MUTOH Unwinder Maintenance Manual
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MUTOH Unwinder Maintenance Manual

Mutoh roll systems maintenance manual
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Mutoh's Roll Systems
Unwinder / Winder 100
Winder 30

Maintenance Manual

MUTOH EUROPE N.V.
AP-74100, Rev : 2.0, 13/01/2005

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Summary of Contents for MUTOH Unwinder

  • Page 1: Maintenance Manual

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

  • Page 3: Copyright Notice

    This document may not be reproduced by any means, in whole or in part, without written permission of the copyright owner. This document is furnished to support the Mutoh’s Unwinder / Winder 100, Unwinder 100 / Winder 30. In consideration of the furnishing of the information contained in this document, the party to whom it is given,...
  • Page 4 Roll systems – Maintenance Manual AP-74100, Rev. 2.0, 12/01/05...

  • Page 5: Important Notice

    The product and the contents of this publication may be changed without prior notification. MUTOH EUROPE N.V. has made the best efforts to keep this publication free from error, but if you find any uncertainties or misprints, please call us or the shop where you bought this equipment.
  • Page 6 Roll systems – Maintenance Manual AP-74100, Rev. 2.0, 12/01/05...

  • Page 7: Table Of Contents

    ............................11 NTRODUCTION 2.2. P ........................11 ART NAMES AND FUNCTIONS 2.2.1. Unwinder / Winder 100 ..........................11 2.2.2. Operation panel unwinder/winder 100 ......................12 2.2.3 Winder 30 ............................... 13 2.2.4. Operation Panel Winder 30 ........................... 14 2.2.5. Unwinder 100..............................15 2.2.6.
  • Page 8 5. APPENDIX..............................59 5.1. I ............................59 NTRODUCTION 5.2. W ........................... 59 IRING IAGRAM 5.3. E ........................... 60 XPLODED IEWS 5.3.1 Assembling unwinder/winder 100 ........................61 5.3.2 Assembling unwinder 100/winder 30......................78 5.3.3 Unwinder 30 ..............................99 AP-74100, Rev. 2.0, 12/01/05...

  • Page 9: Safety Instructions

    Roll systems – Maintenance Manual 1. SAFETY INSTRUCTIONS 1.1. INTRODUCTION This chapter explains the meaning of safety terms for personnel who operate this equipment and important safety instructions. Important : • Be sure to follow all instructions and warnings in this manual when using the equipment.

  • Page 10: Warning Labels

    • 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 100 Roll unit handle label unwinder 100 Rear tensioning label unwinder 100...

  • Page 11: Product Overview

    Roll unit Supports the roll media. Roll-off foot switch This switch is used to roll-up or roll-off roll media of the unwinder 100. Front Tension System Adjust the tension of the media between the paper guide and the roll-up system.

  • Page 12: Operation Panel Unwinder/Winder 100

    The operation panel is used to set operational conditions. Name Function Part of the operation panel controlling the unwinder 100. Part of the operation panel controlling the winder 100. In case you loaded media with printed side on the outside select Print Side Selector ‘OUT’, otherwise select ‘IN’.

  • Page 13: Winder 30

    Roll systems – Maintenance Manual 2.2.3 Winder 30 Name Function Winder 30 motorized unit Winds and collects the printed roll media. Media sensor Detects the printed media. Scroller receiver Loads the scroller for the winding unit. Power switch Turn the product ON and OFF. Operation Panel This panel is used to set operational conditions, and the status of the product.

  • Page 14: Operation Panel Winder 30

    Roll systems – Maintenance Manual 2.2.4. Operation Panel Winder 30 The operation panel is used to set operational conditions and to check / display the status of the product. (1) Operation switches Name Function AUTO switch Used to automatically wind the roll media. →...
  • Page 15 Rail Assembly Carries the roll units. Motorized roll unit Supports the roll media. Roll unit Supports the roll media. Roll-off foot switch This switch is used to roll-up or roll-off roll media of the unwinder 100. AP-74100, Rev. 2.0, 12/01/05...

