigo RIP Installer Welcome window to appear. Make sure that the HP Indigo RIP dongle is connected to the press. Click Next. •15. If the Previous Installation Detected message appears, click Next.
Page 35: Figure 24 Alert Message
•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.
Page 36: Reinstalling The Ink File
HP Indigo press ws4000 Cluster 1 procedures Figure 26 RIP Administration window, RIP Configurations tab •5. Click the RIP Configurations tab to bring it forward. •6. In the RIP Key field, enter your RIP key number. •7. Click OK. The RIP Administrations window closes.
Page 37: Software Testing Procedures
•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.
Page 38: Figure 28 System Table Editor Whs_R_Sw_Ver Parameter
•3. Perform the wizard procedure and close the window at the end of the calibration. Perform color adjust calibration Perform the color adjust calibration after calibrating the ILD on the HP Indigo press ws4000. •1. On the press software, select Adjustments, Color Adjustment and Calibration.
Page 39: Automatic Machine Lut
HP Indigo press ws4000 Cluster 1 procedures •2. In the Automatic Color Adjustment area, click Standard. The Auto Color Adjustment wizard opens. •3. Perform the wizard procedure and close the window at the end of the calibration. Note: If the Full Color Adjust Calibration fails, retry the Calibration until success is achieved.
Page 40: Figure 29 Opening The Substrate Scaling Correction Wizard
HP Indigo press ws4000 Cluster 1 procedures Figure 29 Opening the Substrate Scaling Correction wizard •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.
Page 41: Figure 31 Opening The Press Configuration Parameters
HP Indigo press ws4000 Cluster 1 procedures 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. proprietary and confidential CA293-00600, Rev 00...
Page 42: Figure 32 Motion Profile Field On Press Configuration Screen
HP Indigo press ws4000 Cluster 1 procedures Figure 32 Motion Profile field on Press Configuration screen •6. Go to 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.
Page 43: Figure 33 Substrate Scaling Correction Wizard Print Step
HP Indigo press ws4000 Cluster 1 procedures 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.
Page 44: Figure 35 Rl Conflict Notification Message
HP Indigo press ws4000 Cluster 1 procedures If there is a discrepancy between the repeat length of the previous print job and the repeat length of the new job, a notification message is displayed. Figure 35 RL Conflict notification message •9.
Page 45: Figure 36 Mmi Screen To Recalibrate Press
HP Indigo press ws4000 Cluster 1 procedures Figure 36 MMI screen to recalibrate press Click the Calibrate button. Click the Close button. •11. Click the Print button on the wizard again to print the Scaling job Ten copies of the Scaling job are printed and the wizard Enter Values step screen is displayed.
Page 46: Figure 37 Periphery Edge Lines
HP Indigo press ws4000 Cluster 1 procedures 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 proprietary and confidential...
Page 47: Figure 39 Directions For Measuring Scaling Job As Found On Job Sheet
HP Indigo press ws4000 Cluster 1 procedures •3. Use a magnifying glass and a ruler to measure the Image length, Repeat Length 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.
Page 48: Figure 40 Substrate Scaling Correction Screen Enter Values Step
HP Indigo press ws4000 Cluster 1 procedures Figure 40 Substrate Scaling Correction screen Enter Values step •1. Copy the five Image length and Repeat Length values from the Scaling job sheets and one value of the Image Width into the appropriate fields on the wizard Enter Values step.
Page 49: Figure 42 Values Within Tolerance Appear In Green
HP Indigo press ws4000 Cluster 1 procedures •3. Click the Print button to print the Scaling job. Ten copies of the Scaling job are printed. The wizard Enter Values step is displayed. Figure 42 Values within tolerance appear in green •4.
Page 50: Figure 43 Substrate Scaling Correction Wizard Analysis Step
HP Indigo press ws4000 Cluster 1 procedures Checking the Scaling job ruler accuracy Figure 43 Substrate Scaling Correction wizard Analysis step When the Image length, Repeat Length and Image width values are all within tolerance, the wizard Analysis step is displayed.
Page 51: Figure 44 Substrate Scaling Correction Wizard Fix Step
HP Indigo press ws4000 Cluster 1 procedures Adding or subtracting the deviation in the Fix step Figure 44 Substrate Scaling Correction wizard Fix step •1. Find and measure the greatest deviation between the benchmark and printed rulers. •2. If the printed ruler is shorter than the benchmark ruler, enter the deviation in the field on the screen.
Page 52: Figure 45 Finish Button
HP Indigo press ws4000 Cluster 1 procedures Figure 45 Finish button •6. Click the Finish button in the wizard Finish step. This concludes the scaling procedure for the Operator mode. CEs working in the Technician mode If there are still differences between the rulers over the course of several different...
Page 53: Printing The Catp Job
HP Indigo press ws4000 Cluster 1 procedures Figure 46 Web Handling field Default Web Scaling Correction parameter •1. Open the Press configuration parameters, accessed by: Options, Press Configuration. •2. Select the Web Handling parameters. Enter the grayed out Default Web Scaling Correction value from the wizard Fix step that was entered in the Default Web Scaling Correction parameters.
Page 54: Total Shutdown Procedure
HP Indigo press ws4000 Cluster 1 procedures •5. Ensure that the Vacuum Box Type is set to Version 3. •6. At the prompt to Restart the press software, select Later. Total Shutdown procedure The following procedure describes a total shut down of the press: •1.
Page 55: Figure 47 Removing Junction Box
HP Indigo press ws4000 Cluster 1 procedures Removing the printing engine junction box Figure 47 Removing junction box On the Output side of the press, remove the junction box. •1. Unscrew and remove the two screws on the top and the two screws on the bottom of the junction box.
Page 56: Removing The Unwinder Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures Removing the bottom cover •1. On the Input side of the press, 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).
Page 57: Figure 49 Pull Out The Bottom Of The Front Unwinder Cover
HP Indigo press ws4000 Cluster 1 procedures Figure 49 Pull out the bottom of the front Unwinder cover Pull out the bottom of the cover Lift the cover up and off the Unwinder. •2. Remove the Unwinder rear cover. Release the air pressure by pressing on the air nozzle trigger.
Page 58: Figure 50 Disconnecting Unwinder Rear Panel
HP Indigo press ws4000 Cluster 1 procedures Figure 50 Disconnecting Unwinder rear panel Disconnect the air hose from the air connector. Disconnect the Molex connector. proprietary and confidential CA293-00600, Rev 00 page 58 of 221...
