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Roll systems – Maintenance Manual

AP-74100, Rev. 2.0, 12/01/05

5.3. EXPLODED VIEWS

This section includes the exploded views.

Notes :

For the latest ‘exploded views’ and ‘part description’, please refer to the spare part

lists of the unit.

For spare parts, please refer to the latest spare part list.

Specifications are liable to changes without prior notice.

Each chapter is divided in two. This because there has to be made a difference between winding systems
manufactured before 2005 and systems manufactured as from 2005.

As from manufacturing date 2005

Before manufacturing date 2005

Summary of Contents for Unwinder

Page 1: ...Mutoh s Roll Systems Unwinder Winder 100 Winder 30 Maintenance Manual MUTOH EUROPE N V AP 74100 Rev 2 0 13 01 2005 ...

Page 2: ...Roll systems Maintenance Manual 2 AP 74100 Rev 2 0 12 01 05 ...

Page 3: ... information contained in this document the party to whom it is given assumes its custody and control and agrees to the following The information herein contained is given in confidence and any part thereof shall not be copied or reproduced without written consent of Mutoh Europe N V This document or the contents herein under no circumstances shall be used in the manufacture or reproduction of the...

Page 4: ...Roll systems Maintenance Manual 4 AP 74100 Rev 2 0 12 01 05 ...

Page 5: ...ur radio and TV reception antenna or feeder Change the direction of the product Move either the product or the receiving antenna so there is more distance between them Be sure the product and the receiving antenna are on separate power lines 2 Trademark mentioned in this manual MUTOH is a registered trademark or product name of MUTOH INDUSTRIES LTD Centronics and Bitronics are registered trademark...

Page 6: ...Roll systems Maintenance Manual 6 AP 74100 Rev 2 0 12 01 05 ...

Page 7: ...sors 31 3 6 REMOVALS ONTO THE ROLL UNIT 32 3 6 1 Replacing the core cone of the roll unit 32 3 6 2 Replacing the core cone of the motorized roll unit 33 3 6 3 Replacing the motor in the motorized roll unit 34 3 6 4 Connecting the motor 35 3 7 REPLACEMENT OF THE SCROLLER ASSEMBLY 36 3 7 1 Replacing the scroller R assembly 36 3 7 2 Replacing the scroller L assembly 37 4 ADJUSTMENTS 39 4 1 SENSOR TEN...

Page 8: ...ance Manual 8 AP 74100 Rev 2 0 12 01 05 5 APPENDIX 59 5 1 INTRODUCTION 59 5 2 WIRING DIAGRAM 59 5 3 EXPLODED VIEWS 60 5 3 1 Assembling unwinder winder 100 61 5 3 2 Assembling unwinder 100 winder 30 78 5 3 3 Unwinder 30 99 ...

Page 9: ...bodily injury moderately or lightly or damage to your equipment Note Contains important information and useful tips on the operation of your printer 1 3 IMPORTANT SAFETY INSTRUCTIONS General safety instructions that must be observed to use the equipment safely are explained below Do not stand on or place heavy objects on the unit Doing so may result in the unit tipping or falling over and causing ...

Page 10: ...ls Notes Make sure that all labels can be recognized If text or illustrations cannot be seen clearly either clean or replace the label When cleaning labels use a cloth with water or neutral detergent Do not use a solvent or gasoline If a warning label is damaged lost or cannot be recognized replace the label When replacing warning labels contact your local MUTOH dealer Foot switch label unwinder 1...

Page 11: ...nsion system Adjust the tension of the media between the roll off system and the media feed slot 3 PCB Box Contains the boards to control the unwinder winder 100 4 Rail Assembly Carries the roll units 5 Motorized roll unit Supports the roll media 6 Roll unit Supports the roll media 7 Roll off foot switch This switch is used to roll up or roll off roll media of the unwinder 100 8 Front Tension Syst...

Page 12: ... and Automatic mode Manual 3 Unwinder 100 LED Automatic LED lights up when pushing one of the buttons Motor turns LED flashes Motor is off LED is out Outside printing Inside printing 4 Backwards button Roll off unwinder Roll up unwinder 5 Forwards button Roll up unwinder Roll off unwinder 6 Winder 100 power ON Power ON or OFF the winder 100 Manual 7 Winder 100 LED Automatic LED lights up when push...

Page 13: ...r 30 motorized unit Winds and collects the printed roll media 2 Media sensor Detects the printed media 3 Scroller receiver Loads the scroller for the winding unit 4 Power switch Turn the product ON and OFF 5 Operation Panel This panel is used to set operational conditions and the status of the product ...