  • Page 16: Unwinder 100

    Roll systems – Maintenance Manual 2.2.6. Operation Panel Unwinder 100 The operation panel is used to set operational conditions. Name Function In case you loaded media with printed side on the outside select Print Side Selector ‘OUT’, otherwise select ‘IN’.

  • Page 17: Parts Replacement

    Because the new media guide can have a slight different shape, thickness… Notes : After replacing the parts, perform the adjustment of the unwinder / winder 100 as described in the User’s Guide. AP-74100, Rev. 2.0, 12/01/05...

  • Page 18: Removal On The Operation Panel

    Roll systems – Maintenance Manual 3.2. 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.

  • Page 19: Replace The Operation Panel Pcb Box

    Roll systems – Maintenance Manual 3.2.2. Replace the operation 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.

  • Page 20: Connecting The Pcb Board Operation Panel With The Operation Panel

    Roll systems – Maintenance Manual 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. AP-74100, Rev. 2.0, 12/01/05...

  • Page 21: Removal Of The Pcb Box Of The Unwinder / Winder 100

    Roll systems – Maintenance Manual 3.3. REMOVAL OF THE PCB BOX OF THE UNWINDER/WINDER Important : Before replacing parts, be sure to perform the following operations. Turn the machine power OFF. Remove the product's electrical plug from the socket. Otherwise, you may suffer electric shock or the machine’s electric circuits may be damaged.
  • Page 22 Roll systems – Maintenance Manual 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. AP-74100, Rev.

  • Page 23: How To Replace The Pcb Board Of The Pcb Box

    Roll systems – Maintenance Manual 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.

  • Page 24: How To Replace The Power Supply Connector

    Roll systems – Maintenance Manual Caution : Be sure not to damage the 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.
  • Page 25 Roll systems – Maintenance Manual 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 AP-74100, Rev.

  • Page 26: Connections In The Pcb Box

    Roll systems – Maintenance Manual 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. AP-74100, Rev.

  • Page 27: Removal Of The Pcb Box Of The Winder 30

    Roll systems – Maintenance Manual 3.4 REMOVAL OF THE PCB BOX OF THE WINDER 30 To replace the PCB board, please 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.
  • Page 28 Roll systems – Maintenance Manual Step 3 : Remove the screw and 3 spacers of the PCB board. Part Spacers 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. AP-74100, Rev.

  • Page 29: Removal Onto The Tensioning System

    Roll systems – Maintenance Manual 3.5. REMOVAL ONTO THE TENSIONING SYSTEM 3.5.1 Replacing the 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.
  • Page 30 Roll systems – Maintenance Manual 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. AP-74100, Rev. 2.0, 12/01/05...

  • Page 31: Connecting The Sensors

    Roll systems – Maintenance Manual 3.5.2 Connecting the sensors Please find below the connections of the sensors in the tensioning system. Before manufacturing date 2005 As from manufacturing date 2005 Part Item Sensor Sensor Description Number covered registration MK-51607 Front Stop Front motorized roll unit is turning –...

  • Page 32: Removals Onto The Roll Unit

    Roll systems – Maintenance Manual 3.6. REMOVALS ONTO THE ROLL UNIT 3.6.1. Replacing 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 :...

  • Page 33: Replacing The Core Cone Of The Motorized Roll Unit

    Roll systems – Maintenance Manual 3.6.2. Replacing the core cone of the motorized roll unit Step 1 : Loosen 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 :...

  • Page 34: Replacing The Motor In The Motorized Roll Unit

    Roll systems – Maintenance Manual 3.6.3. Replacing the motor in the motorized roll unit Step 1 : Loosen 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. Step 4 : Loosen the three screws fixing the gear.

  • Page 35: Connecting The Motor

    Roll systems – Maintenance Manual 3.6.4. 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.