Page 59: Figure 51 Removing The Unwinder Rear Panel
HP Indigo press ws4000 Cluster 1 procedures Figure 51 Removing the Unwinder rear panel 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: Figure 53 Take Out Unwinder Deflector Roller To Remove Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures Removing the Unwinder and understep rollers Figure 53 Take out Unwinder deflector roller to remove vacuum box •4. Remove the Unwinder deflector roller. proprietary and confidential CA293-00600, Rev 00 page 60 of 221...
Page 61: Figure 54 Removing Unwinder Lower Roller Screw On Front Wall
HP Indigo press ws4000 Cluster 1 procedures Figure 54 Removing Unwinder lower roller screw on front wall proprietary and confidential CA293-00600, Rev 00 page 61 of 221...
Page 62: Figure 55 Removing Unwinder Lower Roller Screw On Rear Wall
HP Indigo press ws4000 Cluster 1 procedures Figure 55 Removing Unwinder lower roller screw on rear wall Remove the two screws that secure the roller to the walls of the Unwinder. •b. Remove the roller. The rear of roller axle is shorter and has a spacer on its end.
Page 63: Figure 56 Unwinder Side Understep Roller To Be Replaced
HP Indigo press ws4000 Cluster 1 procedures •5. Remove the Unwinder stepping plate rollers. Figure 56 Unwinder side understep roller to be replaced Lift stepping plate. Remove the two screws that secure the roller to the walls of the stepping plate assembly.
Page 64: Figure 57 Input Press Side Understep Roller To Be Replaced
HP Indigo press ws4000 Cluster 1 procedures •6. Remove the last roller under the stepping plate. Figure 57 Input press side Understep roller to be replaced Remove the two screws that secure the roller to the walls of the stepping plate assembly.
Page 65: Figure 58 Removing The Unwinder Nip Roller Drive Motor
HP Indigo press ws4000 Cluster 1 procedures Figure 58 Removing the Unwinder Nip roller drive motor Removing the Unwinder vacuum box sensor •1. Remove the Unwinder vacuum box sensor. Closeup view of Figure 59 Unplugged vacuum box sensor Unplug the Unwinder vacuum box sensor Molex.
Page 66: Figure 60 Removing Vacuum Box Bracket Screws
HP Indigo press ws4000 Cluster 1 procedures •1. Remove the screws holding the Input side vacuum box brackets. Discard these brackets. Note: Support the vacuum box when releasing the last screws so the vacuum box doesn’t fall. Figure 60 Removing vacuum box bracket screws •2.
Page 67: Installing The Inverters In The Electric Cabinet
HP Indigo press ws4000 Cluster 1 procedures •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: Figure 63 Electric Cabinet Before Inverter Installation
HP Indigo press ws4000 Cluster 1 procedures 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. proprietary and confidential CA293-00600, Rev 00...
Page 69: Figure 64 22Q3 And 22Q5 Switches
HP Indigo press ws4000 Cluster 1 procedures 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.
Page 70: Figure 65 71K1, 71K2 And 71K4 Circuit Protectors
HP Indigo press ws4000 Cluster 1 procedures 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: Figure 66 X15, X16 Ac Block Connection
HP Indigo press ws4000 Cluster 1 procedures Figure 66 X15, X16 AC block connection •4. Disconnect the 71K2 wires from the T1,T2,T3 positions that go to the X16, AC block connection in the L1, L2, L3 positions. Remove the wires.
Page 72: Figure 67 Blower Connector Boxes
HP Indigo press ws4000 Cluster 1 procedures Figure 67 Blower connector boxes Open the blower connector boxes. proprietary and confidential CA293-00600, Rev 00 page 72 of 221...
Page 73: Figure 68 Blower Wiring
HP Indigo press ws4000 Cluster 1 procedures Figure 68 Blower wiring Disconnect and discard the cables to the blowers. Note: The order of connecting the wires to the terminals determines the phase. If the same order is not maintained, the fan may blow in the reverse direction.
Page 74: Figure 69 60A0 Power Supply
HP Indigo press ws4000 Cluster 1 procedures Figure 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.
Page 75: Figure 70 60A5 Electronic Block
HP Indigo press ws4000 Cluster 1 procedures Figure 70 60A5 electronic block •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.
Page 76: Figure 72 New 22Q3 And 22Q5 Circuit Breakers
HP Indigo press ws4000 Cluster 1 procedures •16. Wrap the two exposed red wire ends with insulated 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.
Page 77: Figure 73 Inverters Installed On Electric Cabinet
HP Indigo press ws4000 Cluster 1 procedures Figure 73 Inverters installed on electric cabinet •19. Install the inverters on the electric cabinet door. Measure four holes down on the cabinet door from the cable channel in the middle of the door.
Page 78: Figure 74 Blower Connector Box Connections
HP Indigo press ws4000 Cluster 1 procedures Figure 74 Blower connector box connections •21. Connect the wires to the blower connector boxes as they were before (Figure 68). Note: Ensure that the wires from the inverter are not sharply bent as they fit in the connector box.
Page 79: Figure 75 3 Brown Wires To The 22Q3 Breaker
HP Indigo press ws4000 Cluster 1 procedures Figure 75 3 brown wires to the 22Q3 breaker Connect 3 brown wires to the 22Q3 breaker and 3 brown wires to their labeled positions on the 22Q5 breaker. proprietary and confidential CA293-00600, Rev 00...
Page 80: Figure 76 Connecting The 60A0 Power Supply
HP Indigo press ws4000 Cluster 1 procedures Figure 76 Connecting the 60A0 power supply Connect one violet wire to the 60A0 #1pin. Connect one violet wire to the 60A0 #2pin. Connect one violet wire to the 60A5 #1pin. Connect one violet wire to the 60A5 #2pin.
Page 81: Figure 77 Unidrive
HP Indigo press ws4000 Cluster 1 procedures Figure 77 Unidrive Connect one violet wire to the Unidrive Unwinder blower unit 26UO-25. Connect one red to the Unwinder blower unit 26UO-9. Connect one black wire to the Unwinder blower unit 26UO-11.
Page 82: Figure 78 Unwinder Junction Box
HP Indigo press ws4000 Cluster 1 procedures 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.
Page 83: Figure 79 Side View Of The Connector Terminal
HP Indigo press ws4000 Cluster 1 procedures Figure 79 Side view of the connector 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.
