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Troubleshooting Print Alignment and Ghosting Issues – Version CVersion DVersion EVersion A

Applicable Model: K-605 DTF PrinterK-602, K-603, K-604KM-602, S-30, S-60A-602, A-604, A-502

(More models may be added in future updates.)

White and Color Layers Not Aligned Vertically — How to Calibrate? (Vertical Misalignment – White/Color Ink)

Goal: Fix vertical misalignment between the white and color layers so they are perfectly aligned top-to-bottom.

❌ Incorrect

White and color layers not aligned — please adjust

✅ Correct

White and color layers fully aligned — no need to adjust

Full Process (3 Main Tasks):

1.1 Check and Turn ON Vacuum Suction

1.2 Check the Paper Feeder Switch — set to Forward

1.3 Perform Two Calibrations:

1.3.1 Step Calibration (adjusts feed distance for accurate scaling)
1.3.2 Vertical Alignment Calibration (aligns white and color layers vertically)

Full Process (4 Main Tasks):

1.1 Check and Turn ON Vacuum Suction

1.2 Check the Paper Feeder Switch — set to Forward

1.3 Check the Feed motor damping system — Left and right sides are in relaxed state.

1.4 Perform Two Calibrations:

1.4.1 Step Calibration (adjusts feed distance for accurate scaling)
1.4.2 Vertical Alignment Calibration (aligns white and color layers vertically)

Full Process (2 Main Tasks):

1.1 Check and Turn ON Vacuum Suction

1.2 Perform Two Calibrations:

1.2.1 Step Calibration (adjusts feed distance for accurate scaling)
1.2.2 Vertical Alignment Calibration (aligns white and color layers vertically)

Detailed Steps

Solution and Step-by-Step Instructions

1.1 Make sure the vacuum suction is turned on.

Location of Suction Switch K602 K 603 K 604

1.1-1-Location-of-Suction-Switch

Location of Suction Switch KM602 S30 S60

1.1-1-Location-of-Suction-Switch

❌ Incorrect

1.1-2 Suction closed

✅ Correct

1.1-3 Suction on

1.2 Paper feeder switch — set to ‘Forward’

Paper feeder switch

❌Incorrect

Reverse

❌Incorrect

Off

✅Correct

Forward

Location of Paper Feeder Switch K602 K603 K604

1.2-1 Paper feeder switch

❌ Incorrect

Labeling of Paper Feeder Switch Reverse K602 K603 K604

1.2-2-Reverse

Labeling of Paper Feeder Switch Off K602 K603 K604

1.2-3-Of

✅Correct

Labeling of Paper Feeder Switch Forward K602 K603 K604

1.2-4-Forward

1.31.2 Check the calibration settings (this involves two steps: step calibration first, followed by vertical alignment calibration).

1.3.11.2.1 Step Calibration: Adjusts the feed distance to ensure accurate image scaling.

Step-by-Step Instructions:

Step 1 Access the Calibration Menu
Open the printer control software and click the “Calibrate” section.

Enter the calibration page

Step 2 Access and Print the Calibration Chart
A dialog box will appear. Select “Base Step”, then click “Print” to start printing the step calibration chart. (Ensure the media is loaded and the printer is ready)

Print the Step Calibration Chart KM602 S30 S60

1.2.1-2-Print-the-Step-Calibration-Chart

Step 3 Find the set of lines where the left and right columns overlap most clearly, and Record the number.

Look at the printed chart. In the first row, find the group of lines from the left and right columns that overlap perfectly, and record the number shown below.

Find the Lines that Overlaps Perfectly KM602 S30 S60

1.2.1-3-Find-the-Lines-that-Overlaps-Perfectly

Step 4 Adjust the Calibration value

Enter the number in “Revise” and click “=>”

Rough Adjustment (Initial Calibration)

Use the value that gives the best overlap — for example, if -32 looks best, enter -32 as the Calibration number.

Fine Adjustment (Precise Calibration)

If the result is still not ideal, make fine adjustments using decimal number, such as -2.1, -2.2… up to -2.91.1, 1.2… up to 1.9, until the best result is achieved.