  • Page 36: Replacement Of The Scroller Assembly

    Roll systems – Maintenance Manual 3.7 REPLACEMENT OF THE SCROLLER ASSEMBLY 3.7.1. Replacing the scroller R assembly (1) Replacing the scroller R assembly Step 1 : Remove the 4 hexagon socket head springs fixing the scroller R assembly. 1 = Scroller R assembly 2 = Hexagon socket head springs Step 2 : Replace the scroller R assembly.

  • Page 37: Replacing The Scroller L Assembly

    Roll systems – Maintenance Manual Step 3 : Remove the E ring fixing the axes of the rollers to be replaced. 1 = Pressure roller 2 = Roller 1 3 = Roller 2 4 = E ring (E-3) 5 = E ring (E-4) Step 4 : Replace the rollers.
  • Page 38 Roll systems – Maintenance Manual (2) Replacing the pressure roller and roller 1 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 L assembly Step 2 : Remove scroller receptacle cover R.

  • Page 39: Adjustments

    If the start sensor is covered, the motor will start to accelerate as long as the start sensor is covered. By using two sensors, the unwinder / winder 100 will automatically adjust the media feed / winder speed to the printing speed of the printer.

  • Page 40: Adjust The Sensors Of The Front Tensioning Bar

    Roll systems – Maintenance Manual 4.1.2. Adjust the sensors of the front tensioning bar To adjust the sensors of the front tensioning system, please follow the instructions mentioned below. Notes : To adjust the sensors, loosen the set screws on the adjustment lip, rotate the sensor disc to the correct position and tighten the set screws.
  • Page 41 Roll systems – Maintenance Manual 4.1.2.2. 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 front tensioning system in the 25° position. (Please see to the angle markings on the front tensioning system.

  • Page 42: Adjust The Sensors Of The Rear Tensioning Bar

    Roll systems – Maintenance Manual 4.1.3. Adjust the sensors of the rear tensioning bar To adjust the sensors of the rear tensioning system, please follow the instructions mentioned below. Notes : All rear tensioning bar angles are compared to the horizontal plane. First adjust the stop sensor, then the start sensor.
  • Page 43 Roll systems – Maintenance Manual Step 5 : Rotate (“downwards”) the adjustment lip carefully until the stop sensor is covered. (For the adjustment direction, please refer to the section “Sensor disc and adjustment direction”.) The “Automatic” LED will stop blinking. The rear motor will stop turning.
  • Page 44 Roll systems – Maintenance Manual Step 4 : Rotate (“upwards”) the adjustment lip carefully until the start sensor is covered. (For 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.

  • Page 45: Sensor Disc And Adjustment Direction

    Roll systems – Maintenance Manual 4.1.4. Sensor 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: Angle Mark Front Tensioning System

    Roll systems – Maintenance Manual 4.1.5. Angle mark 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°...

  • Page 47: Start Sensor Position

    Roll systems – Maintenance Manual 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. •...

  • Page 48: Sensor ( Tension Bar ) Adjustment Unwinder 100 / Winder 30

    If the start sensor is covered, the motor will start to accelerate as long as the start sensor is covered. By using two sensor, the unwinder will automatically adjust the media feed / winder speed to the printing speed of the printer.

  • Page 49: Adjust The Sensors Of The Rear Tensioning Bar

    Roll systems – Maintenance Manual 4.2.2. Adjust the sensors of the rear tensioning bar To adjust the sensors of the rear tensioning system, please follow the instructions mentioned below. Notes : All rear tensioning bar angles are compared to the horizontal plane. First adjust the stop sensor, then the start sensor.
  • Page 50 Roll systems – Maintenance Manual 4.2.2.2. 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 sensor system”.) Step 3 : Switch the Rear to AUTOMATIC.

  • Page 51: Sensor Disc And Adjustment Direction

    Roll systems – Maintenance Manual 4.2.3. Sensor disc and adjustment 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°...