Page 14: ...lly rotates forward The media is wound with the printed side at the outside OFF Used when operating the MANUAL switch Backward When the media sensor detects the media the scroller automatically rotates backward The media is wound with the printed side at the inside 2 MANUAL switch The winder system is manually operated Forward The scroller rotates forward Backward The scroller rotates backward 2 S...

Page 15: ...rinting position 2 Rear Tension system Adjust the tension of the media between the roll off system and the media feed slot 3 PCB Box Contains the boards to control the unwinder 100 4 Rail Assembly Carries the roll units 5 Motorized roll unit Supports the roll media 6 Roll unit Supports the roll media 7 Roll off foot switch This switch is used to roll up or roll off roll media of the unwinder 100 ...

Page 16: ...e on the outside select OUT otherwise select IN 2 Unwinder 100 power ON Toggle between Manual and Automatic mode Manual 3 Unwinder 100 LED Automatic LED lights up when pushing one of the buttons Motor turns LED flashes Motor is off LED is out Outside printing Inside printing 4 Backwards button Roll off unwinder Roll up unwinder 5 Forwards button Roll up unwinder Roll off unwinder 6 Power LED Light...

Page 17: ...ter Caution Assembling and disassembling the unit are possible only for the parts for which disassembling procedures are shown in the operation manual Do not disassemble any frame parts or parts for which disassembling procedures are not shown in the manual Doing so may cause trouble that cannot be restored as the unit is originally assembled in the factory with a high accuracy of 1 100 mm Caution...

Page 18: ... 2 REMOVAL ON THE OPERATION PANEL 3 2 1 Replace the operation panel cover Step 1 Remove the eight screws fixing the operation panel Caution Be sure not to damage the cables nor the connectors Step 2 Carefully loosen the connectors Step 3 Remove the operation panel ...

Page 19: ... panel PCB box Step 1 Remove the operation panel Step 2 Loosen the sensor cables Step 3 Remove the parallel connector cable Step 4 Loosen the two screws fixing the parallel connector Step 5 Loosen the four screws fixing the operation panel PCB box Step 6 Remove the operation panel PCB box ...

Page 20: ...intenance Manual 20 AP 74100 Rev 2 0 12 01 05 3 2 3 Connecting the PCB board operation panel with the operation panel Connections at the operation panel are Caution Be sure not to damage the cables nor the connectors ...

Page 21: ... s electrical plug from the socket Otherwise you may suffer electric shock or the machine s electric circuits may be damaged Disconnect all cables from the machine Not doing so could cause damage to the printer 3 3 1 How to replace the power supply board Step 1 Remove all connectors from the PCB box Step 2 Remove the PCB box from the beam Step 3 Loosen the 16 screws fixing the cover of the PCB box...

Page 22: ...ce Manual 22 AP 74100 Rev 2 0 12 01 05 Step 5 Remove the connectors Caution Be sure not to damage the cables nor the connectors Step 6 Remove the four screws fixing the power supply board Step 7 Remove the power supply board ...

Page 23: ...3 3 2 How to replace the PCB board of the PCB box Step 1 Remove all connectors from the PCB box Step 2 Remove the PCB box from the beam Step 3 Loosen the 16 screws fixing the cover of the PCB box Step 4 Remove the cover of the PCB box Step 5 Remove the connectors ...

Page 24: ...cables nor the connectors Step 6 Remove the two screws fixing the parallel connector Step 7 Remove the six screws fixing the PCB board Step 8 Remove the PCB board 3 3 3 How to replace the power supply connector Step 1 Remove all connectors from the PCB box Step 2 Remove the PCB box from the beam ...

Page 25: ... 25 AP 74100 Rev 2 0 12 01 05 Step 3 Loosen the 16 screws fixing the cover of the PCB box Step 4 Remove the cover of the PCB box Step 5 Remove the two screws fixing the power supply connector Step 6 Remove the power supply connector ...

Page 26: ...anual 26 AP 74100 Rev 2 0 12 01 05 3 3 4 Connections in the PCB box Please connect as shown in the picture below 1 white 2 black 3 green yellow grounding Notes Please make sure to fix the cables together by using the cable clamp ...

Page 27: ...follow the steps mentioned below Step 1 Remove the five screws of the top cover of the take up system and disconnect the power supply cable No Part 1 Top cover screws 2 Power supply cable Step 2 Remove the two screws of the switch board and disconnect the black flat cable connected to the PCB board No Part 1 Switch board attaching screws ...

Page 28: ...28 AP 74100 Rev 2 0 12 01 05 Step 3 Remove the screw and 3 spacers of the PCB board No Part 1 Spacers 2 Screw Step 4 Replace the PCB board by a new one EY 80579 Step 5 To re install the removed components reverse the removal procedure ...