Page 84: Figure 81 Press Junction Box
HP Indigo press ws4000 Cluster 1 procedures Connect the green wire to the bottom (positive) row in slot 16. Connect the red wire to the middle (negative) row in slot 15. Connect the blue wire to the middle (negative) row in slot 16.
Page 85: Figure 82 Press Junction Box Connections Closeup
HP Indigo press ws4000 Cluster 1 procedures Figure 82 Press junction box connections closeup •1. Open the junction box on the rear Output wall. •2. Remove the Printing engine CC521 cable that consists of 9 wires connections in the junction box.
Page 86: Figure 83 Running The Vacuum Box Sensor Cable To The Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures Connect the white wire to the top (numbered) row in slot 16. Connect the purple wire to the top (numbered) row in slot 15. Figure 83 Running the vacuum box sensor cable to the vacuum box •4.
Page 87 HP Indigo press ws4000 Cluster 1 procedures Connect from Connect to 24F1-1 (L1) 22Q3-1 22Q3-1 22Q5-1 24F1-3 (L3) 22Q3-3 22Q3-3 22Q5-3 24F1-5 (L3) 22Q3-5 22Q3-5 22Q5-5 60A5-1 Inverter VBFU-10 26UO-25 60A5-2 Inverter VB1-10 24UO-25 Inverter VBFU-16 60A0-1 Inverter VB1-16 60A0-2...
Page 88: Installing The Unwinder Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures Installing the Unwinder Vacuum box •1. Install in the Input side brackets on the Unwinder rear and front walls. Figure 84 Input side vacuum box brackets Install the new vacuum box Input side brackets in place, using the old bracket spacers.
Page 89: Figure 85 Vacuum Box Hoses With Clamps Alternated
HP Indigo press ws4000 Cluster 1 procedures Figure 85 Vacuum box hoses with clamps alternated Alternate the clamp fittings on the hoses for easier access. Connecting Unwinder ground cable Figure 86 Unwinder vacuum box ground cables proprietary and confidential CA293-00600, Rev 00...
Page 90: Installing The Unwinder Nip Roller Drive Motor
HP Indigo press ws4000 Cluster 1 procedures •1. Connect the vacuum box ground cable to the Unwinder wall. Connecting the Unwinder vacuum box sensor •2. Connect the Unwinder vacuum box sensor Molex connector to the connector on the sensor bar.
Page 91: Figure 88 Unwinder Lower Roller
HP Indigo press ws4000 Cluster 1 procedures Figure 88 Unwinder lower roller •1. Install the Unwinder bottom roller. •a. Install the roller so the shorter side of the roller axle is on the rear of Unwinder. Install the spacer on its shorter axle.
Page 92: Figure 90 Installing The Stepping Plate Deflector Roller
HP Indigo press ws4000 Cluster 1 procedures Figure 90 Installing the stepping plate deflector 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 93: Figure 92 Clamps On The Right And Left Sides Of The Roller Axle
HP Indigo press ws4000 Cluster 1 procedures •1. Install long brush on the Unwinder bottom roller. Install the long brush on the brass rod. 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 Place the clamp on the right and left sides of the roller axle and reinstall the screws in the clamp.
Page 94: Figure 94 Longer And Shorter Axles On Understep Roller Input Press Side
HP Indigo press ws4000 Cluster 1 procedures 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 proprietary and confidential CA293-00600, Rev 00...
Page 95: Installing The Tension In Web Label On The Unwinder
HP Indigo press ws4000 Cluster 1 procedures Figure 95 Longer and shorter axles on understep roller Unwinder side The rear roller 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.
Page 96: Figure 96 Placement Of Tension In Web Label
HP Indigo press ws4000 Cluster 1 procedures 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: Removing The Printing Engine Fp (Substrate Transport) Motor
HP Indigo press ws4000 Cluster 1 procedures Removing the printing engine FP (Substrate transport) motor •1. Remove the FP motor. Figure 97 Disconecting ground cable Disconnect the ground cable. proprietary and confidential CA293-00600, Rev 00 page 97 of 221...
Page 98: Figure 98 Disconnecting The Encoder And Power Supply
HP Indigo press ws4000 Cluster 1 procedures Figure 98 Disconnecting the encoder and power supply Disconnect the Encoder and Power connections to the motor. proprietary and confidential CA293-00600, Rev 00 page 98 of 221...
Page 99: Figure 99 Four Screws That Secure The Motor To The Wall
HP Indigo press ws4000 Cluster 1 procedures Figure 99 Four screws that secure the motor to the wall Remove the four screws that secure the motor to the motor plate on the Output wall. Note: Leave the top screw for last, as this supports the motor while you are removing the other screws.
Page 100: Removing The Input Assembly
HP Indigo press ws4000 Cluster 1 procedures Removing the Input assembly Figure 101 Motor plate and Input section drive belt •1. Remove the FP motor plate. proprietary and confidential CA293-00600, Rev 00 page 100 of 221...
Page 101: Figure 102 Impression Encoder Connector
HP Indigo press ws4000 Cluster 1 procedures Figure 102 Impression encoder connector •2. Unplug the impression encoder connector. proprietary and confidential CA293-00600, Rev 00 page 101 of 221...
Page 102: Figure 103 Input Side Ground Cables
HP Indigo press ws4000 Cluster 1 procedures Figure 103 Input side ground cables •3. Disconnect the three Input side ground cables (from the Input wall, the Impression engage motor and the printing engine vacuum box). •4. Cut any ties that secure the second transfer cable.
Page 103: Figure 104 Removing Input Side Vacuum Box Bracket
HP Indigo press ws4000 Cluster 1 procedures Figure 104 Removing Input side vacuum box bracket Remove the screws holding the Input side vacuum box brackets. Figure 105 Output side vacuum box brackets Remove the remaining screws on the Output side brackets.
Page 104: Removing The Printing Engine Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures •7. Disconnect the vacuum hoses from the Input side of the vacuum box (Figure 106). Figure 106 Vacuum box sensor cable Molex and vacuum hoses •8. Disconnect the black and white air hoses from the back of the pneumatic piston.
Page 105: Remaining Steps In Removal Of The Printing Engine Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures Remaining steps in removal of the printing engine vacuum Final steps in removing the printing engine vacuum box •2. On the Output side of the press, remove the remaining screws on the vacuum box brackets.