Adjust the Calibration Value KM602 S30 S60

1.2.1-4-Adjust-the-Calibration-Value

Step 5 Save the Calibration value

Click “Save” to apply it.

Save the Calibration Value KM602 S30 S60

1.2.1-5-Save-the-Calibration-Value

Step 6 Check if Calibration is Complete

If the value of the overlapping line group is “0”, calibration is complete. If not, repeat the above steps until it is.

⚠️ If the value is still not “0” after several attempts, stop and check:

Is vacuum suction turned on?
Is the paper feeder set to Forward?
Is the DTF film slipping or not properly loaded?

Is vacuum suction turned on?
Is the DTF film slipping or not properly loaded?

Fix these issues before repeating calibration.

Step Calibration Completed KM602 S30 S60

1.2.1-6-Step-Calibration-Completed

1.3.21.2.2 Vertical Alignment Calibration

Ensures white and color layers align correctly in the vertical direction.

Step-by-Step Instructions:

Step 1: Access the Vertical Calibration Menu
Open the printer control software and click the “Calibrate” tab.

1.2.2-1

Step 2 Access and Print the Vertical Calibration Chart
A dialog box pops up. Click “Vertical/Overlap”→Click “VertCal Calibration”→Click “Print” to print the vertical calibration chart (Ensure the media is loaded and the printer is ready)

Print the Vertical Calibration Chart KM602 S30 S60

1.2.2-2-Print-the-Vertical-Calibration-Chart

Step 3 Find the group of lines

That Overlaps Perfectly between the left and right columns, and record the number below.

First, look at the printed chart. Each row of calibration lines has its name indicated on the left side of the line. For example, the calibration line in the first row is labeled “G1 (K)”“G1，1（C, M, Y, K, G, R, B, O）”, the second row is labeled “G1 (C)”“G2, 1（W1, W2, W3, W4, W5, W6, W7, W8）”, and so on.
Then, for each row, find the group of lines from the left and right columns that are perfectly overlapping, and check the number displayed directly below that group.
If the value is not “0”, you need to adjust that row accordingly.
For example, in the second row, the value below the group of lines that overlap perfectly on the left and right columns is “-3″“-5“, indicating that this row needs adjustment.
If all other rows have an overlapping group with a value of “0”, then those rows do not need adjustment.
Finally, record the name and value of the row that requires adjustment:“G1 (C)”“G2, 1 (W1, W2, W3, W4, W5, W6, W7, W8)” and “-3”“-5”.

1.2.2-3-Find-the-Lines-that-Overlaps-Perfectly

Step 4 Calculate and Set the Final Calibration Value

Use the following formula:
Final Value = Original Value + Overlap Value
Example: If the original value is 35 and the overlap value is -3-5, then final value:
3-3 + (-3) =05 + (-5) =0
Enter 0 into the G1(C)G2, 1（W1, W2, W3, W4, W5, W6, W7, W8) parameter field in the system. (No need to modify the number in other parameter fields)

1.2.2-4-Set-the-Calibration-Value

Step 5 Save the Calibration Settings
Click “Save” to apply the new calibration value.

Save the Calibration Settings KM602 S30 S60

1.2.2-5-Save the Calibration Settings

Step 6 Check if Calibration is Complete
If the value of the overlapping line group is “0”, calibration is complete. If not, repeat the above steps until it is.

⚠️If the value is still not “0” after several attempts, stop and check:

Is the suction working properly?
Is the DTF film flat and parallel to the feed path?
Is the paper feeder switch in Forward?
Is the DTF film slipping or skewed?

Is vacuum suction turned on?
Is the DTF film flat and parallel to the feed path?
Is the DTF film slipping or not properly loaded?

Correct these issues before redoing calibration.

Vertical Calibration Completed KM602 S30 S60

1.2.2-6-Vertical-Calibration-Completed

1.3 Feed motor damping system — Left and right sides are in relaxed state.

Feed motor damping system K602 K603 K604

1.3-1 Feed motor damping system

❌ Incorrect

Feed motor damping relaxed K602 K603 K604

1.3-2-Feed-motor-damping-relaxed

✅ Correct

Feed motor damping tightened K602 K603 K604

1.3-3-Feed-motor-damping-tightened

✅ Relaxed State: The screw is almost fully tightened inward, with little to no thread visible.
❌ Tightened State: Multiple threads are visibly exposed, indicating the screw is not fully tightened.