Page 29: ...e sensor assy Step 1 Disconnect the power cable of the operation panel Step 2 Loosen the three screws fixing the cover of the tensioning sensor bracket Step 3 Remove the cover Step 4 Loosen the connectors Caution Be sure not to damage the cables nor the connectors Step 5 Loosen the two screws fixing the sensor bracket ...

Page 30: ...s Maintenance Manual 30 AP 74100 Rev 2 0 12 01 05 Step 6 Remove the sensor bracket Before manufacturing date 2005 As from manufacturing date 2005 Notes Repeat the steps above to remove the rear side sensor bracket ...

Page 31: ...oll unit stops turning NO OFF No speed change 2 MK 51605 Front Start Sensor YES ON Front motorized roll unit starts turning faster Speed up NO OFF Rear motorized roll unit is turning constant speed 3 MK 51609 Rear Stop Sensor YES ON The rear motorized roll unit stops turning NO OFF No speed change 4 MK 51608 Rear Start Sensor YES ON Rear motorized roll unit starts turning faster Speed up Notes Ini...

Page 32: ...the core cone of the roll unit Step 1 Remove the top cover of the roll unit Step 2 Remove the front cover of the roll unit With front cover Without front cover Step 3 Loosen the screw fixing the core cone 1 screw fixing the core cone Step 4 Remove the core cone Step 5 Slide the new core cone into the roll unit ...

Page 33: ...sen the cable clip Step 2 Remove the top cover of the motorized roll unit Step 3 Remove the front cover of the motorized roll unit With front cover Without front cover Step 4 Loosen the screw fixing the core cone 1 screw fixing the core cone Step 5 Remove the core cone Step 6 Slide the new core cone into the motorized roll unit ...

Page 34: ... front cover of the motorized roll unit Step 4 Loosen the three screws fixing the gear 1 gear Notes Installation of the gear should be done onto the flat side of the shaft of the motor Use some blue glue Loctite 243 to fix the three screws holding the gear Step 5 Loosen the four screws fixing the motor 1 screws fixing the motor Step 6 Remove the motor Notes During installation of the motor fix the...

Page 35: ... 4 Connecting the motor Step 1 Loosen the cable clip Caution Be sure not to damage the cables nor the connectors Step 2 Remove the top cover of the motorized roll unit Step 3 Remove the cable from the motor connector 1 connection on the motor Step 4 Remove the cable ...

Page 36: ...ller R assembly 1 Scroller R assembly 2 Hexagon socket head springs Step 2 Replace the scroller R assembly Step 3 Reinstall all parts in the opposite order of the removal procedure 2 Replacing the pressure roller roller 1 and roller 2 Step 1 Remove the 4 screws fixing scroller receptacle cover R 1 Scroller receptacle cover R 2 Screws M3x8 fixing scroller receptacle cover R 3 Scroller R assembly St...

Page 37: ...lace the rollers Step 5 Reinstall all parts in the opposite order of the removal procedure 3 7 2 Replacing the scroller L assembly 1 Replacing the scroller L assembly Step 1 Remove the 4 hexagon socket head springs fixing the scroller L assembly 1 Scroller L assembly 2 Hexagon socket head springs Step 2 Replace the scroller L assembly Step 3 Reinstall all parts in the opposite order of the removal...

Page 38: ...1 Scroller receptacle cover R 2 Screws M3x8 fixing scroller receptacle cover R 3 Scroller L assembly Step 2 Remove scroller receptacle cover R Step 3 Remove the E ring fixing the axes of the rollers to be replaced 1 Pressure roller 2 Roller 1 3 E ring E 3 4 E ring E 4 Step 4 Replace the rollers Step 5 Reinstall all parts in the opposite order of the removal procedure ...

Page 39: ...unwinder winder 100 has an automatic speed regulating system controlled by the start and stop sensors If the stop sensor is covered the motor will stop completely If the stop sensor is open the motor will start turning a speed slightly lower than the previous speed When both the stop and start sensor are open the turning speed will remain constant If the start sensor is covered the motor will star...

Page 40: ...tep 2 Hold or ask someone to hold the front tensioning system in the 12 position Please see to the angle markings on the front tensioning system Please refer to the section Angle mark front tensioning system Step 3 Make sure that the stop sensor is not covered Step 4 Switch the Front to AUTOMATIC Toggle the switch down The Automatic LED will start blinking The front motor will start turning at the...