Page 106: Figure 108 Removing The Interlock Cable Bracket
HP Indigo press ws4000 Cluster 1 procedures Figure 108 Removing the interlock cable bracket Remove the bracket behind the interlock. Unplug the Upper Nip interlock Molex connector and push the connector out of the bracket. Note: On older presses, the hole in the press wall is too small to push the connector through.
Page 107: Figure 109 Pneumatic Manifold
HP Indigo press ws4000 Cluster 1 procedures Figure 109 Pneumatic manifold •2. Disconnect the pneumatic manifold connector and air supply. Unscrew the screw on the end manifold module. Slide out the pneumatic manifold from the track. Unscrew and remove the cable connector from the manifold Unplug the main air supply from the manifold.
Page 108: Figure 110 Top And Bottom Ground Cables On Rear Output Wall
HP Indigo press ws4000 Cluster 1 procedures Figure 110 Top and 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.
Page 109: Figure 112 Pushing Molex Out Of Bracket
HP Indigo press ws4000 Cluster 1 procedures Figure 112 Pushing Molex out of bracket Push the Output guard Molex connector out of the bracket. Figure 113 Removing Output and Exit Nip guard interlock cables Unplug the Output Nip guard interlock Molex connector.
Page 110: Replacing The Output Rollers And Web Break Sensor
HP Indigo press ws4000 Cluster 1 procedures Figure 114 Homing sensor •5. Disconnect the homing sensor. •6. Disconnect the Encoder and power cables from the FP drive motor. •7. Remove the Output assembly from the press. Unscrew and remove the three screws on the front and the three screws on the rear Output walls.
Page 111: Figure 115 Replacing Output Rollers And The Web Break Sensor
HP Indigo press ws4000 Cluster 1 procedures Figure 115 Replacing Output rollers and the web break sensor •1. Replace the Output assembly upper rollers. Unscrew and remove the upper roller screws on the rear and the front walls of the Output assembly.
Page 112: Figure 116 New Rollers From Kit
HP Indigo press ws4000 Cluster 1 procedures Figure 116 New rollers from kit 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.
Page 113: Replacing The Web Break Sensor
HP Indigo press ws4000 Cluster 1 procedures Replacing the web break sensor •1. Replace the web break sensor. Figure 117 Sensor kit parts 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.
Page 114: Figure 119 Position Of The Reflector The Reflector Plate And The Bar
HP Indigo press ws4000 Cluster 1 procedures Figure 119 Position of the reflector the reflector plate and the bar Screw the new reflector on the reflector plate. Figure 120 Screwing reflector on support bar 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: Figure 121 Web Break Sensor Assembly As Seen From Inside Press
HP Indigo press ws4000 Cluster 1 procedures Figure 121 Web break Sensor assembly as seen from inside press Screw the paper guide onto the front of the reflector support bar. Fit the air hose feed guides to the back of the reflector support guide.
Page 116: Bid Knobs Bracket
HP Indigo press ws4000 Cluster 1 procedures Calibrating the vacuum box and web break sensor, page 192. BID knobs bracket Output assembly cover Old wire cover Drive NIP guard Figure 123 Output side–printing engine •1. Remove the old wire cover (Figure 123).
Page 117: Figure 125 Marking Knobs
HP Indigo press ws4000 Cluster 1 procedures Mark knobs with “White-out” paint Figure 125 Marking knobs •4. Mark each of the knobs 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.
Page 118: Figure 126 Bid Engage Knob Removal
HP Indigo press ws4000 Cluster 1 procedures Turn screw counterclockwise to remove Figure 126 BID engage knob removal •6. Remove the BID engage knobs by turning each of them counterclockwise (Figure 126) until they come out of the bracket. •7. Loosen the two screws holding the face plate on the new terminal assembly (MPQ-2773-51) (Figure 127).
Page 119: Figure 128 Routing Bid 1 Cable
HP Indigo press ws4000 Cluster 1 procedures BID 1 cable–on inside front wall Figure 128 Routing BID 1 cable •10. The longest path is to BID 1, shown inside the press in Figure 128. BID 7 cable PIP drum Figure 129 BID 7 cable location •11.
Page 120: Figure 130 New Bid 7 Assembly
HP Indigo press ws4000 Cluster 1 procedures Bracket mounting holes Figure 130 New BID 7 assembly •12. BID 7 has a separate terminal assembly (P/N MPQ-2924-31) (Figure 130). Mark the knob at the 12 o’clock position using white paint (“White-out”),...
Page 121: Figure 132 Mark Bid Knobs
HP Indigo press ws4000 Cluster 1 procedures Connects to BID 6– at the top Mark each knob at the 12 0’clock Connects to BID 1– position using white at the bottom paint (“White-out”), after BID cables are fastened in place...
Page 122: Installing The Ild Cooling System
HP Indigo press ws4000 Cluster 1 procedures •4. Attach the hidden bracket behind the corner support using the master screw (Figure 133). •5. Fasten new wire cover (MPQ-1366-02) in place using several screws (Figure 133). An enlarged hole in the new wire cover allows room for the master screw already fastened in place.
Page 123: Figure 135 Ceiling Cover Gasket
HP Indigo press ws4000 Cluster 1 procedures adapter that has three cables coming from it. One cable goes to the GDB panel (Figure 137); one cable is used with the ILD Cooling system. •3. Identify the CCJ38 cable that is marked ILD Engage and that comes from the ESB board.
Page 124: Figure 137 Cc108C Cables Pulled From Esb Board On Back Of Press
HP Indigo press ws4000 Cluster 1 procedures •8. Remove the right Molex connector (J7) from the GDB panel and discard the P/N EHE-4108-51 cable. Top panel Plug CC 108C cable into right GDB socket CC108C cable from the ESB board...
Page 125: Figure 138 Output Assembly Front Cover
HP Indigo press ws4000 Cluster 1 procedures ILD branch of CC108C cable GDB cover Output assembly front cover Figure 138 Output assembly front cover •10. Remove the Output assembly front cover (MPT-3255-03) by loosening the four Allen M5 screws that secure it in place.
Page 126: Figure 140 Roof Top Panel And Left Channel Cover Removed
HP Indigo press ws4000 Cluster 1 procedures •13. Run the ILD cooling branch of the CC108C cable from the ESB board to the top of the press (See Figure 138 and Figure 141). The ILD cooling cable will connect to the ILD cooling fan.