1.4 Check the calibration settings (this involves two steps: step calibration first, followed by vertical alignment calibration).

1.4.1 Step Calibration: Adjusts the feed distance to ensure accurate image scaling.

Step-by-Step Instructions:

Step 1 Access the Calibration Menu
Open the printer control software and click the “Calibrate” tab.

1.4.1-1-Access-the-Step-Calibration-Menu

Step 2 Access and Print the Calibration Chart
A dialog box pops up. Click “Base Step”, then click “Print” to start printing the step calibration chart.（Ensure the media is loaded and the printer is ready.）

1.4.1-2-Print-the-Step-Calibration-Chart

Step 3 Find the group of lines that overlaps perfectly between the left and right columns, and record the number.
Look at the printed chart. In the first row, find the group of lines from the left and right columns that overlap perfectly, and record the number.

1.4.1-3-Find-the-Lines-that-Overlaps-Perfectly

Step 4 Adjust the Calibration value
Enter the number in “Revise” and click “=>”

Rough Adjustment (Initial Calibration)

Use the value that gives the best overlap — for example, if -3 looks best, enter -3 as the Calibration number.

Fine Adjustment (Precise Calibration)

If the result is still not ideal, make fine adjustments using decimal number, such as -2.1, -2.2… up to -2.9, until the best result is achieved.

1.4.1-4-Adjust-the-Calibration-Value

Step 5 Save the Calibration value
Click “Save” to apply it.

1.4.1-5-Save-the-Calibration-Value-K602-K603-K604

Step 6 Check if Calibration is Complete
If the value of the overlapping line group is “0”, calibration is complete. If not, repeat the above steps until it is.

⚠ If the value is still not “0” after several attempts, stop and check:

Is vacuum suction turned on?
Is the paper feeder set to Forward?
Is the feed motor damping system on left and right sides are in relaxed state?
Is the DTF film slipping or not properly loaded?

Fix these issues before repeating calibration.

1.4.1-6-Step-Calibration-Completed

1.4.2 Vertical Alignment Calibration: Ensures white and color layers align correctly in the vertical direction.

Step-by-Step Instructions:

Step 1 Access the Vertical Calibration Menu
Open the printer control software and click the “Calibrate” tab.

1.4.2-1-Access-the-Vertical-Calibration-Menu

Step 2 Access and Print the Vertical Calibration Chart
A dialog box pops up. Click “Vertical/Overlap”→Click “VertCal Calibration”→Click “Print ” to print the vertical calibration chart （Ensure the media is loaded and the printer is ready.）

Print the Vertical Calibration Chart K602 K603 K604

1.4.2-2-Print-the-Vertical-Calibration-Chart

Step 3 Find the group of lines That Overlaps Perfectly between the left and right columns, and record the number below.

First, look at the printed chart. Each row of calibration lines has its name indicated on the left side of the line. For example, the calibration line in the first row is labeled “G1, 1 (C, M, Y, K, G, R, O, B)”, the second row is labeled “G2，1（W1, W2, W3, W4, W5, W6, W7, W8）”, and so on.
Then, for each row, find the group of lines from the left and right columns that are perfectly overlapping, and check the number displayed directly below that group.
If the value is not “0”, you need to adjust that row accordingly.
For example, in the second row, the value below the group of lines that overlap perfectly on the left and right columns is “-5“, indicating that this row needs adjustment.
If all other rows have an overlapping group with a value of “0”, then those rows do not need adjustment.
Finally, record the name and value of the row that requires adjustment: “G2, 1 (W1, W2, W3, W4, W5, W6, W7, W8)” and “-5”.

