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The zip ties are only needed, when someone breaks of the original mechanism

This sounds like the (optical) sensor is interrupted. I've seen it before. The head moves to the right, until it "bumps" into the home position. Then it starts moving to the left, waiting for the sensor to be interrupted by the pinch roller holders. If it's already interrupted at the home...

Do a "fill damper" on this head. If the problem comes back, the damper probably needs replacement. (There are different generations of dampers)

There are 2 head related fuses on the mainboard. There are more on other boards and power supplies.

Does the head move the blade down, at the end of the init. process with media inserted? If not, it's the solenoid, flat cable or the mainboard.

The heads aren't the problem. It's the tubing. The solvent permeates through the tubing. The Eco2 ink is the best for a long head life. (Max1 ink tends to give misfiring nozzles in black after 2 years or so...)

On a VG with actual Firmware, you can do a "Fill Damper" press and hold Pause and Enter, while switching on. Sucking with syringes and soaking can have negative effects. Let it be. The dampers are actively filled by pumps. It's not like the old Rolands with Epson heads.

Check the internal date of the printer.

For DX4 heads, i'd replace the captops every 12 months.(DX7 sooner) Not dirt is the problem, it's deformation of the rubber lip.

I have seen it happen with 3rd party ink at a customer. There it was Cyan.

I would also suggest orange, if you don't have a application/customer for white.(and know the limitations of eco solvent whites) Orange gives a larger gamut in the reds.

Check the heads and the area around for fiber attached. They can accumulate ink mist and when the drop gets too heavy, it falls down. Next possibility could be condensation on the head. If the print zone temp is high and ambient cold, it happens. Reduce print zone temp to 37 Celsius.

Env. match is always automatic. It syncronices the readings from the scan motor encoder with the linear encoder.

Have you done the linear encoder setup?(best done, after the printer temperature has reached working temp for a while) There is also a "Environment Match", for thermal deformation of the encoder strip in user mode.

A is enough.

That's what the Enhancement Kit is intended for, in existing printers. Yours was factory fitted with the enhanced parts.

replace the blade holder

Original Roland blades, or Chinese trash? I've seen some sort of plating coming off, of Chinese blades, destroying the back bearing of the blade holder. Then you get the cut line, you describe. You can try to lubricate this bearing. Otherwise the holder needs replacement. When you hear a noise...

Normally, you should get a RML file for Versaworks, because a ICC without ink limits and linearization is pretty useless.

Try object, path, simplify in illustrator.