Page 127: Figure 141 Running The Cc108C Cable From The Esb Board To The Left Channel
HP Indigo press ws4000 Cluster 1 procedures Figure 141 Running the CC108C cable from the ESB board to the left channel •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).
Page 128: Figure 142 Mpt-4099-51 Light Guard Assembly
HP Indigo press ws4000 Cluster 1 procedures Yellow hose Figure 142 MPT-4099-51 Light guard assembly Note: The light guard assembly P/N MPT-4099-52 has been modified to include the ILD cooling fan and air tube unit. The modified light guard assembly’s name has been changed to ILD cooling assembly (P/N CA292-00840).
Page 129: Figure 143 Ild Cooling Assembly P/N 245-00840
HP Indigo press ws4000 Cluster 1 procedures Air tube unit Slot fits in rear of press ILD cooling fan CC108C connector Figure 143 ILD cooling assembly P/N 245-00840 •8. Install the ILD cooling assembly into the top of the press in place of the light guard assembly using the four M6 screws that were used to secure the light guard assembly.
Page 130: Black Rod Replacement
HP Indigo press ws4000 Cluster 1 procedures •16. Put the top panel in place. Black rod replacement The relevant parts of the scorotron and scorotron bridge that appear in this procedure include the following: Figure 145 Scorotrons and scorotron bridge...
Page 131: Figure 146 Removing The Scorotrons
HP Indigo press ws4000 Cluster 1 procedures •1. Ensure that for this procedure the system is Shut down and the main power supply and the UPS is switched off. •2. Cover the PIP during this procedure so that it does not get damaged.
Page 132: Figure 148 Removing The Screw From The Back Of The Pivot Shaft
HP Indigo press ws4000 Cluster 1 procedures Figure 148 Removing the screw from the back of the pivot shaft •5. On the back of the press, remove the screw that secures the pivot shaft (See Figure 148). Note: Hold the pivot shaft steady if the screw turns during removal.
Page 133: Figure 150 Removing The Pivot Arms
HP Indigo press ws4000 Cluster 1 procedures 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: Installing The Output Assembly
HP Indigo press ws4000 Cluster 1 procedures •9. On the front of the press, remove the screw on the pivot shaft (See Figure 151). •10. Remove C clips on the bushing assemblies (See Figure 145, part 7). •11. Remove the pivot levers (See Figure 145, part 3).
Page 135: Figure 152 Spacers Between The Drive Motor And The Plate
HP Indigo press ws4000 Cluster 1 procedures 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.
Page 136: Figure 154 Reconnecting Encoder And Power Connectors
HP Indigo press ws4000 Cluster 1 procedures •5. Repeat steps 1-3 for each of the other three screws that secure the drive motor to the plate. The following procedures describe installing the Output assembly. Note: This procedure requires two people.
Page 137: Figure 155 Push Interlock Cable Molex Connector Through The Wall
HP Indigo press ws4000 Cluster 1 procedures Figure 155 Push interlock cable Molex connector through the wall Push the interlock cable Molex connector through the wall. Figure 156 Connect the interlock Molex Fit the Molex connector into the interlock bracket and connect the interlock Molex connector.
Page 138: Figure 157 Secure The Interlock And Pneumatic Piston
HP Indigo press ws4000 Cluster 1 procedures Figure 157 Secure the interlock and pneumatic piston Install the interlock assembly and the pneumatic piston onto the Output rear wall. Ensure the air hose is connected to the pneumatic piston. Plug it in if it is not connected.
Page 139: Figure 158 Replacing The Interlock Cable Cover
HP Indigo press ws4000 Cluster 1 procedures Figure 158 Replacing the interlock cable cover Replace the interlock cable cover on the Output assembly frame and tighten the screws. Figure 159 Pneumatic manifold proprietary and confidential CA293-00600, Rev 00 page 139 of 221...
Page 140: Figure 160 Connecting The Manifold Connector
HP Indigo press ws4000 Cluster 1 procedures •7. Connect the pneumatic manifold connector and air supply. Unscrew the screw on the end manifold module. Slide out the pneumatic manifold from the track. Figure 160 Connecting the manifold connector c. Connect the cable connector to the manifold.
Page 141: Figure 161 Connecting The Main Air Supply To The Manifold
HP Indigo press ws4000 Cluster 1 procedures Figure 161 Connecting the main air supply to the manifold Connect the main air supply to the manifold. proprietary and confidential CA293-00600, Rev 00 page 141 of 221...
Page 142: Figure 162 Engage Nip Roller Air Hoses
HP Indigo press ws4000 Cluster 1 procedures 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 proprietary and confidential CA293-00600, Rev 00 page 142 of 221...
Page 143: Installing The Printing Engine Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures •9. Attach the two ground cables near the 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.
Page 144: Figure 164 Vacuum Box Supporters
HP Indigo press ws4000 Cluster 1 procedures Figure 164 Vacuum box supporters •1. Assemble the vacuum box 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.
Page 145: Figure 166 Vacuum Box Ground Cables
HP Indigo press ws4000 Cluster 1 procedures 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: Figure 167 Installing Input And Output Side Vacuum Box Brackets
HP Indigo press ws4000 Cluster 1 procedures Figure 167 Installing Input and Output side vacuum box brackets •2. Place the vacuum box in the press and attach the vacuum box brackets to the press walls. Do not tighten the screws.
Page 148: Figure 168 Vacuum Box Hoses With Clamps Alternated
HP Indigo press ws4000 Cluster 1 procedures Figure 168 Vacuum box hoses with clamps alternated Alternate the clamp fittings on the hoses for easier access. proprietary and confidential CA293-00600, Rev 00 page 148 of 221...
Page 149: Figure 169 Cables From Touchscreen To Junction Box And Profibus
HP Indigo press ws4000 Cluster 1 procedures Installing the junction box •1. Install the junction box on the rear Output wall with the four original screws. Figure 169 Cables from touchscreen to junction box and Profibus Connect the gray touchscreen connector cable that comes out of the bottom of the junction box to the side of the touchscreen.
Page 150: Installing The Input Assembly
HP Indigo press ws4000 Cluster 1 procedures Installing the Input assembly •1. Ensure that the paper feed guide is installed on the press. •2. It would be necessary here to record the Input assembly number to update the Unidrive before installing the assembly in the press, but there was no change to the offset motor number.
Page 151: Figure 170 Motor Plate Position
HP Indigo press ws4000 Cluster 1 procedures Figure 170 Motor plate position 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.