Page 41: ...section Sensor disc and adjustment direction The Automatic LED will light continuously The front motor will start accelerating 1 Rear stop adjustment direction 2 Rear start adjustment direction 3 Front stop adjustment direction 4 Front start adjustment direction Step 5 Tighten the start screw on the adjustment lip Notes If necessary during adjustment return to the initial speed by toggling the Aut...

Page 42: ...e stop sensor then the start sensor 4 1 3 1 Adjust the stop sensor Step 1 Make sure that the start sensor is not covered while adjusting the stop sensor Step 2 Hold or ask someone to hold the rear tensioning system in the horizontal position Please refer to the section Stop sensor system Step 3 Make sure that the stop sensor is not covered Step 4 Switch the Rear to AUTOMATIC Toggle the switch down...

Page 43: ...tion 3 Front stop adjustment direction 4 Front start adjustment direction Step 6 Tighten the stop screw on the adjustment lip 4 1 3 2 Adjust the start sensor Step 1 Make sure that the start sensor is not covered and the Automatic switch is set to Manual Switch in the up position Step 2 Hold or ask someone to hold the rear tensioning system in an approx 30 position Please refer to the section Start...

Page 44: ...tment direction Step 5 Tighten the start screw on the adjustment lip Notes If necessary during adjustment return to the initial speed by toggling the Automatic switch to manual and back Notes The stop sensor should be covered if the rear tensioning system is horizontal or lower Rear Automatic LED is OFF should be open if the rear tensioning system is horizontal or higher Rear Automatic LED is blin...

Page 45: ...r disc and adjustment direction 1 Rear stop sensor 2 Rear start sensor 1 Front stop sensor 2 Front start sensor 3 Set screw 4 Sensor disc 1 Rear stop adjustment direction 2 Rear start adjustment direction 3 Front stop adjustment direction 4 Front start adjustment direction ...

Page 46: ...rk front tensioning system 4 1 6 Stop Sensor Position A Front Stop Sensor B Rear Stop Sensor Notes The Front Stop Sensor should be covered if the front tension bar has an angle of 12 or less The Rear Stop Sensor should be covered if the rear tension bar is horizontal or lower ...

Page 47: ...5 4 1 7 Start Sensor Position A Front Start Sensor B Rear Start Sensor Notes The Front Start Sensor should be covered if the front tension bar has an angle of 25 or more The Rear Start Sensor should be covered if the rear tension bar has an angle of 30 or more ...

Page 48: ... unwinder has an automatic speed regulating system controlled by the start and stop sensor If the stop sensor is covered the motor will stop completely If the stop sensor is open the motor will start turning a speed slightly lower than the previous speed When both the stop and start sensor are open the turning speed will remain constant If the start sensor is covered the motor will start to accele...

Page 49: ...r Step 2 Hold or ask someone to hold the rear tensioning system in the horizontal position Please refer to the section Stop sensor system Step 3 Make sure that the stop sensor is not covered Step 4 Switch the Rear to AUTOMATIC Toggle the switch down The Automatic LED will start blinking The rear motor will start turning at the initial speed very low Step 5 Rotate downwards the adjustment lip caref...

Page 50: ...r the adjustment direction please refer to the section Sensor disc and adjustment direction The Automatic LED will light continuously The rear motor will start accelerating Step 5 Tighten the start screw on the adjustment lip Notes If necessary during adjustment return to the initial speed by toggling the Automatic switch to manual and back Notes The stop sensor should be covered if the rear tensi...

Page 51: ...justment direction 1 Rear stop sensor 2 Rear start sensor 4 2 4 Stop Sensor Position A Rear Stop Sensor Notes The Front Stop Sensor should be covered if the front tension bar has an angle of 12 or less The Rear Stop Sensor should be covered if the rear tension bar is horizontal or lower ...

Page 52: ...2 0 12 01 05 4 2 5 Start Sensor Position A Rear Start Sensor Notes The Front Start Sensor should be covered if the front tension bar has an angle of 25 or more The Rear Start Sensor should be covered if the rear tension bar has an angle of 30 or more ...

Page 53: ...bration of the front tensioning system and the roll up systems Because the new media guide can have a slight different shape thickness 4 3 1 Calibration of the rear tensioning system Step 1 Standing on the rear side of the unit use some tape to create a loop around the up most left side of one bar of the tension system Step 2 Put the pressure rollers in the up position Step 3 Slide the strip forwa...

Page 54: ...e unit place the adjustment plate onto the large strip and slide it against the pressure rollers Step 6 Manually draw a line Step 7 Slide the strip to the left side of the unit Pull the strip so there is an equal tension Step 8 Manually draw a line Check if both lines are overlapping Step 9 If not you have to perform the following adjustment procedure ...