  • Page 52: Start Sensor Position

    Roll systems – Maintenance Manual 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°...

  • Page 53: Calibration Of The Unwinder 100 And Winder 100

    Roll systems – Maintenance Manual 4.3 CALIBRATION OF THE UNWINDER 100 AND WINDER 100 Caution : • In case you have replaced the front and/or rear media guide, always perform a calibration of the front tensioning system and the roll-up systems. Because the new media guide can have a slight different shape, thickness…...
  • Page 54 Roll systems – Maintenance Manual Step 4 : Pull the strip so there is an equal tension. Step 5 : Standing at the front side of the unit, place the adjustment plate onto the large strip and slide it against the pressure rollers. Step 6 : Manually draw a line.
  • Page 55 Roll systems – Maintenance Manual Step 10 : Standing at the rear 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.

  • Page 56: Calibration Of The Front And Rear Roll Unit

    Roll systems – Maintenance Manual 4.3.2 Calibration of the front and rear roll unit. Caution : • In case you have replaced the front and/or rear media guide, always perform a calibration of the front tensioning system and the roll-up systems. Because the new media guide can have a slight different shape, thickness…...
  • Page 57 Roll systems – Maintenance Manual Step 7 : Manually draw a line. Step 8 : Slide the 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.
  • Page 58 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: Appendix

    5. APPENDIX 5.1. INTRODUCTION This chapter provides referential information such as service data and exploded views. 5.2. WIRING DIAGRAM AP-74100, Rev. 2.0, 12/01/05...

  • Page 60: Exploded Views

    Roll systems – Maintenance Manual 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.