Page 152: Replacing The Fp Motor Belt
HP Indigo press ws4000 Cluster 1 procedures Figure 171 Installing motor on Output assembly wall Install the motor with the connectors facing down through the motor plate, NIP drive belt, the Input section drive belt and the hole in the press wall.
Page 153: Figure 172 Removing The Preheater Connector Bracket Cover
HP Indigo press ws4000 Cluster 1 procedures 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. proprietary and confidential CA293-00600, Rev 00...
Page 154: Figure 174 Removing The Reheater Spindle And Spring
HP Indigo press ws4000 Cluster 1 procedures 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 proprietary and confidential CA293-00600, Rev 00...
Page 155: Figure 176 Removing The Inner Gear Pin
HP Indigo press ws4000 Cluster 1 procedures •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: Figure 178 Replacing The Preheater Spidle And Screw
HP Indigo press ws4000 Cluster 1 procedures •7. Slide out the gear and remove the Input section drive belt. •8. Replace the Input section drive belt onto the Feed III gear. •9. Slide the Feed III gear onto its spindle.
Page 157: Figure 179 Gates Sonic Meter 505C
HP Indigo press ws4000 Cluster 1 procedures Figure 179 Gates Sonic meter 505C •2. Press the Power button. Figure 180 Measuring belt tension proprietary and confidential CA293-00600, Rev 00 page 157 of 221...
Page 158: Figure 181 Plucking The Belt To Get A Reading
HP Indigo press ws4000 Cluster 1 procedures •3. Press the Measure button, and then 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).
Page 159: Figure 182 Belt Locations
HP Indigo press ws4000 Cluster 1 procedures (3) Motor belt (2) Printing Head (1) Printing Head belt Motor belt Press exit side Press Input side Figure 182 Belt locations Take a tension measurement on the Printing head belt as follows: With one hand hold the meter so that its microphone is one cm above the mid-point of the upper belt section.
Page 160: Installing The Anti-Drip Kit Assembly
HP Indigo press ws4000 Cluster 1 procedures Figure 183 Loosening the motor bracket Use an M6 Allen key to loosen the four Allen screws securing the gear. Move the gear to loosen or tighten the belt as necessary. Tighten the screws.
Page 161: Figure 185 New Parts In Place-Press Feed Side
HP Indigo press ws4000 Cluster 1 procedures The final location of the new parts is shown in Figure 185. Part 2 Part 3 Hose clamp Part 1 Part 4 Figure 185 New parts in place—press feed side Note: A second person will be needed to assist the operator in installing part 2.
Page 162: Figure 187 Press Front
HP Indigo press ws4000 Cluster 1 procedures •5. Remove the cleaning station blade (Figure 187). Cleaning station blade Lever used to disengage the ITM hood—lever down for ITM hood removal Figure 187 Press front •6. Remove the cleaning station connector (Figure 188).
Page 163: Figure 189 Remove The Cleaning Station
HP Indigo press ws4000 Cluster 1 procedures Cleaning station Figure 189 Remove the cleaning station •8. Remove the IR sensor. First, remove the bracket which holds the IR sensor cable in position (Figure 190). IR sensor Marking tape IR sensor...
Page 164: Figure 191 Remove Ir Sensor Electrical Connector
HP Indigo press ws4000 Cluster 1 procedures IR sensor electrical connector Figure 191 Remove IR sensor electrical connector •10. Pull the IR sensor cable and connector though the front wall, 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).
Page 165: Figure 192 Remove Ir Sensor Bracket
HP Indigo press ws4000 Cluster 1 procedures IR sensor bracket mounting screw—on inner front wall IR sensor bracket mountings screw— on outer front wall Figure 192 Remove IR sensor bracket •14. Remove the four screws which support the tray below the PIP drum (Figure 193).
Page 166: Figure 193 Remove Tray Below Pip Drum
HP Indigo press ws4000 Cluster 1 procedures PIP drum Tray below PIP drum Fourth screw Rear mounting—third Front mounting—two screw accessible from screws accessible from outer rear wall outer front wall Figure 193 Remove tray below PIP drum •15. Remove the two screws located below the PIP brake controller which support the tray (Figure 194).
Page 167: Figure 195 Remove Tray Support Screw In Rear Of Press
HP Indigo press ws4000 Cluster 1 procedures Tray mounting screw Flywheel Figure 195 Remove tray support screw in rear of press •17. Remove 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).
Page 168: Figure 197 Install New Rear Bracket And Cable Clamp
HP Indigo press ws4000 Cluster 1 procedures •2. Install the new rear bracket and new cable clamp, which supports the cleaning station hose and cable (Figure 197). Notice that the new bracket has a screw built into it for attaching the new cable clamp.
Page 169: Figure 198 Install Catch Tray Below Pip Drum
HP Indigo press ws4000 Cluster 1 procedures PIP drum New catch tray Fasten screw Figure 198 Install catch tray below PIP drum •4. Fasten the screw which attaches the catch tray from the rear of the press (Figure 199). Tray mounting...
Page 170: Figure 200 Fasten Catch Tray Support Screws In Front Of Press
HP Indigo press ws4000 Cluster 1 procedures PIP brake controller Fasten two tray support screws Figure 200 Fasten catch tray support screws in front of press •6. Install the new IR sensor bracket using two screws (Figure 201). IR sensor set...
Page 171: Figure 202 Insert Ir Sensor Cable Through Wall And Attach Ir Sensor Cable
HP Indigo press ws4000 Cluster 1 procedures 2 Tighten this screw to hold IR sensor cable bracket in place Lubrication access holes in bracket 1 Route IR sensor connector through the front wall Figure 202 Insert IR sensor cable through wall and attach IR sensor cable •9.
Page 172: Figure 204 Move Bracket To Center
HP Indigo press ws4000 Cluster 1 procedures 2-mm Allen key Sliding bracket Guide rail Figure 204 Move bracket to center •12. Attach the gutter underneath the beam which sits behind the rail holding the moveable bracket (Figure 205). Beam Fasten screw at one...
Page 173: Installing The Printing Engine Antistatic Brushes
HP Indigo press ws4000 Cluster 1 procedures •17. Connect the cleaning station connector (Figure 188). •18. Reinsert the cleaning station blade at the front of the press (Figure 187). •19. Put the ITM hood back in place by pushing it into the rear wall (Figure 186), and then locking it into place using the ITM hood latch located on the outside front wall (Figure 187).