Page 55: ...ar side of the unit loosen the 4 screws on the right tension bar bracket Step 11 Use the 2 screws 1 in the tension bar bracket to adjust the tension system Important Make sure to turn both screws an equal amount of terms Step 12 Repeat step 6 to step 12 until the lines overlaps each other ...

Page 56: ...an have a slight different shape thickness Step 1 Install a core between the roll unit and the motorized roll unit Step 2 Standing at the front of the unit use some tape to create a loop with the synthetic paper Step 3 Put the loop around the core installed on to the winder Step 4 Put the pressure rollers in the up position Step 5 Slide the strip forwards Step 6 Standing at the front side of the u...

Page 57: ...e strip to the left side of the unit Pull the strip so there is an equal tension Step 9 Manually draw a line Check if both lines are overlapping Step 10 If not you have to perform the following adjustment procedure Step 11 Use the amount of adjustment brackets so it will cover the space between the lines ...

Page 58: ... deviation of the winder system below the rail assembly Step 13 If both lines overlap calibrations is OK Step 14 Now fix the screws with roll so the rail assy doesn t move anymore Step 15 Perform the same adjustment procedure for the unwinder at the rear unit Step 16 If this is completed your calibration of the unwinder winder 100 is finished ...

Page 59: ...59 AP 74100 Rev 2 0 12 01 05 5 APPENDIX 5 1 INTRODUCTION This chapter provides referential information such as service data and exploded views 5 2 WIRING DIAGRAM ...

Page 60: ...refer to the spare part lists of the unit For spare parts please refer to the latest spare part list Specifications are liable to changes without prior notice Each chapter is divided in two This because there has to be made a difference between winding systems manufactured before 2005 and systems manufactured as from 2005 As from manufacturing date 2005 Before manufacturing date 2005 ...

Page 61: ...Roll Systems Maintenance Manual 61 AP 74100 Rev 2 0 11 01 05 5 3 1 Assembling unwinder winder 100 5 3 1 1 As from manufacturing year 2005 If necessary remove all parts of the current winder system ...

Page 62: ...s with 8 bolts M6x12 Make sure the Waste ink Tank Bracket is on the right hand side of the machine ITEM PART DESCRIPTION QUANTITY 1 DIN 912 Standard M6x12 ELVZ 8 2 Leg Clamp Part 1 Rollfeed Rockhopper II 2 3 Leg Clamp Part 2 Rollfeed Rockhopper II 1 4 Waste Ink Tank Bracket Assy Rollfeed Rockhopper II 1 ...

Page 63: ...AP 74100 Rev 2 0 11 01 05 Step 2 Assemble the PCB box using 4 bolts M6x55 and 4 teeth washers M6 ITEM PART DESCRIPTION QUANTITY 1 DIN912 standard M6x55 ELVZ 4 2 Lock Washer Internal Teeth M6 ELVZ 4 3 PCB Box Assy Rollfeed Rockhopper II 1 ...

Page 64: ...e rail Place the rail assembly on the leg clamps Use the hole slot hole combinations to position the rail Make sure the short side of the rail is on the right hand side of the printer ITEM PART DESCRIPTION QUANTITY 1 Adjusting Foot Bracket Rollfeed Universal 4 1 1 Only for 87 printers 2 Hex Flange Button Head M5x8 ELVZ 16 1 2 87 printers 6 pcs 50 64 2 pc 3 Levelling element M12 6 2 4 Steel bar Ass...

Page 65: ...e is on the right hand side of the machine Connect the motor cable to the PCB box Front motor connector next to the power inlet Rear motor second connector next to the power inlet ITEM PART DESCRIPTION QUANTITY 1 Clamp Lever M10x40 4 2 Sledge Left Assy Rollfeed Universal 2 3 Sledge Bracket Part 2 Rollfeed Universal 4 4 Sledge Right Assy Rollfeed Universal 2 ...

Page 66: ...en the bolts on the left bracket yet Only the 87 printer use the most outer holes on the left side of the printer for assembling the left mounting bracket ITEM PART DESCRIPTION QUANTITY ITEM PART DESCRIPTION QUANTITY 1 DIN 912 Standard M6x16 ELVZ 8 5 Plain Washer DINI25 I A M6 8 2 Lock Washer Internal Teeth M6 ELVZ 1 3 Mounting Bracket Left Assy Rollfeed Rockhopper II 1 4 Mounting Bracket Right As...