  • Page 61: Assembling Unwinder/Winder 100

    Roll Systems – Maintenance Manual 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. AP-74100, Rev. 2.0, 11/01/05...
  • Page 62 Roll Systems – Maintenance Manual Step 1 : Assemble the Foot Mounting Brackets with 8 bolts M6x12. Make sure the Waste-ink Tank Bracket is on the right hand side of the machine. ITEM PART DESCRIPTION QUANTITY DIN 912 Standard M6x12 ELVZ Leg Clamp Part 1 Rollfeed Rockhopper II Leg Clamp Part 2 Rollfeed Rockhopper II Waste Ink Tank Bracket Assy Rollfeed Rockhopper II...
  • Page 63 Roll Systems – Maintenance Manual Step 2 : Assemble the PCB-box, using 4 bolts M6x55 and 4 teeth washers M6.. ITEM PART DESCRIPTION QUANTITY DIN912 standard M6x55 ELVZ Lock Washer Internal Teeth M6 ELVZ PCB Box Assy Rollfeed Rockhopper II AP-74100, Rev.
  • Page 64 Roll Systems – Maintenance Manual Step 3 : On the 87” printer, assemble the support brackets and adjusting feet on both ends of the rail. Assemble the adjusting foot on the middle bracket of the 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.
  • Page 65 Roll Systems – Maintenance Manual Step 4 : Assemble the Roll support Assemblies. Make sure to driven roll support (with motor and cable) 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...
  • Page 66 Roll Systems – Maintenance Manual Step 5 : Assemble the left and right mounting brackets. Use 4 bolts M6x16 with a plain washer M6 on each bracket. Use 1 teeth washer M6 on the right bracket. Do not tighten the bolts on the left bracket yet. Only the 87”...
  • Page 67 Roll Systems – Maintenance Manual Step 6 : Assemble the 2 shafts in the left Mounting bracket assembly. Assemble the front and rear swingbar assembly. Use the screws M4x10 to fix the assemblies ITEM PART DESCRIPTION QUANTITY Pan Head Screw Shaft swingbar D-lock Rollfeed Rockhopper II Swingbar Assy Rollfeed Rockhopper II Swingbar Front Assy Rollfeed Rockhopper II...
  • Page 68 Roll Systems – Maintenance Manual Step 7 : 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 Hex Flange Buttonhead M5x8 ELVZ Spacer PA D18 x d8.2 x H10...
  • Page 69 Roll Systems – Maintenance Manual 5.3.1.2 Before manufacturing year 2005 If necessary, remove all parts of the current winder system. AP-74100, Rev. 2.0, 11/01/05...
  • Page 70 Roll Systems – Maintenance Manual Step 1 : Assemble the Foot Mounting Brackets with 8 bolts M6x12. Make sure the Waste-ink Tank Bracket is on the right hand side of the machine. ITEM PART DESCRIPTION QUANTITY DIN 912 Standard M6x12 ELVZ Leg Clamp Part 1 Rollfeed Rockhopper II Leg Clamp Part 2 Rollfeed Rockhopper II Waste Ink Tank Bracket Assy Rollfeed Rockhopper II...
  • Page 71 Roll Systems – Maintenance Manual Step 2 : Assemble the PCB-box, using 4 bolts M6x55 and 4 teeth washers M6.. ITEM PART DESCRIPTION QUANTITY DIN912 standard M6x55 ELVZ Lock Washer Internal Teeth M6 ELVZ PCB Box Assy Rollfeed Rockhopper II AP-74100, Rev.
  • Page 72 Roll Systems – Maintenance Manual Step 3 : On the 87” printer, assemble the support brackets and adjusting feet on both ends of the rail. Assemble the adjusting foot on the middle bracket of the 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.
  • Page 73 Roll Systems – Maintenance Manual Step 4 : Assemble the Roll support Assemblies. Make sure to driven roll support (with motor and cable) 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...
  • Page 74 Roll Systems – Maintenance Manual Step 5 : Assemble the left and right mounting brackets. Use 4 bolts M6x16 with a plain washer M6 on each bracket. Use 1 teeth washer M6 on the right bracket. Do not tighten the bolts on the left bracket yet. Only the 87”...
  • Page 75 Roll Systems – Maintenance Manual Step 6 : Remove the rear cover on the right mounting bracket. Remove the 3 screws holding the operation panel. Put the operating panel aside. BE CAREFUL NOT TO DAMAGE THE CABLES LEADING TO THE PANEL. Assemble the 4 shafts.
  • Page 76 Roll Systems – Maintenance Manual Step 7 : Assemble the rear tensioning system, using 2 screws M4x10. Put a lock washer M5 between each screw 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...
  • Page 77 Roll Systems – Maintenance Manual Step 8 : Perform the alignment procedure. After inserting the adjusting spacers (if necessary), fix the Rail assembly 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...