Page 174: Figure 208 Short Anistatic Brush Installed On The Inspection Plate
HP Indigo press ws4000 Cluster 1 procedures 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).
Page 175: Figure 210 Inspection Plate And Antistatic Brush Installed
HP Indigo press ws4000 Cluster 1 procedures Figure 210 Inspection plate and antistatic brush installed •4. Install long brush on the lower Exit roller. Figure 211 Long brush brass rod and clamps Install the long brush on the brass rod if it is not already installed.
Page 176: Leveling The Press
HP Indigo press ws4000 Cluster 1 procedures Figure 212 Clamps on the right and left sides of the roller axle Place the clamp on the right and left sides of the roller axle and reinstall the screws in the clamp.
Page 177: Figure 214 Leveling The Press
HP Indigo press ws4000 Cluster 1 procedures Figure 214 Leveling the press There are leveling pads 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.
Page 178: Figure 216 Leveling Pad Height Adjustment Bolt
HP Indigo press ws4000 Cluster 1 procedures TURN THIS BOLT TO ADJUST HEIGHT 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).
Page 179: Aligning The Unwinder To The Press
HP Indigo press ws4000 Cluster 1 procedures Leveling the vacuum box Figure 217 Leveling the vacuum box •3. Use a level to 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.
Page 180: Figure 218 Distance Jig
HP Indigo press ws4000 Cluster 1 procedures Figure 218 Distance jig Figure 219 Using the distance jig •3. Move the distance jig along the rollers from front to rear to measure the distance between the engine input roller and the Unwinder lower output roller at both the front and rear (Figure 17).
Page 181: Rewinder Antistatic Bars
HP Indigo press ws4000 Cluster 1 procedures 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: Figure 222 Removing The Screws
HP Indigo press ws4000 Cluster 1 procedures •1. Remove 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).
Page 183: Installing The Ild Cooling Assembly On The Ild Support Bar
HP Indigo press ws4000 Cluster 1 procedures Direction of the brackets Figure 224 Brackets facing center of table •3. Place the antistatic bars under the substrate and fit them into the slots in each bracket. Note: Ensure that the bar fits evenly in the brackets and does not jut out more on one side than on the other.
Page 184: Figure 225 Ild Cooling Unit On Its Bracket
HP Indigo press ws4000 Cluster 1 procedures ILD assembly on ILD bracket ILD cooling bracket on Exit module outside press Screw Note four holes on bracket ILD support bar ILD cooling hose on ILD cooling bracket Figure 225 ILD cooling unit on its bracket.
Page 185: Powering Up The Press
HP Indigo press ws4000 Cluster 1 procedures Powering up the press •1. Turn on the water supply. •2. Turn on the air supply. •3. Turn ON the main power source from the wall. •4. Turn ON the Main switch on the electric cabinet.
Page 186 HP Indigo press ws4000 Cluster 1 procedures Note: The first time you press the M button, you must press it for a very short time. Do not press it for a long, or it will take you out of set parameters mode.
Page 187: Setting Position Of The Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures •19. Use the UP and Down arrows to enter the parameter 32. •20. Press the M button. The left (parameter) LED displays 32. The right (value) LED displays L2 and flickers. •21. Use the UP and Down arrows until the value ON is displayed in the LED.
Page 188: Corner Job Calibration
HP Indigo press ws4000 Cluster 1 procedures Figure 228 Damaged impression roller • ITM temperature 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.
Page 189 HP Indigo press ws4000 Cluster 1 procedures Note: When 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.
Page 190: Figure 229 Printing The Rectangle (Corner) On The Drum
HP Indigo press ws4000 Cluster 1 procedures RECTANGLE (CORNER) PIP DRUM PRINT ON DRUM PUBLISHER-564 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: Figure 230 Measuring From The Left Side Of The Drum (Old And New Drums)
HP Indigo press ws4000 Cluster 1 procedures Figure 230 Measuring from the left side of the drum (old and new drums) proprietary and confidential CA293-00600, Rev 00 page 191 of 221...
Page 192: Troubleshooting
HP Indigo press ws4000 Cluster 1 procedures •5. Use a ruler to measure the distance from the inner edge of the left ITM gear to the left edge of the corner mark. See Figure 230. In the calibration wizard, enter the measurement value in the Left field.
Page 193: Figure 232 Tape Down The Sponge On The Sensor Strip
HP Indigo press ws4000 Cluster 1 procedures 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.
Page 194: Figure 234 Lit Leds Seen From The End Of The Sensor Strip On Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures •3. Ensure the sensor mode is set to D. To set the mode to D, turn the slot counter-clockwise to the end position. The slot will be set to D. Note: During this procedure you will only be adjusting the right or SENS screw.
Page 195: Figure 235 Checking The Sensor On The Vacuum Box
HP Indigo press ws4000 Cluster 1 procedures Testing vacuum box sensors Figure 235 Checking the sensor on the vacuum box 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.
Page 196: Figure 236 Vacuum Box Tsp Screen Showing Only The Middle Sensor Is Covered
HP Indigo press ws4000 Cluster 1 procedures Figure 236 Vacuum box TSP 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.
Page 197: Vacuum Box Sensor Troubleshooting
HP Indigo press ws4000 Cluster 1 procedures •1. Ensure the sensor mode is set to D. To set the mode to D, turn the slot counter-clockwise to the end position. The slot will be set to D. Note: During this procedure you will only be adjusting the right or SENS screw.
Page 198: Figure 238 Diagnostic Screen
HP Indigo press ws4000 Cluster 1 procedures Figure 238 Diagnostic screen •13. Open the vacuum box Diagnostic screen. When there is nothing inside the vacuum box, all three sensors on the screen should be clear (indicating 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.
Page 199: Figure 239 Remove The Sensor
HP Indigo press ws4000 Cluster 1 procedures 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. proprietary and confidential CA293-00600, Rev 00...
Page 200: Figure 240 Removing Clip From The Sensor
HP Indigo press ws4000 Cluster 1 procedures Figure 240 Removing clip from the sensor •3. Using a flat head screwdriver, twisting the screwdriver in a clockwise and counterclockwise direction, gently remove the clip from the back of the sensor. Figure 241 Pull sensor off its base •4.