1.4.2-3-Record-the-Number

Step 4 Calculate and Set the Final Calibration Value
Use the following formula:
Final Value = Original Value + Overlap Value
Example: If the original value is 5 and the overlap value is -5, then the final value:
5 + (-5) =0
Enter 0 into the G2, 1(W1,W2,W3,W4,W5,W6,W7,W8) parameter field in the system. (No need to modify the number in other parameter fields)

Set the Calibration Value K602 K603 K604

1.4.2-4-Set-the-Calibration-Value

Step 5 Save the Calibration Settings
Click “Save” to apply the new calibration value.

Save the Calibration Settings K602 K603 K604

1.4.2-5-Save the Calibration Settings

Step 6 Check if Calibration is Complete
If the value of the overlapping line group is “0”, calibration is complete. If not, repeat the above steps until it is.
⚠ If the value is still not “0” after several attempts, stop and check:

Is the suction working properly?
Is the DTF film flat and parallel to the feed path?
Is the paper feeder switch in Forward?
Is the DTF film slipping or skewed?

Correct these issues before redoing calibration.

Vertical Calibration Completed K602 K603 K604

1.4.2-6-Vertical-Calibration-Completed

Vertical Misalignment Between White and Color Inks

The white and color layers are not properly aligned in the vertical direction.

Incorrect❌

White and color layers not aligned — please adjust

Correct✅

White and color layers fully aligned — no need to adjust

Solution and Step-by-Step Instructions:

Step 1: Make sure the vacuum suction is turned on.

Step 2: Paper feeder switch — set to ‘Forward’

Step 3: Check the tension knobs on both sides of the paper feeding motors. Make sure both are in a relaxed state.

Relaxed State: The knob is almost fully screwed in, with little or no thread exposed.
Tightened State: The knob is less screwed in, with several thread loops clearly visible.

Step 4: Check the calibration settings

(This involves two steps: step calibration first, followed by vertical alignment calibration).

4.1 Step Calibration: Adjusts the feed distance to ensure accurate image scaling.

Step-by-Step Instructions:

4.1.1 Access the Calibration Menu
Open the printer control software and Click the “Adjust” section.

4.1.2 Access and Print the Calibration Chart
Click “Step Adjust”, then click “Print Adjust” to start printing the step calibration chart.

4.1.3 Find the Line That Overlaps Perfectly and Record the number.
Look at the printed chart and find the line where the two sets overlap most clearly. Write down the number shown next to that line.

4.1.4 Adjust the Calibration value
Enter the number and click “Calculate”

Step ①: Rough Adjustment (Initial Calibration)
Use the value that gives the best overlap — for example, if -3 looks best, enter -3 as the calibration number.

Step ②: Fine Adjustment (Precise Calibration)
If the result is still not ideal, make fine adjustments using decimal number, such as -2.1, -2.2… up to -2.9, until the best result is achieved.

4.1.5 Enter and Save the Calibration value
Input the final calibration number and click “Save” to apply it.

4.1.6 Check if Calibration is Complete
If the number where both left and right lines overlap is “0”, calibration is complete. If not, repeat the above steps until it is.

4.2 Vertical Alignment Calibration: Ensures white and color layers align correctly in the vertical direction.
Step-by-Step Instructions:

Step-by-Step Instructions:

4.2.1 Access the Vertical Calibration Menu
Open the printer control software and Click “Adjust”section.

4.2.2 Access the Vertical Calibration Page
Click “Head Space”→Click “Vertical”→Click “Print Adjust” to print the vertical calibration chart (Ensure the media is loaded and the printer is ready)

4.2.3 Find the Value Where Black and White Overlap
Look at the printed chart and identify the number where the black line and white background overlap most perfectly. Record that number.

4.2.4 Calculate and Set the Final Calibration Value
Use the following formula:
Final Value = Original Value + Overlap Value
Example: If the original value is 731.8 and the overlap value is -4, then:
731.8 + (-4) = 727.8
Enter 727.8 into the H2 parameter field in the system. (No need to modify the number in H1)

Rough Adjustment: Start with the integer value where overlap is most obvious.
Fine Adjustment: If needed, fine-tune using decimal values (e.g. -0.2, +0.3, etc.) until the overlap is perfect.

4.2.5 Save the Calibration Settings
Click “Save” to apply the new calibration value.

If the overlap value is 0, the calibration is complete. If not, repeat the steps until it is.