  • Page 78: Assembling Unwinder 100/Winder 30

    5.3.2.1 As from manufacturing year 2005 Assembly information when combining winder 30 with unwinder 100 Replace the sensor assy delivered with the Winder 30 by the new Media Sensor Assy. Place the media sensor assy in the middle of the printing width of the printer.
  • Page 79 Roll Systems – Maintenance Manual 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 AP-74100, Rev.
  • Page 80 Roll Systems – Maintenance Manual Step 2 : Assemble the Foot Mounting Brackets with 8 bolts M6x12. Make sure the Waste-ink Tank Bracket is on the right hand side of the machine. ITEM PART DESCRIPTION QUANTITY DIN 912 Standard M6x12 ELVZ Leg Clamp Part 1 Rollfeed Rockhopper II Leg Clamp Part 2 Rollfeed Rockhopper II Waste Ink Tank Bracket Assy Rollfeed Rockhopper II...
  • Page 81 Roll Systems – Maintenance Manual Step 3 : Reinstall the waste bottle on the place described below. For a Falcon II For a Rockhopper II AP-74100, Rev. 2.0, 11/01/05...
  • Page 82 Roll Systems – Maintenance Manual Step 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 Hex Flange Button head M5x8 ELVZ PCB Box Assy Rollfeed Rockhopper II PCB Box Bracket Rollfeed Rockhopper II AP-74100, Rev.
  • Page 83 Roll Systems – Maintenance Manual Step 5 : On the 87” printer, assemble the support brackets and adjusting feet on both ends of the rail. Assemble the adjusting foot on the middle bracket of the 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.
  • Page 84 Roll Systems – Maintenance Manual Step 6 : Assemble the Roll support Assemblies. Make sure to driven roll 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...
  • Page 85 Roll Systems – Maintenance Manual Step 7 : Assemble the left and right mounting brackets. Use 4 bolts M6x16 with a plain washer M6 on each bracket. Use 1 teeth washer M6 on the right bracket. Do not tighten the bolts on the left bracket yet. Only the 87”...
  • Page 86 Roll Systems – Maintenance Manual Step 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 Pan Head Screw M4x10 Shaft tensioning bar D-lock Rollfeed Tensioning bar Rollfeed AP-74100, Rev.
  • Page 87 Roll Systems – Maintenance Manual Step 9 : After alignment of the roll drive assembly (and putting the adjustment 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...
  • Page 88 5.3.2.2 Before manufacturing year 2005 Assembly information when combining winder 30 with unwinder 100 Replace the sensor assy delivered with the Winder 30 by the new Media Sensor Assy. Place the media sensor assy in the middle of the printing width of the printer.
  • Page 89 Roll Systems – Maintenance Manual 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 AP-74100, Rev.
  • Page 90 Roll Systems – Maintenance Manual Step 2 : Assemble the Foot Mounting Brackets with 8 bolts M6x12. Make sure the Waste-ink Tank Bracket is on the right hand side of the machine. ITEM PART DESCRIPTION QUANTITY DIN 912 Standard M6x12 ELVZ Leg Clamp Part 1 Rollfeed Rockhopper II Leg Clamp Part 2 Rollfeed Rockhopper II Waste Ink Tank Bracket Assy Rollfeed Rockhopper II...
  • Page 91 Roll Systems – Maintenance Manual Step 3 : Reinstall the waste bottle on the place described below. For a Falcon II For a Rockhopper II AP-74100, Rev. 2.0, 11/01/05...
  • Page 92 Roll Systems – Maintenance Manual Step 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 Hex Flange Button head M5x8 ELVZ PCB Box Assy Rollfeed Rockhopper II PCB Box Bracket Rollfeed Rockhopper II AP-74100, Rev.
  • Page 93 Roll Systems – Maintenance Manual Step 5 : On the 87” printer, assemble the support brackets and adjusting feet on both ends of the rail. Assemble the adjusting foot on the middle bracket of the 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.
  • Page 94 Roll Systems – Maintenance Manual Step 6 : Assemble the Roll support Assemblies. Make sure to driven roll 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...
  • Page 95 Roll Systems – Maintenance Manual Step 7 : Assemble the left and right mounting brackets. Use 4 bolts M6x16 with a plain washer M6 on each bracket. Use 1 teeth washer M6 on the right bracket. Do not tighten the bolts on the left bracket yet. Only the 87”...
  • Page 96 Roll Systems – Maintenance Manual Step 8 : Remove the rear cover on the Right Mounting. Assemble the 2 shafts. On 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.
  • Page 97 Roll Systems – Maintenance Manual Step 9 : Assemble the rear tensioning system, using 2 screws M4x10. Put a 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...
  • Page 98 Roll Systems – Maintenance Manual Step 10 : Perform the alignment procedure. After inserting the adjusting spacers (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...

  • Page 99: Unwinder 30

    Roll Systems – Maintenance Manual 5.3.3 Unwinder 30 Scroller support L AP-74100, Rev. 2.0, 11/01/05...
  • Page 100 Roll Systems – Maintenance Manual Scroller support R AP-74100, Rev. 2.0, 11/01/05...
  • Page 101 Roll Systems – Maintenance Manual AP-74100, Rev. 2.0, 11/01/05...

This manual is also suitable for:

Winder 100Winder 30Unwinder 100

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