Page 67: ... Mounting bracket assembly Assemble the front and rear swingbar assembly Use the screws M4x10 to fix the assemblies ITEM PART DESCRIPTION QUANTITY 1 Pan Head Screw 4 2 Shaft swingbar D lock Rollfeed Rockhopper II 2 3 Swingbar Assy Rollfeed Rockhopper II 1 4 Swingbar Front Assy Rollfeed Rockhopper II 1 ...

Page 68: ...After alignment and putting the spacer in place if necessary of the front and rear rolldrive assemblies use the bolts M5x8 and white spacers to fix the rolldrive assemblies ITEM PART DESCRIPTION QUANTITY 1 Hex Flange Buttonhead M5x8 ELVZ 8 2 Spacer PA D18 x d8 2 x H10 8 ...

Page 69: ...Roll Systems Maintenance Manual 69 AP 74100 Rev 2 0 11 01 05 5 3 1 2 Before manufacturing year 2005 If necessary remove all parts of the current winder system ...

Page 70: ...s with 8 bolts M6x12 Make sure the Waste ink Tank Bracket is on the right hand side of the machine ITEM PART DESCRIPTION QUANTITY 1 DIN 912 Standard M6x12 ELVZ 8 2 Leg Clamp Part 1 Rollfeed Rockhopper II 2 3 Leg Clamp Part 2 Rollfeed Rockhopper II 1 4 Waste Ink Tank Bracket Assy Rollfeed Rockhopper II 1 ...

Page 71: ...AP 74100 Rev 2 0 11 01 05 Step 2 Assemble the PCB box using 4 bolts M6x55 and 4 teeth washers M6 ITEM PART DESCRIPTION QUANTITY 1 DIN912 standard M6x55 ELVZ 4 2 Lock Washer Internal Teeth M6 ELVZ 4 3 PCB Box Assy Rollfeed Rockhopper II 1 ...

Page 72: ...e rail Place the rail assembly on the leg clamps Use the hole slot hole combinations to position the rail Make sure the short side of the rail is on the right hand side of the printer ITEM PART DESCRIPTION QUANTITY 1 Adjusting Foot Bracket Rollfeed Universal 4 1 1 Only for 87 printers 2 Hex Flange Button Head M5x8 ELVZ 16 1 2 87 printers 6 pcs 50 64 2 pc 3 Levelling element M12 6 2 4 Steel bar Ass...

Page 73: ...e is on the right hand side of the machine Connect the motor cable to the PCB box Front motor connector next to the power inlet Rear motor second connector next to the power inlet ITEM PART DESCRIPTION QUANTITY 1 Clamp Lever M10x40 4 2 Sledge Left Assy Rollfeed Universal 2 3 Sledge Bracket Part 2 Rollfeed Universal 4 4 Sledge Right Assy Rollfeed Universal 2 ...

Page 74: ...en the bolts on the left bracket yet Only the 87 printer use the most outer holes on the left side of the printer for assembling the left mounting bracket ITEM PART DESCRIPTION QUANTITY ITEM PART DESCRIPTION QUANTITY 1 DIN 912 Standard M6x16 ELVZ 8 5 Plain Washer DINI25 I A M6 8 2 Lock Washer Internal Teeth M6 ELVZ 1 3 Mounting Bracket Left Assy Rollfeed Rockhopper II 1 4 Mounting Bracket Right As...

Page 75: ...ting panel aside BE CAREFUL NOT TO DAMAGE THE CABLES LEADING TO THE PANEL Assemble the 4 shafts On the right hand side assemble 2 detection lips on each shaft each detection should be in the gap of the sensors Do not tighten the set screws on the sensor lips ITEM PART DESCRIPTION QUANTITY 1 Sensor Lip Assy Rollfeed Rockhopper II 4 2 Shaft tensioning system Rollfeed Rockhopper II 4 ...

Page 76: ... and tensioning system shaft TIGHTEN THE SCREWS FIRMLY After assembling the front and rear tensioning system tighten the bolts on the left support bracket ITEM PART DESCRIPTION QUANTITY 1 Lock Washer External Teeth M5 ELVZ 4 2 Pan Head Screw M4x10 4 3 Rear tensioning system assy Rollfeed Rockhopper II 87 1 4 Front tensioning system assy Rollfeed Rockhopper II 87 1 ...

Page 77: ...bly with 2 spacers and 2 cap screws on each side Assemble the waste ink tank holder Assemble the cable connecting the operating panel to the PCB box Connect the foot switch third connector next to the power inlet ITEM PART DESCRIPTION QUANTITY 1 Foot switch KF2 IS IS 1 2 Hex Flange Button Head M5x8 ELVZ 4 3 Spacer PA D18xd8 2xH10 4 4 Waste bottle roll feed RH RJ 8164 1 ...