Page 201: Downloading Parameters To The Unidrive Using Unisoft
HP Indigo press ws4000 Cluster 1 procedures Figure 243 Clip fits into the sensor •6. The clip is shaped to fit into the sensor groove and only fits in one direction. Reinstall the clip into the sensor. •7. Reinstall the sensor on the sensor strip. The plate on the bottom of the sensor functions as a nut for the two screws.
Page 202 HP Indigo press ws4000 Cluster 1 procedures •2. Press the up/down arrow buttons to change the parameter number of the parameter name. The parameter value shown is the value for the parameter name that you found. To change the parameter value of a parameter name that you found, do the following: •1.
Page 203: Downloading System Files To The Unidrive
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 WinFlasher 3 from the CD-ROM drive, file \TOOLS\Winflash\winflash.exe.
Page 204 HP Indigo press ws4000 Cluster 1 procedures •6. Change the radio 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.
Page 205: Test Procedures
HP Indigo press ws4000 Cluster 1 procedures •12. Press the Red button. •13. When the Download Complete message window appears, click Finish. •14. Quit WinFlasher 3 and continue with the parameter downloading procedure. Test procedures BID knobs bracket for ws4000 •15.
Page 206: Printing Catp Job
HP Indigo press ws4000 Cluster 1 procedures •2. Observe that the substrate does not touch the Rewinder plate as it passes over the Rewinder. Printing CATP job •1. Print the CATP job and verify that the press print quality is the same as before.
Page 207: Scorotron Black Rod Replacement
HP Indigo press ws4000 Cluster 1 procedures Scorotron black rod replacement Discard pivot shaft. ILD cooling system Discard the Light guard assembly, P/N MPT-4099-51. Anti-drip kit assembly Discard the following parts: Old IR sensor bracket Old tray Old rear bracket...
Page 208 HP Indigo press ws4000 Cluster 1 procedures Component Description Part Numbers CA240-11250 DRIPPING CROSSBAR DR CA244-00310 IR SENSOR TECH ASSY CA244-01190 UNDER C/S BATH TECH CA245-03210 DRIPPING ITM WIRE GU EZC-0142-25 TIE CABLE CLEAR MBA-0408-50 SCREW ALLEN M4x8 S.S SCREW ALLEN M4x16 S.
Page 209 HP Indigo press ws4000 Cluster 1 procedures CA240-05480 REAR WALL - FEED UNI CA240-11290 DRIPPING SUPPORT CA245-00940 2ND TRANSFER STATION CA245-02950 UNTI STATIC BRUSH AD CA245-03540 REAR 2ND XFER - WEB CA245-03550 FRONT 2ND XFER - WEB EZC-0001-10 CLAMP CABLE 1/4...
Page 210 HP Indigo press ws4000 Cluster 1 procedures MWP-0501-50 WASHER FLAT M5 D9 S1 MZH-0341-01 PIPE AIR 4MM CLEAR MZH-0343-01 PIPE AIR 6mm CLEAR MZH-0344-01 PIPE AIR 6mm BLACK Description CA292-00390 KIT FCO DELTA EXIT-3 FOR Component Description Part Numbers CA240-06290...
Page 211 HP Indigo press ws4000 Cluster 1 procedures EHE-1156-51 CABLE ASSY W156 MBA-0410-50 SCREW ALLEN M4x10 ST MBS-0820-10 SCREW SHOULDER M8/D1 MBS-0830-10 SCREW SHOULDER M8/D1 MWL-0401-50 WASHER SPRING M4 D7 MWS-0400-01 WASHER M4 LOCK TOOTH Q5379-00190 DOC. - BOM REPORT FO...
Page 212 HP Indigo press ws4000 Cluster 1 procedures Description CA292-00400 KIT FCO BETA FOR BLACK R Component Description Part Numbers MPT-0325-02 AXLE,BRIDGE LEFT Q5379-00190 DOC. - BOM REPORT FO Description CA292-00350 KIT FCO FOR BID KNOBS FO Component Description Part Numbers...
Page 213 HP Indigo press ws4000 Cluster 1 procedures EZP-6700-09 PIN SOCKET 22-28 AWG EZS-0500-00 TUBING SHRINK 1/2 BL Description EHE-4251-51 CABLE ASSY CC251 VACUUM Component Description Part Numbers EHC-1022-05 CABLE 10 COND 22AWG ENO-5210-02 CONN 10 PIN MINI FIT ENT-0105-05 CABLE-END TERMINAL I...
Page 214 HP Indigo press ws4000 Cluster 1 procedures EHS-0004-01 CABLE PROFIBUS FC ST EZM-0292-70 MARKER ADHESIVE 20X3 Description MLB-1039-01 TENSION IN WEB ACCORDING TO DANCER PRESSURE LABEL Description CA261-07420 CABLE ASSY CC70 CUSTOMER Component Description Part Numbers 8123-0008 CABLE-SHLD 26AWG 8-C...
Page 215: Replacing The Second Transfer Knob
HP Indigo press ws4000 Cluster 1 procedures Replacing the second transfer knob Note: This procedure is performed if the Input assembly does not contain the new second transfer adjustment knob and knob housing brackets. Normally they will be included with the new Input assembly.
Page 216: Figure 247 Lifting Off The Knob Cover
HP Indigo press ws4000 Cluster 1 procedures 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: Figure 249 Removing C Clip
HP Indigo press ws4000 Cluster 1 procedures Figure 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.
Page 218: Figure 251 Closeup Of Outside Of Wall
HP Indigo press ws4000 Cluster 1 procedures Figure 251 Closeup of outside 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.
Page 219: Figure 253 Second Transfer Cable Clip
HP Indigo press ws4000 Cluster 1 procedures 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. proprietary and confidential...
Page 220: Attached Documents
HP Indigo press ws4000 Cluster 1 procedures Attached documents Appendix proprietary and confidential CA293-00600, Rev 00 page 220 of 221...
Page 221 FCO feedback Complete this form immediately after implementation of the FCO. Send the fax to: Att: Customer Support **Yossi Bahar***** Hewlett-Packard Company, Indigo Division Fax: +972-8-938-5517 Date (d Mon yr): FCO number: Press serial number: Customer name: Country/state: Technician name: Tel: Fax: If any parts listed in the BOM are missing or faulty, enter the following information from the orange QC...

HP Indigo Press WS4000 Service Manual

1 Purpose

2 Implementation

3 Prerequisites

4 Procedure

Quick Links

Troubleshooting

Related Manuals for HP Indigo Press WS4000

Summary of Contents for HP Indigo Press WS4000