Page 78: ...inter Replace the scroller assembly delivered with the Winder 30 by the new Scroller Support Assembly For 87 only Replace the interface plate on the Motor Box Assembly by the new Interface Plate ITEM PART DESCRIPTION QUANTITY ITEM PART DESCRIPTION QUANTITY 1 Countersunk Screw M4x10 Nickel Coated 4 5 Pan Head Screw M4x10 6 2 Hex Flange Button head M4x10 ELVZ 4 6 Scroller Support Assy Rockhopper II ...

Page 79: ...2 0 11 01 05 Step 1 If necessary remove all parts of the current winder system and waste bottle Be careful not to spoil ink onto your system avoid this by folding the tubes Waste Bottle Position on a Rockhopper II Waste Bottle Position on a Falcon II ...

Page 80: ...s with 8 bolts M6x12 Make sure the Waste ink Tank Bracket is on the right hand side of the machine ITEM PART DESCRIPTION QUANTITY 1 DIN 912 Standard M6x12 ELVZ 8 2 Leg Clamp Part 1 Rollfeed Rockhopper II 2 3 Leg Clamp Part 2 Rollfeed Rockhopper II 1 4 Waste Ink Tank Bracket Assy Rollfeed Rockhopper II 1 ...

Page 81: ...Roll Systems Maintenance Manual 81 AP 74100 Rev 2 0 11 01 05 Step 3 Reinstall the waste bottle on the place described below For a Falcon II For a Rockhopper II ...

Page 82: ...tep 4 Assemble the PCB box bracket onto the PCB box using 6 bolts M5x8 Hang the PCB box assy on the Support Beam ITEM PART DESCRIPTION QUANTITY 1 Hex Flange Button head M5x8 ELVZ 6 2 PCB Box Assy Rollfeed Rockhopper II 1 3 PCB Box Bracket Rollfeed Rockhopper II 1 ...

Page 83: ...e rail Place the rail assembly on the leg clamps Use the hole slot hole combinations to position the rail Make sure the short side of the rail is on the right hand side of the printer ITEM PART DESCRIPTION QUANTITY 1 Adjusting Foot Bracket Rollfeed Universal 2 1 1 Only for 87 printers 2 Hex Flange Button Head M5x8 ELVZ 8 1 2 87 printers 3 pcs 50 64 1 pc 3 Levelling element M12 3 2 4 Steel bar Assy...

Page 84: ... support with motor and cable is on the right hand side of the machine Connect the motor cable to the PCB box second connector next to the power inlet ITEM PART DESCRIPTION QUANTITY 1 Clamp Lever M10x40 2 2 Sledge Left Assy Rollfeed Universal 1 3 Sledge Bracket Part 2 Rollfeed Universal 2 4 Sledge Right Assy Rollfeed Universal 1 ...

Page 85: ...en the bolts on the left bracket yet Only the 87 printer use the most outer holes on the left side of the printer for assembling the left mounting bracket ITEM PART DESCRIPTION QUANTITY ITEM PART DESCRIPTION QUANTITY 1 DIN 912 Standard M6x16 ELVZ 8 5 Plain Washer DINI25 I A M6 8 2 Lock Washer Internal Teeth M6 ELVZ 1 3 Mounting Bracket Left Assy Rollfeed Rockhopper II 1 4 Mounting Bracket Right As...

Page 86: ...tep 8 Put the shaft in the left hand side mounting bracket Assemble the tensioning bar assembly Fix the tensioning bar with 2 screws M4x10 ITEM PART DESCRIPTION QUANTITY 1 Pan Head Screw M4x10 2 2 Shaft tensioning bar D lock Rollfeed 1 3 Tensioning bar Rollfeed 1 ...

Page 87: ...nt spacers in place of necessary fix the rail from the roll drive assembly to the printer foot using 4 bolts M5x8 and 4 white spacers Connect the foot switch to the PCB box Third connector next to the power inlet ITEM PART DESCRIPTION QUANTITY 1 Foot switch KF2 1S 1S 1 2 Hex flange Buttonhead M5x8 ELVZ 4 3 Spacer PA D18 x d8 2 x H10 4 ...

Page 88: ...oller assembly delivered with the Winder 30 by the new Scroller Support Assembly For 87 only Replace the interface plate on the Motor Box Assembly by the new Interface Plate ITEM PART DESCRIPTION QUANTITY ITEM PART DESCRIPTION QUANTITY 1 Countersunk Screw M4x10 Nickel Coated 4 5 Pan Head Screw M4x10 6 2 Hex Flange Button head M4x10 ELVZ 4 6 Scroller Support Assy Rockhopper II 50 and 64 1 3 Interfa...

Page 89: ...2 0 11 01 05 Step 1 If necessary remove all parts of the current winder system and waste bottle Be careful not to spoil ink onto your system avoid this by folding the tubes Waste Bottle Position on a Rockhopper II Waste Bottle Position on a Falcon II ...

Page 90: ...s with 8 bolts M6x12 Make sure the Waste ink Tank Bracket is on the right hand side of the machine ITEM PART DESCRIPTION QUANTITY 1 DIN 912 Standard M6x12 ELVZ 8 2 Leg Clamp Part 1 Rollfeed Rockhopper II 2 3 Leg Clamp Part 2 Rollfeed Rockhopper II 1 4 Waste Ink Tank Bracket Assy Rollfeed Rockhopper II 1 ...

Page 91: ...Roll Systems Maintenance Manual 91 AP 74100 Rev 2 0 11 01 05 Step 3 Reinstall the waste bottle on the place described below For a Falcon II For a Rockhopper II ...

Page 92: ...tep 4 Assemble the PCB box bracket onto the PCB box using 6 bolts M5x8 Hang the PCB box assy on the Support Beam ITEM PART DESCRIPTION QUANTITY 1 Hex Flange Button head M5x8 ELVZ 6 2 PCB Box Assy Rollfeed Rockhopper II 1 3 PCB Box Bracket Rollfeed Rockhopper II 1 ...

Page 93: ...e rail Place the rail assembly on the leg clamps Use the hole slot hole combinations to position the rail Make sure the short side of the rail is on the right hand side of the printer ITEM PART DESCRIPTION QUANTITY 1 Adjusting Foot Bracket Rollfeed Universal 2 1 1 Only for 87 printers 2 Hex Flange Button Head M5x8 ELVZ 8 1 2 87 printers 3 pcs 50 64 1 pc 3 Levelling element M12 3 2 4 Steel bar Assy...

Page 94: ... support with motor and cable is on the right hand side of the machine Connect the motor cable to the PCB box second connector next to the power inlet ITEM PART DESCRIPTION QUANTITY 1 Clamp Lever M10x40 2 2 Sledge Left Assy Rollfeed Universal 1 3 Sledge Bracket Part 2 Rollfeed Universal 2 4 Sledge Right Assy Rollfeed Universal 1 ...

Page 95: ...en the bolts on the left bracket yet Only the 87 printer use the most outer holes on the left side of the printer for assembling the left mounting bracket ITEM PART DESCRIPTION QUANTITY ITEM PART DESCRIPTION QUANTITY 1 DIN 912 Standard M6x16 ELVZ 8 5 Plain Washer DINI25 I A M6 8 2 Lock Washer Internal Teeth M6 ELVZ 1 3 Mounting Bracket Left Assy Rollfeed Rockhopper II 1 4 Mounting Bracket Right As...

Page 96: ... the right hand side assemble 2 sensor lips on the shaft Make sure each sensor lip is in a sensor gap Do not tighten the set screws in the sensor lips Assemble the cable between the operating panel and the PCB box ITEM PART DESCRIPTION QUANTITY 1 Sensor Lip Assy Rollfeed Rockhopper II 2 2 Shaft tensioning system Rollfeed Rockhopper II 2 ...

Page 97: ... lock washer M5 between each screw and tensioning system shaft TIGHTEN THE SCREWS FIRMLY After assembling the rear tensioning system tighten the bolts on the left support bracket ITEM PART DESCRIPTION QUANTITY 1 Lock Washer External Teeth M5 ELVZ 2 2 Pan Head Screw M4x10 2 3 Rear tensioning system assy Rollfeed Rockhopper II 87 1 ...

Page 98: ...s if necessary fix the Rail assembly with 2 spacers and 2 cap screws on each side Assemble the waste ink tank holder Connect the foot switch third connector next to the power inlet ITEM PART DESCRIPTION QUANTITY 1 Foot switch KF2 IS IS 1 2 Hex Flange Button Head M5x8 ELVZ 4 3 Spacer PA D18xd8 2xH10 4 4 Waste bottle roll feed RH RJ 8164 1 ...

Page 99: ...Roll Systems Maintenance Manual 99 AP 74100 Rev 2 0 11 01 05 5 3 3 Unwinder 30 Scroller support L ...

Page 100: ...Roll Systems Maintenance Manual 100 AP 74100 Rev 2 0 11 01 05 Scroller support R ...

Page 101: ...Roll Systems Maintenance Manual 101 AP 74100 Rev 2 0 11 01 05 ...

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